Dropzone's 1994 4Runner Expedition/Overland Build

[Dropzone]

tested out my rear seat bottom removal bolts that I made a couple of months ago
They worked out great, was able to pop them out with out a wrench and took a few seconds

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The missus has an art business and the 4runner works great for hauling her display stuff
I used to have to lay the rack on top of the seat bottoms, awkward and wasted space
Now they go in first and lay flat

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[Dropzone]

took the grandminion out to his great grandparents house a few days ago.
He loves it because my folks live at the end of a long private gravel road so he can practice his driving skills
tatum by ocdropzone, on Flickr

mom had one of her flags out so had to get a pic of the 4runner's flag with her's
Screenshot_20181201-175245_Instagram by ocdropzone, on Flickr

 

[Dropzone]

I have participated in t4r.org's secret Santa gift exchange the last few years.
This year I recieved a set of RGB LED rock lights that you can control from your phone. I still have to figure out Austin's screen name but all I can say is Thanks!
These things are pretty dang cool.
Finally had a chance to play with them tonight. I will have to figure out how to upload a video with out photobucket, may suck it up and do youtube because having the lights play to music is pretty frigging cool

 

[Dropzone]

FJ Cruiser Side Sun Shade

picked up an FJ Cruiser Side Mounted Sun shade. I wasn't sure how well it would work but was happy to find that the mounting holes were the correct distance (fingers were crossed my guess was right) to match mounting holes for the stock grab handles on the door frame. Yep, they were

I will color match it when it warms up a little.
Should be nice during the summer

 

[Dropzone]

dodged a bullet a few days ago.
went out the night before to grab some stuff from the 4runner using the spare key. headed out the next day to make a run to the hardware store and found this..

 

[Dropzone]

played with some wiring today.
been wanting to add some fender mounted turn signals for awhile. Also added some grill mounted LED's like all the cool kids have. Mine have a little twist since the outer LED's double as signals.

 

[Dropzone]

Dual Gear drive transfer case to A340 auto install

Ok time to make this thing go slow
Dual T/C's recycled from the 81 Trekker
Trail Gear Skid plate
Inchworm Gear auto to geared transfer case adapter
RADesigns triple sticks

 

[Dropzone]

cleaned up the transfer cases, dug out parts, painted the crossmember and got a little side tracked.

I like my T-G tube bumper but really like an ARB bumper. But hard to get the missus to go for something that costs about 2x's what I paid for the 4runner.
I have always hated not having a place to stick stuff when working on the 4runner. With the help of a CAD program(Amazon box) I used some scrap aluminum diamond plate, made a fascia piece for each side. Drilled and tapped the bumper for some #8 Allen bolts.
​​​​​​​

 

[4Reak Show]

Don't forget to check out Coastal Offroad for bumper options. They have some killer kits for our 2nd gens. Better than ARB in my opinion. I'm just waiting for nice weather to paint it. They are weld together kits, and [MENTION=77310]BrandonF[/MENTION] has been on the spot for all my concerns.

Any questions about it let me know. Either way, your current setup is marvelous. Gonna love seeing the duals, keep it up as always.

 

[Dropzone]

Did a few miscellaneous projects for #turnsignaltuesday before starting the transfercase.
Eliminated my zip tied license plate mount by welding a couple of bolts to center mount the license and the turn signals are hard mounted after 3 years of zip ties.

Truck will be sentenced to the garage for what is hopefully only a few days for converting the A340 auto to geared transfer cases
When I made my version 1.0 of LED tail lights I got a little crazy with epoxy and it got lopsided and blocked part of the LED's.
Version 2.0's LED's are free of any epoxy on the lenses. Output should be clearer and more even

 

[Dropzone]

2nd Gen Turn Signal Flasher

My turn signals have been having a hyper flash effect since I converted to LED's. [MENTION=80771]RAD4Runner[/MENTION] mentioned a couple of ideas to fix it. I remembered I had an EP-35 LED compatible flasher unit stashed.

The 2nd gen flasher unit is a pain to get to. Its mounted under the dash to the left of the steering column.
The EP35 is a direct replacement for the stock flasher
Link to video on IG showing normal turn signal instead of hyperflashing
Robb on Instagram: “The 2nd gen 4runner turn signal relay is mounted on the left side of the steering column. Sorta a pain to get to. Pulled the lower cover…”

 

[RAD4Runner]

...
The EP35 is a direct replacement for the stock flasher
Link to video on IG showing normal turn signal instead of hyperflashing...

Nice!


https://scontent-lax3-1.cdninstagra...c_ht=scontent-lax3-1.cdninstagram.com&vtsbc=1

 

[Dropzone]

Nice!


https://scontent-lax3-1.cdninstagra...c_ht=scontent-lax3-1.cdninstagram.com&vtsbc=1

Thanks!!

