Extreme 3rd Gen Build! Insane!

[NotKewl]

*** WARNING ***​

This build thread contains shocking images of a perfectly good 2002 Toyota 4Runner being torn apart... I mean to shreds, and built back up as a one-off hardcore ROCK CRAWLER / TRAIL RIG capable of defeating the toughest trails in the nation! Moab, Rubicon, et al, here we come!!! And from bone stock to trail ready in less than 6 months! Those of you sensitive to seeing sheet-metal ripped, torn, cut, welded on, parts flying, etc. should avert your eyes. Move on to another mild build with plastidip and simple aftermarket bolt-on parts that my 8-year-old could install in her sleep. This isn't the build for you! But if you are ready to see some kewl 5H!T, then you are in the right place because it's about to get real up in here!

TOC to specific parts of the build and full parts list below.

*** END WARNING ***​

Shall we begin then? ......

The base vehicle:
2002 SR5 4WD

The previous setup (prior to June 2016) is the usual starting point for these rigs, a mild lift (3") bigger tires (33"), new upper control arms, some armor, twinkly bits like go faster stickers, etc. You know what I mean. What we all do when we get a new T4R Toy, we pamper it and bestow many gifts of easy to bolt on parts.

Here she is June of 2013, the morning after a 1.5-hour flight to Pensylvania where I purchased her CHEAP (eBay), followed by an eight-hour drive to North Carolina (where I lived at that point in time).



The first build was pretty much the same stuff in a dozen or more threads on this site and several other forums have that show the lift kit install, how I blacked out all the chrome, etc. Stuff I won't bore you with in this thread. Why? Because this thread is dedicated to the BIG HARD-CORE build up. Yup, SAS with 1 tons, body mods, engine mods, etc. Basically, I'm building a street legal-ish rock crawler (because I live in Tennessee now, and that's what we do here, play on the rocks)!
Here she is in 2015. What she looked like up until September 2016.


Here's a quick video of its previous state running trail 41 (black) at Adventure Off Road Park in South Pittsburg, TN during Trail Fest 2016. Keep in mind, this vehicle still had the IFS up front and was only locked in the rear until the last night of trail fest took out my rear ring gear (that's what prompted this extreme build). Now, those Dana 60's in my basement get put to use, yeah buddy!
Trail 41 - Trail Fest 2016 - YouTube

And this is what she is starting to look like now... And getting better every week!


CHIMERA
Current Specifications (as of April 2017)
Drivetrain & Suspension

• Front Axle: Fully built King-Pin High-Pinon Dana 60 (1978 Ford F350 Snowfighter Axle) with ChroMolly Axles, 35 Spline inner and outers, drive flanges. Lincoln locked factory 4:10 gears (will be upgraded to 5:36 later)
• Rear axle: GM Corporate 14 Bolt Full Float with ChroMo axle shafts and Disc brake conversion. Lincoln locked 4:10 gears.
• NP205 Transfer Case with Blackbox underdrive and triple sticks
• 16" Radflo 2.5 air shocks
• Front and rear Line locks (For doing digs - that's what triple sticks does for you :naughty: )
• Trail-Gear 8" Ram and Full Hydraulic Steering Kit

Tires and Wheels

• Total Metal Innovations DIY Beadlock kit
• Pro Comp Series 90 Steel Wheels
• Pro Comp Extreme MT/2 tires in the 40x13.50x17 flavor

Body Mods

• Dovetailed front and back
• Custom built cage and tube back-half
• FJ-40 style grill and headlight mod
• Custom LED Lighting

Build Table of Contents
Tear Down:

• It Begins
• Window removal and sheet metal cutting begins
• Rear suspension removal
• Interior tear down
• Project name and logo.
• Front suspension removal

Build up:

• Tires arrive!
• Rims, Beadlock building, and Disk Brake conversion and GM 14 Bolt Axle build start
• GM 14 Bolt axle build finish
• Mounting tires
• Fuel Cell build up
• Start of Dana 60 build and Transfercase Build
• Oil pan swap

Electrical:

• Electrical Wiring Explanation

Final Tear Down for Repurposing.

• 
  Saying Goodbye to the ol' girl

 

[ShooterMcGavin]

Ok... I've got to see what happens here

...I'm loving the numbers so far. Dana 60, 40" tires, triple sticks,...

 

[NotKewl]

*** Edit Note *** I did not end up using this doubler and it' for sale if you are interested PM me.

Looky what the UPS man brought me today! My GM NP203 Range Box to mount up to my Ford NP205 transfer case. Built specifically for my rig (as a divorced unit) by the engineers at Offroad Design in Colorado. Got the triple stick kit too. This rig is going to not just be a masterpiece, but also a billy goat!

Here's the triple stick shift kit for the dual range setup. I will convert the 205 shift rails to allow for front digs. Basically, separate the front and rear outputs so that I can run the T4R in just rear wheel drive, or just front wheel drive in any setting: 4H, 4L, or 4Double Low (4:1 crawl Ratio).

More to come!

