Dropzone's 1994 4Runner Expedition/Overland Build

[Dropzone]

I haven't been really active on this forum since my long term project has been an 81 Toyota Trekker:



The truck is highly capable: 5.29's, dual cases, full caged.
It has been fun for the last 8 years but it is just getting beat to death. Frame is about shot. I am kind of tired of the whole beat the truck in the rocks phase.

I have been thinking about another truck/4runner as a replacement. SOmething that can act as a capable weekend warrior/semi daily driver.

So a few days ago look what the Dodge dragged home

Picked up my neice's 1994 4runner with 195k on it.
Recent rebuild on the 3.turd so it actually runs decents, dog slow with the Auto.
I got it dirt cheap, low 3 digit numbers due to a failed bearing/CV on the right front wheel that lead to this

Totally froze on her and freaked her out. Her mom said come get it.

It is kind of dirty but should clean up nicely

Has the usual drivers side torn seat but other than that nothing sometime with a vacuum and carpet cleaner can't cure

Plan is to tear apart the right front and see what got fubar'ed.
It needs tires, an exhaust and the left rear passenger window won't roll down.

Long term plan is to turn it into a more family friendly trail runner, won't have the same capabilities as the Trekker but time will tell. Looking to build something I can take the grandkids out to enjoy the woods in and maybe the occasional 2-3 night weekend expedition.

It will get some front (with a winch) and rear bumpers, probably an extra gas tank, drawer unit/sleeping platform. Maybe something like an ARB fridge.
Definitely a locker, sliders.
Thinking 33x10.50's for tires.

Build will be a slow one

 

[ralatkins]

Same year and color as mine.... I am intrigued

 

[BigRyan1986]

[MENTION=101372]Dropzone[/MENTION] Nice runner it is also the same color as mine. Im in Lakewood WA and i am parting out a 2nd gen if you need anything let me know

 

[Dropzone]

Same year and color as mine.... I am intrigued

Thanks, I kind of like the color too

[MENTION=101372]Dropzone[/MENTION] Nice runner it is also the same color as mine. Im in Lakewood WA and i am parting out a 2nd gen if you need anything let me know

Ryan- thanks, may hit you up for some stuff.
Gotta figure out what direction I am going to go suspension wise (LT or SAS) but may fixed the Fubar bearing and axle and drive it stock this winter.

 

[BigRyan1986]

Thanks, I kind of like the color too


Ryan- thanks, may hit you up for some stuff.
Gotta figure out what direction I am going to go suspension wise (LT or SAS) but may fixed the Fubar bearing and axle and drive it stock this winter.

Im planning a SAS this winter and maybe rebuild my engine or swap it. I have to get the wifey out of the hospital first.

 

[Dropzone]

Im planning a SAS this winter and maybe rebuild my engine or swap it. I have to get the wifey out of the hospital first.

Prayers your missus gets better, been there myself a long time ago. It can be rough

Installed my $5 pick N pull vent visors I scored at the Labor Day sale

And scored a bunch of parts I need now and some for just in case since the price was to good to pass up, most of it compliments of the Great Him, thanks Isaac

 

[BigRyan1986]

Prayers your missus gets better, been there myself a long time ago. It can be rough

Thanks for your thoughts. She gets to come home today or tomorrow :happy:. I actually saw a fresh set of vent shades this weekend at my pick n pull. I would have bought them if i had the extra money. Scored some seats for my bro in law's 86 2wd yota project and some brand new lowering/lift blocks. We are going to put a real healthy 327 into his 2wd once he gathers all his parts together.

 

[Dropzone]

Started pulling stuff off the Trekker over the weekend
I am really glad I never installed my winch on this bumper, it took about 10 minutes to drill out rosette welds and cutting with a cut off wheel to get it off. I am pretty sure the winch would have peeled it off.
But it certainly served it's purpose over the years and I am hoping it will bolt up to the 4Runner since the T-G winch plate was designed for later trucks

Sliders are beat but new legs will let them have a new life on the 4Runner

 

[KidVermicious]

NOOOOOOOOOOOOOOOOOOOOOO you're taking the Trekker apart??? Don't do it man!

 

[Dropzone]

NOOOOOOOOOOOOOOOOOOOOOO you're taking the Trekker apart??? Don't do it man!

I hear you. It was a tough decision but after almost 9 years the Trekker is just plain tired. Financially it was an easy decision to recycle a lot of stuff from the trekker. I figure by the time I buy brackets, an auto to geared t/c adapter and other junk I will be into the 4runner for less than $2k including the purchase price of the truck

 

[PlanetExpress]

What are you going to do with the trekker? It's a great looking truck man. Shame to see it taken apart.

 

[81Trekker]

If your thinking of selling it I may be interested. But I think you should keep it and turn it into a nice DD/weekend toy! I would hate to see another Trekker bite the dust...

 

[Dropzone]

What are you going to do with the trekker? It's a great looking truck man. Shame to see it taken apart.

Thanks for the compliments. The Trekker is being stripped down to the shell, frame, engine & Transmission. I am keeping the dual cases, axles, springs and seats

If your thinking of selling it I may be interested. But I think you should keep it and turn it into a nice DD/weekend toy! I would hate to see another Trekker bite the dust...

The trekker was pretty beat when i got it 8.5 years ago. The top leaks in a couple of places. I am kind of tired of dealing with 35 year old truck issues as far as wiring etc. It looks like it will be going back to one of the former owners of the truck.
I am pretty burned out on the truck. I took the front axle apart back in June to rebuild it and it has just sat. Since picking up the 4Runner my wife has said it is nice to see me motivated again.

