Stuck CAPS
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Alright, now that I've got around 1/3 of the price saved up now, it won't be too long before I start sourcing parts. Now, I know that the vast majority of you haven't converted a 4th gen to 4WD, but a lot of you will still be able to answer some questions about it.
First things first, a list of parts for the conversion:
Now for the questions:
1. Some of these parts are "not avail via Toyota", but I don't know whether that means available through the dealerships to the public, or made by some independent contractor strictly for Toyota. Any input would be nice. [MENTION=64685]TOY2G[/MENTION] if you could chime in on this (We've spoken about the overall conversion in the past, but we never really got too far into the discussion of how a plug is acquired outside what's mentioned in that post over at T120.)
2. Doing this in steps: Say that I have the 4WD Trans and the transfer case bolted up, as well as the shorter drive shaft for a 4WD drive-train installed. Assuming the T-Case is not sitting in 4LO, would I be able to drive without the 4WD ECM, front Diff, 4WD hubs, CV Axles, etc.? Even with the 4WD ECM and selector switch wired up (still no front half of drive train), would I be able to drive? OR would I have to knock it all out before I'm able to drive again?
3. Where IS the Torsen center differential located: Within the transfer case? If not, if it's somewhere between the two, would I be able to get one later on? [MENTION=4242]mysticz[/MENTION] IIRC, you're running with no center differential: I don't know if you've driven a (factory) 4x4 4R, but would it even be worth it going back in and adding a center differential if the answer to the first part of the question is that I would lose one by buying the Transmission and Transfer case separately?
4. For the 4WD lights, would I be able to get by not using a 4WD light at all? From what I've learned from speaking to [MENTION=63211]emelianenkov[/MENTION] and [MENTION=64685]TOY2G[/MENTION] , is that I would have to find an instrument cluster at or around my mileage to swap in. I also found that I could buy a full instrument cluster from the dealership, and get the mileage dialed in, but that would be expensive. If I were to find an instrument cluster under my current mileage, would I somehow be able to increase the mileage to my current mileage, or get this done without running myself 1 or 2 grand over my estimated cost?
5. Specifically; to those who have done (at least somewhat) extensive modification under their 4Rs, i.e. 4WD conversion, Transmission replacement, Transfer case replacement, etc.; Living in MO, we get a lot of salt on our roads, so rust is, to say the very least, a problem. How much time should I expect to put into re-tapping holes, etc., and are there any preemptive maneuvers I could take to avoid having to retap holes? (Bolts are much easier to replace without re-tapping, and buying bolts isn't too much of a problem
)
Thanks in advance to those who read through this lengthy post, especially those who are able to help with some of these questions/concerns. Please refrain from the "Just trade your truck in for a 4WD" posts. I'm set on this, not only because I want to keep MY truck (Because I REALLY do), but also because this project, although pretty extensive, is something I want to do. I guess you could say it has slowly become a dream of mine.
Edit: I will make my best effort to write this up with pictures, etc, using factory parts, because although MysticZ's write-up has helped quite a bit, its only problem, in my case, at least, is that a lot of it was custom work, using parts from the FJ, etc. (Not trying to bag on you, MysticZ
)
First things first, a list of parts for the conversion:
TOY2G said:- 4x4 Transmission with Transfer Case
- Front Diff (with matching rear gears if you can pull that off.)
- Both CVs (Right & Left )
- Both Drive Shafts (Front & Rear)
- Front Diff Mounting Bracket (Y Shaped Bracket that holds up the Tail)
- Front Diff Mounting Arms w/bushings (you will also need the long bolts, I recommend also using a diff drop kit also)
- Front Hub and Bearing Assembly (the old one gets destroyed when removed to install Drive Flange)
- Front 4x4 drive flange
- Front Wheel Bearing Seal Kit
- 4x4 skid plate
- 4WD Shift Selector (2wd T4R are prewired for the switch)
- 4x4 controller ECM (89530-35310)
- Toyota pin convectors for ECM
- ECM Plugs (90980-12149 & 90980-12150) Note: one plug is prewired, the second plug (from the ECM to the t-case you will have to make your own harness or cut one out of a donor, the parts are not avail via Toyota)
- 4wd dash light
- Transfer Case Cross Member
- Transfer Case Mount
Now for the questions:
1. Some of these parts are "not avail via Toyota", but I don't know whether that means available through the dealerships to the public, or made by some independent contractor strictly for Toyota. Any input would be nice. [MENTION=64685]TOY2G[/MENTION] if you could chime in on this (We've spoken about the overall conversion in the past, but we never really got too far into the discussion of how a plug is acquired outside what's mentioned in that post over at T120.)
2. Doing this in steps: Say that I have the 4WD Trans and the transfer case bolted up, as well as the shorter drive shaft for a 4WD drive-train installed. Assuming the T-Case is not sitting in 4LO, would I be able to drive without the 4WD ECM, front Diff, 4WD hubs, CV Axles, etc.? Even with the 4WD ECM and selector switch wired up (still no front half of drive train), would I be able to drive? OR would I have to knock it all out before I'm able to drive again?
3. Where IS the Torsen center differential located: Within the transfer case? If not, if it's somewhere between the two, would I be able to get one later on? [MENTION=4242]mysticz[/MENTION] IIRC, you're running with no center differential: I don't know if you've driven a (factory) 4x4 4R, but would it even be worth it going back in and adding a center differential if the answer to the first part of the question is that I would lose one by buying the Transmission and Transfer case separately?
4. For the 4WD lights, would I be able to get by not using a 4WD light at all? From what I've learned from speaking to [MENTION=63211]emelianenkov[/MENTION] and [MENTION=64685]TOY2G[/MENTION] , is that I would have to find an instrument cluster at or around my mileage to swap in. I also found that I could buy a full instrument cluster from the dealership, and get the mileage dialed in, but that would be expensive. If I were to find an instrument cluster under my current mileage, would I somehow be able to increase the mileage to my current mileage, or get this done without running myself 1 or 2 grand over my estimated cost?
5. Specifically; to those who have done (at least somewhat) extensive modification under their 4Rs, i.e. 4WD conversion, Transmission replacement, Transfer case replacement, etc.; Living in MO, we get a lot of salt on our roads, so rust is, to say the very least, a problem. How much time should I expect to put into re-tapping holes, etc., and are there any preemptive maneuvers I could take to avoid having to retap holes? (Bolts are much easier to replace without re-tapping, and buying bolts isn't too much of a problem
Thanks in advance to those who read through this lengthy post, especially those who are able to help with some of these questions/concerns. Please refrain from the "Just trade your truck in for a 4WD" posts. I'm set on this, not only because I want to keep MY truck (Because I REALLY do), but also because this project, although pretty extensive, is something I want to do. I guess you could say it has slowly become a dream of mine.
Edit: I will make my best effort to write this up with pictures, etc, using factory parts, because although MysticZ's write-up has helped quite a bit, its only problem, in my case, at least, is that a lot of it was custom work, using parts from the FJ, etc. (Not trying to bag on you, MysticZ
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