Been feeling like crap for a couple of days but had to get off my butt and get going on converting the chain drive t/c to gear driven dual cases.
Oh and note to self: next project vehicle is gonna be a manual transmission. I frigging can't stand the smell of ATF
First thing was installing the @radesigns_products triple sticks. Install is straight forward except I fought getting the rear case to go into 4wd. It had been several years since I worked on transfer cases when I remembered about the detent spring. Gave the Allen head bolt a few turns.. now it goes into 4wd/2wd and low/high easily

Pile of parts on one side. Similar pile under the truck

And the diamond plate bumper covers I made a few days ago work great for a drink holder

Hopefully make better progress tomorrow

 

[Dropzone]

Finally feeling better so was able to finish the tear down of the A340 transfer case.
One interesting thing I didn't notice until I went to pull the cross member is that the driver side mounts outside the frame rail while the passenger side mounts to the inside of the frame rail.
Found some paint pen marks on the output shaft, makes me wonder if that is from the factory or somebody worked on this thing before.
The last gear section probably weighs was much as the geared dual cases..thinking the truck actually may end up lighter by a few pounds

Anybody need some auto t/c parts? Free just cover shipping

 

[superex87]

So you converted a A340H from the hydro transfer case to a gear drive case? What conversion kit did you use? Or does this just bolt up?
My 4Runner is a 94 as well and this is something I would love to do with mine. Keep up the good work! Truck looks great.


Sent from my iPhone using Tapatalk

 

[Dropzone]

So you converted a A340H from the hydro transfer case to a gear drive case? What conversion kit did you use? Or does this just bolt up?
My 4Runner is a 94 as well and this is something I would love to do with mine. Keep up the good work! Truck looks great.


Sent from my iPhone using Tapatalk

I am using the Inchworm Gear Auto to geared transfer case adapter.
I bought mine a year ago just after Trail-Gear bought Low range Off Road(who had bought inchworm) I don't see it on Low Range's website any more.

I am about halfway through the conversion, hopefully finish it this week.

Looking around the web I am not sure you can get a new adapter anymore. Marlin has a 5 speed adapter.

 

[Dropzone]

The slowest Auto to geared transfercase conversion continues and I may have run into a big snag. When I ordered Trail-Gear crossmember from [MENTION=4819]lowrange[/MENTION]offroad over a year ago I didn't notice it said it was not for autos. I guess I was pumped to see a good deal with free shipping(it weighs a ton)
The mounts are the same as the factory, if push comes to shove I found my Bud-Built crossmember from the Trekker. I should be able to use it to help make an extension if need be.
I would rather go this route than have to go to a Front Range Off Road type of crossmember that bolts to the back of the transfer case.

Got the output shaft cut on the transmission so for sure no turning back now.
Hard to believe this thing still has fluid draining after a few days. Started to pull the pan and it started coming out again.

Should get the valve body pulled tomorrow to convert the parking pawl(stock is in the t/c)

 

[Dropzone]

Got the valve body off the A340H. Sort of a pain.
Looks like someone had been in the trans before looking at the dents in two of the tubes. The two co springs to the front went flying. Thought I saw something else pop out.
The small check valve spring/ball didn't fly.
I did find a small part in the bucket the ATF was dripping into. @radesigns_products hoping you might know what it is. It was the same bucket from the t/c so it could be from that.
No luck in the manual or finding it in parts diagram or YouTube videos.

So finally found the part # for the gasket 35433 30064.
Rory confirmed for me on Facebook that the gasket has to be replaced. I was hoping to not have to tear into it that far...oh well

This thing may not be back together this weekend ray:
I should have worked on it earlier in the week.

 

[Dropzone]

So to make this thing be able to park you have to remove the valve body to convert it. OK no problem. Mentioned in post above the valve body needed gaskets
Those came in after a few days. Dealer said both were there. So start taking it apart to replace the gaskets
Oops I get two of the same. Fudge...
Taking
Finally got up the nerve to start replacing the valve body gaskets plus it took a few days to get gaskets. Dealer said both gaskets were there..cool..well got two of the same..
so road block #1
Road block #2 is a small plunger fell out when I lifted the upper portion of the valve body apart. Gotta figure out where that goes, looked at assorted stuff on the web I know its # 35449B/C and goes above a solenoid.
Fortunately that is the only thing that popped out. Check Balls and strainers all stayed where there should be.
If anyone has advice I surewould appreciate it #a340 #canofworms

I thought I would have had problems with the check ball but got lucky there. Ordered a gasket set off Ebay so will start again when it gets in.

 

[Dropzone]

Ok so since I am kinda stuck at this point and burned out looking at transmission diagrams I stole the bathroom scale and wanted to find out of the 4runner was gonna loose a few pounds with this conversion.

threw this pile in some buckets(minus crossmember)


the chain drive parts ended up weighing 101 pounds between the two buckets.

the assembled dual gear drive cases were 120 pounds

So for a net increase of about 20 pounds more gearing options and two more levers on the transmission tunnel the additional weight will be worth it.
​​​​​​​trivial I know ...
,