 

[4Runnin2000]

This thread is starting off very nicely.

 

[Scramble]

Thanks for reminding me why I dont do Black trails. Good luck with this sick build!

 

[Gadgetguy]

Thanks for reminding me why I dont do Black trails. Good luck with this sick build!

Dude your truck could drive that

 

[Kotrin]

On my 3rd gen build thread you can see my Father's Single Cab Toyota Pickup(Hilux minus the diesel) and he's running RCV axles and triple stick like your showing. When we buried down to the Frame in his pick-up on our overland trip, it was a simple low gear and he walked up as if it was nothing. He went to MOAB 2 weeks prior and walked up (I forget this trail but included a picture). He wants me to go next year and says I can do pretty much EVERY trail with my rig as it sits (minus the extreme, but their is trails to bypass everything).




Did I hear UCA for sale?? Shoot me a PM with your price if you trully are wanting to get rid of them..

Loving the build and subscribed!

 

[NotKewl]

He wants me to go next year and says I can do pretty much EVERY trail with my rig as it sits (minus the extreme, but their is trails to bypass everything).

Yeah, I've taken I lot of crap from folks about my IFS, but I've taken my basically stock rig (except for lift, tires, and locker) on some pretty tough trails, and big hill climbs with no problems. It's more about the way you drive it. Don't stomp on the skinny pedal with the front wheels fully clocked over left or right, try it, and if it's not going to go, don't be macho, go to plan B (winch).

Strangely enough, this stock rig has pulled Jeeps with 35's and full lockers out of some tough situations before. Giving it's joking nickname of the Jeep Recovery Unit.

In fact, even riding on black trails with just 33's, I rarely have to winch and I've never broken a CV joint. The only thing I've ever busted was after a hard weekend of wheeling the Trail Fest, I bounced on a night run and popped my Ring Gear.

 

[Kotrin]

Yeah, I've taken I lot of crap from folks about my IFS, but I've taken my basically stock rig (except for lift, tires, and locker) on some pretty tough trails, and big hill climbs with no problems. It's more about the way you drive it. Don't stomp on the skinny pedal with the front wheels fully clocked over left or right, try it, and if it's not going to go, don't be macho, go to plan B (winch).

Strangely enough, this stock rig has pulled Jeeps with 35's and full lockers out of some tough situations before. Giving it's joking nickname of the Jeep Recovery Unit.

In fact, even riding on black trails with just 33's, I rarely have to winch and I've never broken a CV joint. The only thing I've ever busted was after a hard weekend of wheeling the Trail Fest, I bounced on a night run and popped my Ring Gear.

We just did this replacement in my fathers rig as on his MOAB trip he broke the RING gear due to original setup. Found out he didn't use the solid sleeve and used the crush sleeve which 'crushed' more if possible. Did you happen to see if maybe your backlash and everything was correct before dissassemble? Its crazy how that stuff can break, but we can do my dad's in just a few hours front or rear (Solid Axles on both...heh).

I would have checked paint before tearing it apart. If it happens again check it. Have noticed that certain things tend to move in hardcore wheeling that isn't supposed to move and causes it to be damaged. Have you already extendned your breathing lines for the Diff & Electronic Locker in the rear(along with front diff, Transmission & Transfer case??).

Sorry I rambled on so long =(

Before my medical accident I was going to SAS my 5th GEN, now I got a 3rd gen and I can't do the SAS or rock crawling anymore, so I do simple trails and watch from the road/pictures =)

 

[Scramble]

Dude your truck could drive that

Yea it could, but I don't have sliders yet & I'm not into body carnage. That hill is steeper than it looks on video. Did you see him sliding to the right when he tried to go left around that rock? Who knows maybe I would have made it going left, my tires are new. (After watching it again going over the rocks on the right side was the easier route) In 4 lo 1st gear my truck crawls Blue trails with ease. You don't need "down hill assist" with a 5 speed.:heh:

 

[Gadgetguy]

Yea it could, but I don't have sliders yet & I'm not into body carnage. That hill is steeper than it looks on video. Did you see him sliding to the right when he tried to go left around that rock? Who knows maybe I would have made it going left, my tires are new. (After watching it again going over the rocks on the right side was the easier route) In 4 lo 1st gear my truck crawls Blue trails with ease. You don't need "down hill assist" with a 5 speed.:heh:

I hear ya, I haven't gotten my sliders built yet (me being lazy) so I'm pretty careful as well. Neither video or photos do obstacles justice, EVER lol.

 

[NotKewl]

I would have checked paint before tearing it apart. If it happens again check it. Have noticed that certain things tend to move in hardcore wheeling that isn't supposed to move and causes it to be damaged. Have you already extendned your breathing lines for the Diff & Electronic Locker in the rear(along with front diff, Transmission & Transfer case??).

