Black798's 98 limited build thread

I also noticed the ring gear looks a little funky with the small streaks in the pattern. Not sure if this is normal for freshly broken in ring gear or not.
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These lines are called mill marks. They're a useful visual indicator of gear ware. Its almost like how freshly casted brand new gears have visual surface pitting sometimes but after a ton of wear they slowly become nice and shiny untill they basically blow up like your old front diff. I know this is an old post, but if you ever tear apart a diff again, now you know.
 
Got the axle housing finished up today and did a quick dry assembly with the hubs diff and axle shafts to make sure everything is still lined up and it looks like were in business. Super stoked with how this turned out and i cant wait to start the next phase which will be cutting off all the rear suspension from the links back to redo it. That wont be happeing for awhile since that also means I need another car to drive while the 4runner is cut up but I think the 4runner becoming just a toy was inevitable and the timing really couldn't be better. Pictures really dont do this thing justice, its absolutely massive and makes the axle in the 4runner currently look like it belongs in a RC car haha.

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Suppose its time for an update. Ive been super busy with school and work lately which only got worse due to all this COVID bs. But luckily still managed to get my annual moab trip in. The dates we had worked out perfect and we ended up leaving town the day before they shut down everything to visitors. This year we ended up getting an AirBnb which was hands down one of the best things we could have done. So nice having a shower and not getting caught out in the rain with our pants down like last year and it was much closer to town so getting moving early was way easier. Not going to do a full writeup but heres some of the highlights and the link to the full flickr album.
Moab 2020 | Flickr

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And in more recent news I finally got a daily. 2008 Audi A4 S line with the 2.0 turbo and a 6 speed manual. Super fun car to drive and its been averaging 25 mpg even with me driving like a jackass everywhere which is awesome. Best part though is that it means the 4runner is now 100% a toy so I can actually take it apart and do these bigger projects I have been planning out. Hoping that within the next month or so Ill be able to get all the remaining parts I need to swap the rear axle in and get the housing off to powder coat so I can stop worrying about that 8 inch diff. Also have started putting my lbj elimination plan into place with the new front control arms to keep things together untill I get the money and parts for the front SAS. Thats all for now

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The axle looks good! :D

Looks like a fun Moab trip, I can't wait to get back out there! The car looks nice too, having a second vehicle is almost necessary once you start running harder trails. I remember the headache all too well, I had to buy a $500 beater just so I could get to work Monday morning.

I have no idea why you have issues with rear wheel bearings! Haha

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The axle looks good! :D

Looks like a fun Moab trip, I can't wait to get back out there! The car looks nice too, having a second vehicle is almost necessary once you start running harder trails. I remember the headache all too well, I had to buy a $500 beater just so I could get to work Monday morning.

I have no idea why you have issues with rear wheel bearings! Haha

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No clue why the shafts and bearings keep getting jacked up haha. The second car has already been a lifesaver when it comes to the hassle of always feeling like "oh shit I need to get this done by sunday night so I can still make it work" Its cool to say your daily is also your crawler but it definitely gets old after awhile. Since getting it the 4runner hasnt moved off the jackstands in the garage and its so nice to be able to take the time to look at it from every angle and not feel rushed. Should really open up some possibilities.

Cant wait to see your "4runner" get put through its paces that thing looks badass! :biggrin1:
 
Can't wait to see how you set everything up to get that new axle in place! I know you're super busy, but I was wondering if you're still selling the plans for your skid plates?
 
Can't wait to see how you set everything up to get that new axle in place! I know you're super busy, but I was wondering if you're still selling the plans for your skid plates?

I've honestly just been giving them to people lately. I made the plans a long time ago and over time lost some.of the files so they aren't really complete anymore but still give a decent starting point so if you want them I can send them to you
 
Suppose its time for another multi month update lol. Pretty uneventful summer as far as wheeling trips. Middle of August we drove up north to Kalispell to go check out the Wild Bill OHV area. This is the only full size accessible OHV park in the state that I know of an is supposed to be the hardest of the hard. I honestly was a little disappointed, the majority of the park is man made obstacles and after awhile it all gets to be the same, you either end up making it or turtling out HARD which I did several times during the day. That ended up resulting in a ripped and bent transmission crossmember, broken transmission mount, and 3 bolts of the 4 that go into the trans worked themselves loose.

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And towards the end of the day this happened... Got super lucky that my slider dug into the wall and stopped the truck from going all the way over onto its side. Happened so fast and I honestly didnt feel like it was in a position it should have rolled but oh well, no damage and I drove out of it.

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This was also the first trip that I trailered the 4runner on which was pretty awesome, way less worrying about driving it home and all of that.

