Dropzone's 1994 4Runner Expedition/Overland Build

[Cali 4runner]

Right on! I can imagine wanting more power.
What about the new cummins r2.8 diesel? Sweet but $$

 

[Dropzone]

Right on! I can imagine wanting more power.
What about the new cummins r2.8 diesel? Sweet but $$

that would be pretty cool..this thing is on a tight budget some who knows what will happen


Finally had time to work on this thing yesterday afternoon
Found out that on th A340H Transfer case the output flange acts like a jeep slip yoke and is the seal. Went to pull the stock flange to add the multi pattern flange and it puked a few quarts of ATF
20171111_151633 by ocdropzone, on Flickr
to top it off the two flanges have a totally different spline count and spline pattern..
20171111_151654 by ocdropzone, on Flickr
the stock out put has pinned studs instead of bolts. I ended up using an 11mm drill to enlarge the holes on the driveshaft flange to make it work
20171111_152238 by ocdropzone, on Flickr
I used the long slip driveshaft from the 81, ended up taking 5" from the outer and 2" from the innershaft
20171111_172557 by ocdropzone, on Flickr
20171111_180557 by ocdropzone, on Flickr
i finally have 4WD just in time for winter daily driver duties and hopefully a few snow runs
20171111_182215 by ocdropzone, on Flickr
had to use the old headlamp to get stuff done since it was dark early
20171111_183104 by ocdropzone, on Flickr

 

[Dropzone]

i have a pile of spare parts and left overs from the trekker.*3rd Gen Trucks have a ton of decent LED taillights on the market but aren't compatible with 4runners due to the mounts. No LED aftermarket LED tail lights that i can find for 2nd gen 4runners and stock taillights even with bright LED replacement 1156 and 1157's leave a lot to be desired so decided to experiment
220* for 12 minutes did the trick
20171115_115127-1*
20171115_120936*
throw tail lights from Trekker and some clear KC LED for signals
20171115_121735*
running lights
20171115_122532*
brake and turn signals
20171115_122849*
not too bad with faded stock lenses

I'll polish the lenses and clear coat them
Maybe rear spray the reflectors before final assembly

 

[Dropzone]

So went to polish the lenses since they are faded as heck, they cracked like crazy
20171116_132114*
pretty much a waste of time...I was heating and separating the housings from the lenses since that is how you do it for headlights...well a set of trashed housings and some frustration i think,*
Hey idiot why didn't you just cut out the back of the housing to mount the LED's (amber light for mock up), Version 2.0 won't have as big of hole cut for the brake light.
20171116_131232**
would have been time and money ahead if I would have done that the 1st time around.*
so said screw it and ordered a new set of aftermarket housings off ebay since the last good set of housing I have has 25 year old lenses and what to keep one good set unmangled.
Also ordered a set of Clear LED brake lights since they should show through the red brake light better.
overall cost will be about $70 and lessons learned.
Version 2.0 should be done next week when stuff comes in and I'll fiberglass the LED's into the new housings

 

[Dropzone]

inventoried the Prius Winter Recovery Kit, with the addition of some soft shackles I figure I can shed a few pounds of steel by dumping some steel shackles. Some I have had for 25+ years. I have a ton more stuff for recovery, I would like to get a 50' winch extension sometime.
The chain is used to remove deadfall

 

[Volcom]

After using soft shackles this year, they are the way to go! I need to order a couple.

 

[Dropzone]

After using soft shackles this year, they are the way to go! I need to order a couple.

Good to hear, i want to pick up a couple more.

How is the snow wheeling is Colorado?

 

[theneckasaurus]

Sweet build! Quick question, the pods you have in the rear that are work lights and turn signals, I've searched just about every variation of "flush mount led work lights/indicator light" you could think of. Do you happen to have a link?

 

[Dropzone]

Sweet build! Quick question, the pods you have in the rear that are work lights and turn signals, I've searched just about every variation of "flush mount led work lights/indicator light" you could think of. Do you happen to have a link?

I found them on ebay, i don't think these are the exact light but very similar
https://www.ebay.com/itm/2x-4Inch-3...ash=item5442d73c91:g:T-IAAOSwnDpaFTrB&vxp=mtr





The transfer case has been making an intermittent noise lately.* Yesterday on the highway going to Turkey dinner it became more noticeable at 60+MPH.* Pretty sure it is the out put shaft bearing.
Instead of dumping $$ into fixing the auto T/C (transmission is working awesome) and my eventual goal was to put the dual cases from The trekker in the 4runner, the missus and I talked it over and I got the go ahead to get the Inchworm auto to geared case adapter.* I was dreading it because it seemed like the price was just going up.
Well I will say thank God it is Black Friday.* Dunno if the adapter was already on sale but it was $325 from Low Range Off Road with an additional 5% off with free shipping and a free T-shirt
dual auto cheap*
so hopefully after the 1st of the year i can get the adapter in (pic borrowed from low range)
dual auto adapter
And have a big huge thing looking like this to put in the 4Runner*(pic borrowed from low range)
dual auto tc*

 

[Dropzone]

decided to give a kinetic recovery rope a try.
These guys are local to me https://spartanrope.com/products/spartan-rope-black-friday-bundle-free-shipping
Black friday sale was a pretty good deal with another soft shackle & storage bag.
Nice and light to stash in the back

 

[Dropzone]

Had a close call tonight, glad the ABS was happy click image to play
fast forward to about 45s
close one 11.30.17 by ocdropzone, on Flickr

 

[Cali 4runner]

Yikes..

That dash cam is so clear.
Were your headlights on? Really hard to tell

 

[Dropzone]

Yikes..

