Berty's OEM+ Build Thread

[Berty_K]

The Goal of my Build
I'm looking to build an OEM+ rig capable of handling mild terrain (think forest roads, some technical stuff). This is still my daily driver, so I need it to continue to be reliable. But, I've also got a persistent itch to tinker and be outdoors.

Complete Trails:
Colorado

• Saints John Road
• Mary's Glacier
• Yankee Hill
• Imogene & Yankee Boy Basin

California

• Crowley Lake Columns (Mammoth)
• Old Coast Road (Big Sur)
• Old Dale Road (Joshua Tree)

Current as of July '21:

 

[Berty_K]

ODO: 244,000

Exterior

• <s>TRD Pro Suspension (Front: Bilstein 6112 w/ 600lbs Eibach Springs and 1/4" spacer, Rear: Bilstein 5120 w/ Dobinson 505 Springs) ( DIY [MENTION=147157]randomtask16[/MENTION])</s>
• Ironman Foam Cell Pro
• JBA High Caster Upper Control Arms (DIY [MENTION=104572]Slowgoat[/MENTION])
• (Added back on) Roof Rack Delete (DIY [MENTION=56894]toy51[/MENTION])
• <s>255 80r17 Toyo Open Country AT2</s>
• 255 80r17 Toyo Open Country AT3
• Tints
• Spidertrax
• Morimoto Mini D2S 5.0 w/ Osram Xenarc CBI bulbs
• Air Lift Suspension
• Custom rear links

Interior

• Custom Trunk Drawers w/ removable sleeping platform
• 9500ix (Hardwired w/ Kill Switch)
• Anker Roav C1 Dash Cam (Hardwired)
• <s>Kenwood Excelon KDC-x501</s>
• JVC KW-M785BW
• Pioneer TS-D69C
• Ram Phone Mount
• Husky Floor Mats
• Vehicle OCD Center Console Organizer

Electronics

• 12 V Fridge Harness
• Victron DCDC converter
• Victron Solar MPPT

Maintenance

• Passenger Wheel Bearing: 5/3/17 @ 135,990
• Passenger CV Axle: 5/3/17 @ 135,990
• Driver Wheel Bearing: 6/30/19 @ 178,193
• Driver CV Axle: 6/30/19 @ 178,193
• Driver CV Axle Seal: 6/30/19 @ 178,193
• Rear Pads & Rotors: 8/23/20 @ 181,370
• 5th gen front caliper, pads, rotors: 7/14/18 @ 156,300
• New OEM Lower Control Arms: 9/30/18 @ 159,750 (DIY)
• Permatex Rust Treatment
• New Radiator: 11/2/18 @ 160,980
• Passenger Axle Seal: 1/26/20 @ 176,139 (First time w/ low quality aftermarket 5/3/17 @ 135,990)
• Transmission Oil Cooler: 4/5/20 @ 178,700
• New Alternator: 8/1/20 @181,000

Recurring Maintenance

• Synthetic Engine Oil w/ ZD3 Filter every 5k miles: 9/1/20 @ 181,574
• All zerks greased with Mobil1 Synthetic: 9/1/20 @ 181,574
• JBA upper control arm zerks greased: 9/1/20 @ 181,574
• 5 Tire Rotation: 1/12/20 @ 175,823
• Mobil1 75W90 in Front Diff: 1/13/20 @ 175,823
• Mobil1 75W90 in Transfer Case: 1/13/20 @ 175,823
• Mobil1 75W90 in Rear Diff: 1/13/20 @ 175,823
• Transmission fluid full flush: 12/28/18 @ 163,798 (DIY)
• 2 stage, DIY paint correction
• Wax
  

 

[Berty_K]

Reserved 2

 

[Berty_K]

Reserved 3

 

[Berty_K]

Spacers are in. Digging the new look.

I triple checked the torques and used red threadlocker on everything

 

[Berty_K]

After noticing my coolant level had dropped, I crawled under my car to check out the radiator.