Next tip was a quick overnighter up to Blue Lake with some friends

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And then another overnighter to whitetail reservoir. This was a super sweet camp spot right on the shore of the lake that somehow had no bugs and was still as can be during the night. On the way out there though I was hearing a faint clicking coming from the driver rear tire fairly often. Checked the lugs multiple times and they were tight, so I figured what was going on was the bent axle shaft I never replaced had finally cracked at the bearing and was on its way out. I took backroads all the way home for fear of the shaft totally snapping and I didnt want to be going 75 in traffic when it happened. Well I got all the way to 3 miles from my house and she let loose on the offramp from the highway. Felt the truck drop and before the tire even went by I knew what it was, saw the tire go by and all I could think was "holy shit thats gonna go back on the highway and kill someone." Thankfully there was very little traffic and after several good bounces the tire ended up 400 yards down the road in the ditch so no injuries or real damages. Since the brake drum and backer plate were totally fubar I said screw it and drove the truck down the offramp into a dirt lot and let it sit for a few days to figure out the repair plan. Went down and pulled the shaft, brought it home and pressed in some spare studs and got it back together and limped home.

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So why did it fail? I really do not know, I know the lugs were tight not even 70 miles before but I do know that this specific corner had been severely over torqued by a certain firestone when I had them replace a bad valve stem a few months back. My guess is the two studs that sheared had cracked, hence the clicking, and the others had stretched so while they torqued to spec they were just elongating. After the two sheared it allowed the wheel to start wobbling working the other 4 loose until the wheel finally let loose. ITs my best guess but also a long shot, anyway just puts the final nail in the coffin for this 8 inch housing, the thing is bent about 3 different ways and has just had all it can take.

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This also ended up being the final trip with the supercharger as well, Ive never been totally happy with the power it gave and have really had a lot of headaches due to it. A knock sensor failure earlier this summer was what finally started putting the pieces together. Even after replacing the sensors and harness with all oem stuff the truck was still running in a soft limp mode below 3k rpm in boost where it would pull all timing out of the ignition curve and just fall on its face. What I figured out was when the rotors got under load it was making enough mechanical noise that it was somehow tripping the knock sensors above 3k rpm and the ecu was transferring that to lower rpm. I didnt want to disable the oem knock system for what realistically was a 30hp over stock gain so off it came and I sold it. So what was next? enter the turbo kit. Its the cx racing manifold kit with one of their nicer gt35 ball bearing turbos. Ill be going into more detail on the kit later but so far im pretty impressed with the quality and super excited to get it installed and running.

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Well time for an update. I finally got started on installing the turbo stuff a few weeks back and have made quite a bit of headway. I decided to just pull the entire motor out because I wanted to give it a really thorough cleaning and with the amount of disassembly I was going to have to do it just made more sense to do it on a stand.

Had a couple buddies over to help and plucked it out with the skid loader, took 8 hours start to finish.
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Yanked the stock manifolds off and luckily didnt snap a single stud in the block. The crossover pipe was another story, ended up breaking almost all of those.

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Next up pulled the valve covers off and went about adjusting the valves. Found 3 valves that were out of spec and moved the exhaust valves to the far loose end of the spec to make sure I wont have any burning issues with the added heat of the turbo. I got lucky and between 5 shims I grabbed at the junkyard and what was in the motor I didnt have to order any new ones.

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After I had the timing belt and all the internal stuff dealt with on the motor I went about mocking up the manifolds so I could hang the turbo to figure out oil lines. AAAnnnddd thats when this happened. No matter how I oriented the crossover this was as good as it would line up on one side with the other side clamped.

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I went back and forth with CX racing and was told to fill the gap with silicone and clamp it and after explaining that it wouldn't work because of obvious reasons was told "fix it your damn self." Nice customer service right? I also was not a fan of the tiny very stiff flex pipe they use so I got a larger more flexible section and rebuilt the whole damn thing to get it fitting up right.

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Dropped the pan to weld in the return bung and put together the return line itself with all -10an fittings. Not the most ideal setup but its about all I knew I could make fit with the placement of other things in the engine bay.

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To help control the heat some I cerakoted the outside of all the tubes and then used eastwoods internal header coating on the inside. Little bit of copper RTV on the vbands and we can assemble this bish

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Since I had the motor out and it was easy I also decided to through bolt the motor mounts so that they cant ever crack and split in half, this should allow them to compress like normal so no added vibration but act almost like a solid mount in tension. I plug welded the bolts in so I didnt have to modify the perches in the truck

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I also welded a mount onto the motor mount bracket on the motor in order to add a GM knock sensor that will interface with my piggyback. This will both allow me to monitor knock for tuning and delete the stock sensors if need be. Forgot pictures of that.

And after all that was buttoned up we dropped the motor back in.

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Obviously a start up video was warranted
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But now the real work starts haha. This is just the basic list I know off the top of my head
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Crossing a big task off that list today. Finished up the intercooler mounting and charge pipe routing/welding. Its not perfect but Im really happy with the fitment of everything and it has given me a lot of motivation to get it all finished up asap.