It's not an e-locker. The 2002 models didn't come with them. I installed a Spartan locker. Worked great. Yeah, I checked the backlash etc, just to see. It was still in spec. What I was trying to climb was pretty dang gnarly. The three rigs ahead of me with bigger tires had to winch. I got cocky and gave it too much skinny pedal, bounced under power and crunch. I've seen Dana 60's and Rockwells break under similar conditions on this very trail, so my stock 4.11 geared Yota 8" ring was most certainly going to crunch. I still drove the thing off the trail and back down to the trailhead and campsite under its own power. Tough little rigs these T4Rs.

I only took the third member out to inspect the damage. It's just the ring gear. No biggy and an easy fix for Yota axles, but I've had a Ford high pinion King Pin Dana 60 sitting in my basement for months waiting for me to get off my butt and just do the SAS. This was the perfect excuse to get started. So that Yota third member, the locker, Axle, etc. are going to whoever wants to buy them off me and I'm going all out on this goat! I have a GM 14 Bolt full float for the rear. 1 Tons all the way.

 

[NotKewl]

I hear ya, I haven't gotten my sliders built yet (me being lazy) so I'm pretty careful as well. Neither video or photos do obstacles justice, EVER lol.

You are absolutely correct. Trail 41 at AOP is the path to what was bounty hill. The whole trail is practically straight up in a fan shape. The video doesn't do it justice. Narrow at the bottom then fans out wide with BIG ass rocks. Our 33's and 35's struggled getting up the quarter mile trail. We did it, but it was slow going in some places. The guy behind me (the dude filming me) went up it in a stock Jeep JKU with 35's and no lockers (Dana 30 mind you). Like I said, it's not always the rig, but the skill of the driver and most importantly, having the right spotter who knows where to put you. You could make it up that trail. It's not too bad. Some of the other black trails at AOP are much gnarlier and steeper. Some I wouldn't try without at least 40" tires because of the size of the rocks. Area 51 is like that. The rock garden too.

 

[NotKewl]

Been several weeks since my last post. Have not only been busy with work, but family as well. However, during the downtime, I did manage to get a few things done. For starters, I got my new BendPak XPS-9 lift installed, got both of my new axles, and started tearing down the front axle (Dana 60 King Pin High Pinion from a 1978 Ford F-350). More to come.

The T4R on the new lift!

Unloading the GM 14 Bolt 10.5" rear axle I got off of Craigslist. These things are cheap and in abundance. Looks like this one got scared on the drive home and wet the bed!

Tearing down the Dana 60 front axle. This is the most sought after Dana 60 on the planet, the rare 1978-79 SnoFighter King Pin High Pinion. Only found on Ford F-250 / F-350 from 1978 and 1979. In crappy condition, these sell for $1,500 all day in TN / NC / GA / and KY. I got this one for much less!!

My custom welded method of removing the old King Pins since I didn't have a big 22mm Hex Key (yet). They are trash, so welding scraps to them to give me a hammering point was OK. the new ones I will need to get the hex key to install.

My D60 BOM Number is 610023-6. Here's a link to look up what axle you have at Crawlapedia. Dana 60 BOM Numbers | Dana 60 Identification

 

[NotKewl]

Sorry about the pictures suddenly not showing up. My server was hacked, but I'm in the process of repairing it and will have them back as soon as possible.


*** UPDATE *** Fixed the server, pics back up.

 

[Chuckles89]

Oh dude! I just noticed you live in Chattanooga! I live in Cookeville. We have a facebook group if you're interested (the link is in my signature)

I am excited to see the pictures when you get your server back up and running!

 

[NotKewl]

Oh dude! I just noticed you live in Chattanooga! I live in Cookeville. We have a facebook group if you're interested (the link is in my signature)

I am excited to see the pictures when you get your server back up and running!

Very cool. I requested to join the group.
Pictures are back up.

 

[NotKewl]

Made an early morning run to Nashville the other day (the closest salvage yards to me) to find some 63" Chevy springs for my SAS. Why leaf springs over a 3-link or 4-link setup? Simple, I have a limited budget for this rig and want to invest in the most important things first (drivetrain and body). I plan to go with a 3-link in the front and triangulated 4-link out back eventually.

After scrounging around the yard for about an hour, I found a single 1991 Z71 with the rear springs still in place, so I cut them out real quick.

I could only find Fords, all the Chevy's had the springs yanked already. So I figured I'd grab me a set (since they were cheap) and see what I could do with them.

.

Looky what else I found! Too bad I didn't have the time or strength to pull it by myself or I would have.

 

[NotKewl]

My new rims showed up today, so of course, I had to try them on. Opened one up and slapped it on the 14 bolt rear axle just for kicks. Looks good! Just needs beadlocks, well that's coming next!

I also managed to spend some time late last night beginning the teardown. Going to strip the whole vehicle to just the bare necessities (you know you have kids when you make a statement like that and you suddenly hear Baloo singing Bear Necessities in your head. :music. Full cage is going in. Most likely a hybrid internal / Exo cage to maximize room inside (I'm a big guy at 6'-4").

 

[Bijan]

It's not an e-locker. The 2002 models didn't come with them. I installed a Spartan locker. Worked great

Did you install yourself? Where did you purchase from and knowing what you know now - would you still choose Spartan?