I definitely have a radiator leak. It looks like a little tumor.

Already have a new Denso radiator coming from rock auto. 120 shipped.

 

[Berty_K]

Notes from My Transmission Fluid Flush

Flushed my transmission fluid today. A few notes I'd like to memorialize.

I used this DIY by [MENTION=113703]46runner[/MENTION]. Its very thorough and walked me through the process in just the right amount of detail. https://www.toyota-4runner.org/4th-gen-t4rs/195074-atf-exchange-using-cooling-line.html. A few notes

• The DIY recommends using a milk jug. Get 2. I did this for two reasons: (1) Less mixing of old and new fluid, and (2) easier to match up amount of new fluid to pump in. I'm extra and bought these from McMaster https://www.mcmaster.com/4169t25
• After you drain the transmission fluid, inspect the fluid. Do two things: (1) smell the fluid and make sure it doesn't smell burnt, and (2) pour some on a white piece of paper and make sure you don't see any metal flakes. My transmission had 163k on OEM fluid and did not exhibit either of these characteristics.
• Its mentioned in the DIY, but make sure you have a short 24mm socket. You won't be able to get a ratchet on the end of a deep socket.
• I bought 14 quarts of ATF WS and used 13. The DIY suggests flushing 12 quarts and adding 12.5 quarts. However, in the DIY at the final fluid level check, nothing comes out of the overflow plug. I flushed 12.5 and added 13 quarts. Fluid did come out at the final fluid level check.
• You'll notice the fluid you are flushing out becomes significantly more red at the end of your flush.

 

[Berty_K]

Exhaust Prep

After 11 Chicago winters and 165k miles on the odometer, my exhaust has finally rotted out. I get a rattle when accelerating from a stop. I believe the outlet pipe from the muffler is partially sheared. Some Highheat JB Weld is currently temporarily holding things in place.

While a SS exhaust is tempting, I've decided to go with Walker components off Rockauto; price and mostly positive experiences on T4R informed this decision.

Once again [MENTION=113703]46runner[/MENTION]'s DIY here was a great reference.

I'll be dousing the exhaust spring bolts with liquid wrench for the next few days.

I'll be replacing everything past the muffler:

• Gasket: 31639
• Spring Bolts: 36454
• Muffler: 56177
• Muffler Hanger (x4): 35725
• Gasket: 31384
• Tail Pipe: 54611
• Tail Pipe Hanger: 35017

All in cost ~$210 +tax/shipping.

FSM Component Overview and Torque Specs

Walker Component Overview

 

[Berty_K]

<s>Some spring time updates: time for more lift.

Ditching the 1/4" spacers and adding the following:
-2.5" Daystar lift: 2.5" Lift Poly Front Coil Spacer Kit for 2005+ Tacoma, 2003+ 4Runner, 2007+ FJ Cruiser (KT09103-4R-03)
-Cornfed .75" rear spacer: 4th and 5th Gen 4Runner rear lift options

I should be lifted about 3/2 and raked about 1.25"

Sets me up nicely for some 255 80r17 tires</s>

Change of Plans

After consulting with Cornfed, they recommended I stay under 2" of spacer lift on my TRD kit. Apparently they're known to fail with spacer lifts greater than 2". As such, I opted not to go with the daystar kit.

Front: I ended up keeping my 1/4" top plate spacer and buying a 1.5" front spacer kit from Cornfed. To compensate for my 1/8" driver side lean, they made my driver side spacer .1" thicker for about an extra .2" of lift. I went with these spacers to match my TRD suspension: 5th Gen 4Runner lift kits

Rear: Also lots of driver side lean. I added a spacer on the rear driver side to lift it .5"

As you can see, my driver side got pushed up a bit more than expected. Does put me over the 2" mark, but I'm not too concerned.

 

[Berty_K]

Took advantage of the nice weather today. Washed the car, changed the oil, greased all zeros, and put my running boards back on.

Cleans up nice for a 10 year old car.