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Fitment with the winch is super tight but just enough
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Next up is getting the transmission cooler and fan re mounted over on the drivers side so that I can route the lines and start reassembling the accessory drive. Shooting to drive it this weekend
 
Got some more turbo updates. So after the last post I finished up the turbo charge pipes, mounting the tranny fan and getting a whole bunch of the vacuum system setup with various check valves and what not to ensure boost pressure wasn't getting to places it needed to be.

After all that I got the truck out driving for the first time and started tying to root out any issues. The first issue I was having was that just to get it to idle I was having to add a ton of fuel and even with that I was having a lot of issues with it not wanting to idle at the right speed, inconsistent throttle response, and overall it just seemed not right. I decided to zero in on the maf sensor since it is what controls the majority of the fueling and here's what I found..

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The pink line is the voltage the maf sensor is outputting and as you can see its all over the place. The peaks and valleys when overlaid on a graph of my AFR was also directly corelated to rich and lean spikes. So I had a turbulence issue that was causing inconsistent readings. After some research I decided I needed a flow straightener of some kind after the bend in the charge tube right before the maf. After a little work in solidworks and some time on the 3d printer here is what I came up with.

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Just a real basic honeycomb pattern that an inch and a half long. Flow restriction will be negligible since each line is only .004" thick.

And hear are the results. Buttery smooth and consistent maf values. This made everything from the idle to drivability way better and made the fuel trims predictable again
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Next thing I started working on was some sort of heat management. I had a lot of issues with the supercharger heat soaking and with the all aluminum radiator my under hood temps were ridiculous. Even just driving around at slow speeds there was always a giant heat cloud around the front of the truck and it just sucked. So heres what I came up with...

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Ill be building an aluminum duct underneath the hood so that snow and water will drain in front of the motor so nothing important is getting iced up. Even without the duct there's already a ton of airflow at idle shooting straight up out of the engine bay so this should really help get the heat up and away from the truck. Lots more work to do
 
I used the hood frame to mark out the lines. I cut from the back side with an airsaw and fine tooth blade. After it was cut I sanded the edges smooth and used some touchup paint fom duplicolor on the edge
 
By far my favorite 3rd gen build of all time. Glad to see this thing continue to evolve my friend. Can't wait to see the next stage with your custom housing SAS.

That turbo setup is making me get out the peanut butter to match all this jelly.
 
Finally getting some work done o this pile so might as well update the build.

Quite a bit has changed with the 4runner in the last couple months as far as the build plan and I am finally getting the time to work on it.

A few weeks ago I got the opportunity to toss the tuck on a dyno to satisfy my curiosity of knowing what the 4runner makes power wise and I was quite impressed with the numbers given how mild the setup is and how conservative the tune is. Final numbers after the 4th pull were 268 hp and 332 ftlbs at the rear tires on 35s, not too shabby for only pushing 8psi on a tune that is running next to no ignition advance and a super rich air fuel ratio. What really made me happy was the overall shape of the graph, I am still hitting my peak torque and horsepower essentially dead on what the factory setup is advertised to do and there isnt a massive spike in power as boost comes on, it comes in strong all the way through the rev range.

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While the power of the turbo and street drivability has been amazing there have been some odd tuning issues that I have been fighting with it when wheeling, these are mostly crazy fuel trims caused by the constant throttle inputs which cause the piggyback and stock ecu to kinda trip over themselves and at times it becomes very annoying and concerning due to the truck going super lean and feeling like it is going to stall out, not exactly the best thing to have happen on an obstacle! This was an issue even with the supercharger but has become much more noticeable with the turbo. In addition to those issues I am over the limit of what the 315cc supra injectors can support power wise which leaves me little to any safety net should something go wrong under load. After a lot of thought I made the decision to go full standalone using a haltech elite 2000 and add a set of 650cc injectors all sourced from SNP Speed Innovations. I spent several hours on the phone with the owner Gabe going over my options and goals and this seemed to be the best solution. Currently waiting for delivery of that here in a few weeks.

While I am waiting on the ecu as well as my new wheels I finally got it together to repair the quarter panel that I crunched on holy cross two years ago. The tailight was finally starting to lose cells in it so the repair had to be made since the tailight had to be ripped out and there was no hope of getting a new one in. It was a very time consuming process and I was very concerned about the paint blending out well but at the end of the day it turned out stellar! While I had everything cut apart I took a little bit of time to trim an inch out of the rear fenders and gut the flares like I had in the front to provide some more room for the new tires.

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Finished product minus blending the clear coat out, still waiting on it to cure to be able to do that.
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Its by no means show quality perfect but for my first major body repair and doing it in a garage it turned out very good and I hope it lasts for many years to come.

Thats pretty much it as far as updates, hoping to start on the suspension work here in the next month or so but I am just going to have to see what happens haha. In the mean time heres a sneak peak at the new meats and some other stuff in the works

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