That dash cam is so clear.
Were your headlights on? Really hard to tell

thanks, it was close. Glad i was already slowing down for the red light

The Dashcam is a Garmin Dashcam 55, a little pricey but it has a ton of cool features like voice activation, lane departure warnings and a few other cool features

the same thought crossed my mind about my headlights but I could see them on the sides of cars as people turned in front of me and on street signs etc.

 

[Dropzone]

LED taillights

Finished up 2nd gen LED conversion 2.0
Came out better than 1.0 but could use a little improvement. I used too much epoxy and it ran down into the lens but the output is awesome over what I had
20171130_120113 by ocdropzone, on Flickr
20171130_120246 by ocdropzone, on Flickr
20171201_154454 by ocdropzone, on Flickr
20171201_154516 by ocdropzone, on Flickr
20171201_172920 by ocdropzone, on Flickr
night shots don't do it justice, the output over 1157/1156 LED's is awesome
20171201_172955-1 by ocdropzone, on Flickr

 

[Dropzone]

parts List for LED converison

got a couple of messages on instajunk and another forum asking for parts and price list so here you go
for the lights I ended up ordering a set of new housings off ebay. I ended up cracking a few lens trying to separate them from the housing. It was easier to try a brand new cheap set
I was able to use the 4" hole saw I had when i did the round lights in the the Trekker. I wasn't able to get all the way through as I ended chewing up a little bit of the inside of one lens.
But it gave me a good outline and I was able to finish cutting the rest to get a rough fit using my dremel. The backside isn't pretty but if I ever make another set i know what to expect

Here is the parts list:
Housings I got on ebay
a pair for $50 shipped, over all quality is decent for the money and if I ended up destroying them during the experiment I wasn't out a ton of cash
https://www.ebay.com/itm/Pair-Tail-...ash=item36043574e6:g:SSoAAOSwBt5ZHca2&vxp=mtr

Brakes lights I was going to order some from Amazon like this, but I found a set of clear ones brake lights I used on the 81 at some point $25/pair
https://www.amazon.com/gp/product/B00K5J23Z6/ref=oh_aui_detailpage_o08_s00?ie=UTF8&psc=1

Turn signals I used a set of KC Cyclone LED's in Clear, again left over in the stash of junk from the 81
https://www.amazon.com/KC-HiLiTES-1...d=1512257173&sr=1-1&keywords=kc+cyclone+clear $26 each, $52 a pair

misc epoxy (i used too much and it dripped into the lens) $10-12 from Ace hardware

so realistic cost was $135'ish but I consider the cost to me more like $60-65 since some parts was stuff i had around few at least a few years.

I used a couple of housings that were the originals on the truck and a set i was given. Still have a couple i bought that will stay on the shelf for back ups. Had a guy ask me today where I got them when i was X-mas shopping. He said that I should have just used 3rd gen truck lights, nope not gonna work unless you do some body work.

For a little more money this set of Euro lenses would be cool using an Amber KC LED for the turn signal
https://www.ebay.com/itm/1990-1991-...sc:ShippingMethodStandard!97078!US!-1&vxp=mtr

 

[Dropzone]

Took the plunge and ordered a kinetic recovery rope from Spartan Rope on Black Friday. Thanks for the recommendation @the_great_him ! Not only did I get a great deal on a great product but they dropped it off personally to my house. Totally unexpected, wish I had been around

 

[Dropzone]

This pile got delivered a week or so ago, piled in a bunch of Xmas deliveries
Never pulled an auto transmission before so gonna be a learning experience but a good one

 

[txlonghorn85]

Just read the last page, and I'm going to need to read the entire thing. Great information, and you have good taste. One note about the IW auto adapter... it was already on sale because Low Range (owner of IW) was recently purchased by Trail Gear and as such, Low Range has discontinued production and support of all IW products. They were liquidating stock. This is presumably so Trail Gear can copy and replace these adapters with their own parts, just as they did with Marlin's adapters. Just thought I'd give you a heads up.

Keep in mind that you'll need 23 spline gear cases now. I also run an a340h and chose to replace with an AW4 auto (same innards) thus giving me access to cases like the Dana 300 and Atlas. More/stronger choices.

 

[Dropzone]

Just read the last page, and I'm going to need to read the entire thing. Great information, and you have good taste. One note about the IW auto adapter... it was already on sale because Low Range (owner of IW) was recently purchased by Trail Gear and as such, Low Range has discontinued production and support of all IW products. They were liquidating stock. This is presumably so Trail Gear can copy and replace these adapters with their own parts, just as they did with Marlin's adapters. Just thought I'd give you a heads up.

Keep in mind that you'll need 23 spline gear cases now. I also run an a340h and chose to replace with an AW4 auto (same innards) thus giving me access to cases like the Dana 300 and Atlas. More/stronger choices.

thanks, appreciate it

I had texted/emailed LROR back in may when the sale to T-G was announced. Trail Gear definitely has a habit of copying stuff. I bought a Bud Built Dual Case crossmember from Chris Gieger (use to work for T-G) 9 or 10 years ago for my 81 Trekker- it came shipped from Trail Gear, what came out a few months later- T-G's dual case crossmembers.

Wasn't sure if it was reduced due to the sale or what, either way my accountant- aka: the missus said go for it

I was able to get the 23 to 21 spline adapter. Funny thing is was shipped from Advance Adapters. Hopefully the 21 spline duals out of my 81 survive for awhile, plus i have 2 more complete cases and a pile of T/C guts. Plan is to take it easy on this truck. Pretty much out of my rock crawling phase but want the option to gear down and not hammer on the truck.
definitely a size difference between the 21 and 23 spline

 

[boscounderfoot]

Hey Ranger!

added a few more horsepower to the 4runner.

spent some time on a Long Range Surveillance team a lifetime ago, my Long Range *Recon membership packet finally came in..

Howdy!

I've got a fresh decal just waiting for the new paint job!