Having a 4 door weekend warrior will be nice for mild trail running. My kids are getting older. My first grandson was born in July so the 4Runner will make hauling him around easier.

 

[Dropzone]

Pretty confident I found the root cause for the right front wheel seizing
When pulling the axle out I found this little gem

 

[Dropzone]

Started swapping out what some of were probably the original bulbs. I am going to need to clean some contacts, some of the LED'S made a huge difference, some not so much.
Map light with 4 SMD 5050 LED compared to the old one

Old vs. New
Maps lights I should be able to find stuff :hillbill:

With all the domes/maps

I will probably add a couple 3w LED rock lights in the back to brighten it up in the cargo area.
Hard to tell from the picture but the brake lights are way better

The 21 year old lens are pretty faded so i'll either need to polish them or pick up new housings.

 

[Dropzone]

Suspension Price List

here are some of the prices I have come up with for doing my SAS and convert to rear leaf springs
front suspension:
Front Spring Hanger Options-
Traditional/commonly used Trail-gear that seems to had 1.5-2" to a lift
front spring hanger $95 normal t-g
Trail-Gear Front Toyota Leaf Spring Hanger w/Bolts and Bushings (110045-1-KIT)

Low range off road low profile front spring hanger $90 - this is the one I will probably go with
Low Profile Front Toyota Leaf Spring Hanger w/Bolts and Bushings by Low Range Off Road (TSP-FSH-LR)

Details
If you are looking for a front spring hanger for your Toyota, this is the best engineered front spring hanger available today. Why? We have found that with excessive off road use, the front hanger can be bashed in many times. The hanger itself usually holds up, but the factory Toyota frame doesnt. The amount of surface to weld on many hangers allows the frame to tear out and roll under the vehicle, especially on Tacoma's.

This hanger resolves these issues by increasing the amount of surface area to weld.

Its also designed to be "Low Profile," meaning that it does not give as much lift as other hangers on the market, by over an inch. That means that your "3 inch springs" will be closer to the 3" lift you are expecting. Your "4 inch springs" will give you closer to the 4" lift you were expecting......and down the line.

FAQ:

Question: Why won't my factory spring hangers work with new longer springs?

Answer: Many aftermarket springs for the Toyota are increased length over stock. In order to allow for maximum flex, they have to use a longer shackle. When you use a longer shackle, your caster is affected. Caster is the forward and rearward tilt of the steering axis from true vertical. If the caster is not correct, your steering wheel will not return to center and your handling will greatly be affected. This hanger allows for: Longer Springs, a "drop" of the front of the spring so that slightly longer shackles can be used in the rear of the front spring while correcting caster so that your vehicle handles correctly.

Question: What front springs will work with this hanger?

Answer: OEM and Aftermarket front springs ranging from OEM length to 47" Long. You will need to weld this hanger in position so as to have a correct shackle angle in the rear of the front spring. It will also assist when doing the common "Rears Up Front" swap.
front shackle frame jig $27
Toyota Solid Axle Swap (SAS) Frame Tubes & Jigs

front shock hoops $65 - if I can't salvage my current set off the Trekker
Inchworm Gear Automatic Transmission Adapter Kit (TCASE-IW-ATAK)

Front bump stops $45
Toyota Bumpstop and Extensions Package Kit

IFS Steering Box mount $45 (not needed)
Toyota IFS Steering Box Mount

Found some cool front frame plates that I will probably go with from
https://www.facebook.com/Xofab?fref=ts
Extreme Options Offroad & Fabrication 4x4 Enumclaw WA | Fabrication Enumclaw | Welding Services Enumclaw

They have a frame plate with an IFS box mount built in:
priced cheap around $50

and a frame support for where the frame is drilled for the rear spring shackle:

front suspension: ~$225-280

rear suspension:
rear upper shock mount $60
Toyota Rear Upper Shock Mount (TSP-RUSM)

rear spring mount hanger (front ) $40
Welded Toyota Leaf Spring Hangers

rear spring shackle mount $45
Toyota Rear Leaf Spring Shackle Mounts (110027-1-KIT)

rear bump stops $45
Toyota Bumpstop and Extensions Package Kit

rear suspension $190

so for about $500 i will have a pretty decent but partially recycled suspension

 

[Dropzone]

Picked up a set of half doors today:hillbill:

Stripped it pretty quick have a nice Crack free dash and other misc stuff

 

[v_man]

I would recommend using those front frame rail enforcement plates, $39.99 is a great deal too, think I paid $80.
By the time you hang a front bumper and wench off the front end, and with turning big tire related stress,
you are really asking your stock frame to do a lot.

Also , gusset and reinforce the heck out of your front shock hangers if you go hoops, ask me how I found out...

before...

after...

 

[Dropzone]

For shock mounts, I may go with Ford Shock towers..

i will definitely be installing the frame reinforcement plates.
I ran into an issue on my 81 where the frame was slightly cracked due to the front spring hanger placing stress on the end of the frame,
I made some brackets like this


ugly welds, but have held well.
I will add something similar to the 4Runner
I think going with the low profile Low Range Off Road front spring hanger will help eliminate some of the stress.

I also really like how the Extreme Off Road Options frame plate has the Steering box mount integrated, that should help reduce stress too.

 

[Dropzone]

started ordering parts yesterday for the SAS.
Ordered this from Extreme Options Fab Thursday morning, had it Friday afternoon. I will be ordering stuff from them again

the integrated steering box mount is a nice touch
rest of the stuff should be here monday from LROR