Sent from my iPhone using Tapatalk

 

[TampaBay_4Runner]

Very nice. I also have an Illinois REI sticker on my 4Runner on the same window but drivers side. Live in Tampa now but grew up in Elmhurst.

 

[Berty_K]

New shoe day. LT255/80r17 Toyo Open Country AT2s. Ride is definitely harsher than my previous P rated tires, but it's marginal in mind.

Sent from my iPhone using Tapatalk

 

[horndogst4r]

Looks good. Do you have any pics showing how far the tires stick out? I am considering that size after my 285/70s wear out.

 

[Berty_K]

Looks good. Do you have any pics showing how far the tires stick out? I am considering that size after my 285/70s wear out.

Driver Front:

Front:

Rear Driver:

 

[_chassis_]

Berty_K, great thread, thanks much.

How long did the radiator replace take you? Did you need to remove the fan and fan clutch? I have similar secretion of coolant. Not an urgent job, but it's on the list.

 

[Berty_K]

Berty_K, great thread, thanks much.

How long did the radiator replace take you? Did you need to remove the fan and fan clutch? I have similar secretion of coolant. Not an urgent job, but it's on the list.

Not long. No, I didn't need to remove the fan or fan clutch. Finished it in about 2 hours and bought everything off Rock Auto.

The spring clamps were suprisingly tricky.

This thread helped me: How To: 4th Gen V6 Radiator Replacement/Tranny Cooler Install | Toyota 4Runner Forum [4Runners.com]

 

[Berty_K]

Changing Transfer Case, Front Differential, and Rear Differential Oil

Required Items:

• 7 Quarts 75w-90 Gear Oil (1.5 Front; 1.5 Transfer Case; 3.2 Rear)
• 24 mm Socket for drain/fill for rear and transfer case
• 10 mm for drain/fill plugs on front differential
• 3x Gasket #12157-10010 (Front Fill, Rear Fill, Rear Drain)
• 1x Gasket #90430-24003 (Front Drain)
• 2x Gasket #90430-18008 (Transfer Case Fill, Transfer Case Drain)
• Torque Wrench
• Drain Pan

Helpful/Optional Items:

• Oil Hand Pump
• Breaker Bar
• Lift/Jack Stands

Front Differential:

1. Remove Front Skid Plate
2. Remove fill plug w/ 10 mm hex
3. Remove drain plug w/ 10 mm hex
4. Drain oil
5. Replace Gaskets (Fill 12157-10010, Drain 90430-24003)
6. Reinstall drain plug w/ 10 mm hex (48 ft/lbs)
7. Add 1.5 Quarts (Until oil dribbles out)
8. Reinstall fill plug w/ 10 mm hex (29 ft/lbs)

Transfer Case:

1. Remove fill plug w/ 24 mm socket
2. Remove drain plug w/ 24 mm socket
3. Drain oil
4. Replace Gaskets (Fill & Drain 90430-18008)
5. Reinstall drain plug w/ 24 mm socket (27ft/lbs)
6. Add 1.5 Quarts (Until oil dribbles out)
7. Reinstall fill plug w/ 24 mm socket (27 ft/lbs)

Rear Differential:

1. Remove fill plug w/ 24 mm socket
2. Remove drain plug w/ 24 mm socket
3. Drain oil
4. Replace Gaskets (Fill & Drain 12157-10010)
5. Reinstall drain plug w/ 24 mm socket (36 ft/lbs)
6. Add 3.2 Quarts (Until oil dribbles out)
7. Reinstall fill plug w/ 24 mm socket (36 ft/lbs)

Sources:

• How To: Differentials and Transfer Case Fluid Service | Toyota 4Runner Forum [4Runners.com]
• Changing Differential & Transfer Case Fluids - Pics Included

 

[Berty_K]

Tire Rotation Guide w/ Spare

Lug Nut Torque Specs: 83 ft/lbs

 

[royal T4R]

You are thorough with your posts, thanks!

 

[Berty_K]

You are thorough with your posts, thanks!

Thanks! Sharing the information I compile.