f250ben’s Intensive Maintenance/Upgrade/Build Thread

[f250ben]

Updated 10/7/18
Current pics, read below for the progression to this point!




Hello all! I just purchased a 2003 4x4 T4r a few weeks ago. Been in the Toyota world for a bit, had a 2010 Tacoma with an OME lift on it and some small mods. Loved it, but my wife and I have a new baby, and we didn’t really need a truck worth 15 grand anymore as my backup commuter vehicle.

So I sold my Tacoma and bought this baby for $6100. It’s got 197k miles on it, so lots of stuff is getting a little worn down. That said, I don’t think it’s ever been worked or driven hard. It has been a grocery getter. Exterior is probably a 8 out of 10, minimal scratches, tiny bit of sun damage. Interior is probably the same, excluding the cracked dash. Runs well, engine feels smooth and even.

My big goals for this project is a capable off-road/camping vehicle that is reliable and running like a top.
Big picture goals include a roof rack, RTT, drawer system, and a DIY front and rear bumper with winch etc. that’s not going to happen till next year, this year is more about an intensive maintenance regimen to get it up to speed.

This is as she sits today. I’ve already done some small things to her, but everything’s basically stock. It’s not going to stay like this for long.

Already done:
Mud flaps cut
OEM running boards removed (pm if interested in buying them from me)
Resonator deleted, tail pipe cut at axle
AJT designs remote fobs and shifter knob, see below for link
https://www.ajtdesign-llc.com/

Already broken and fixed:
Shifter pin broke when shifting into 3rd, shifter got super sloppy. Used this thread:
http://www.toyota-4runner.org/4th-gen-t4rs/216109-screwed-up-my-auto-shifter-loose-floppy.html
Mostly fixed it with epoxy and grinding the groove worn in the little track. Need to go back and build up part where I ground too much off. Now it’s not sloppy, but very little resistance when shifting from D to 3.
Pics to follow of that fix. Very easy, and saves 500 bucks so you don’t have to buy a new shifter assembly.

On to the pics!!!

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[f250ben]

All of this work is going to happen pretty quickly for me ideally. Got a carport that I’m partially enclosing and turning into a workshop, as soon as that’s done (hopefully before end of April) it’s going to be wrenching time for me.

In the meantime, I ordered EVERYTHING needed for this project last night. I may have some odds and ends I am missing, but most of it’s already on the way. And my credit card is smoking a bit.

Upcoming Stuff

Basic Maintenance:
All fluids (oil, gear, coolant, waiting a bit on tranny fluid)
Greasing all fittings
Spark plugs
All filters (air and oil)
Serpentine belt

Preventative Maintenance/Replacements:
Water pump
Fan clutch
All pulleys on belt drive
Inner and outer tie rod ends
HVAC blower motor (squeaks like crazy)
New dash (current one is cracked badly)
HVAC bulbs
All exterior bulbs
All interior bulbs

Upgrades:
Sony XAV AX100 Apple CarPlay headunit
Full Dobinsons suspension
Diff drop
Sway bar drop brackets (haven’t decided about front sway bar yet)

Some more pics, because they’re cool and everybody loves pics:

Terrible current headunit

Cracked dash

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[f250ben]

Reserved for suspension upgrades/pics


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[f250ben]

Reserved for interior upgrades/pics


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[f250ben]

I plan on documenting all of my maintenance here as well. Some of the build threads I have loved the most are the ones that focus on detail projects as someone works through the kinks of their specific 4runner. Especially projects like this one where someone completely overhauled their vehicle after they bought it with a decent amount of miles, and brought it back up to excellent condition.

If anybody has any input on my to do list or something I’ve missed, feel free to jump in!


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[trippyelephantx]

Ill be following along your build thread, I'm hoping to build a storage unit / drawer system in mine too. How did you get your key fob to look like that? I'd love to work on that.

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[dasx86]

I think the fob case is from here: https://www.ajtdesign-llc.com/

Looking forward to the thread...

 

[f250ben]

Thanks y’all!

The link above is correct for the key fob. I also purchased my shifter knob from AJT. Super great customer service, I emailed the guy with a question and he responded within minutes.

Also, I’m going to go back to my first few posts and update all of the references to parts and purchases with part #’s, links where applicable, and prices. In my opinion, that some of the most helpful information I can find when reading through someone else’s build thread. Also the information that is least often included in a build thread.

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[jspark99]

Looking forward to this thread! I think you got a good plan to start

 

[nuron]

I jus got an 03 SR5 as well and I'm going through the same thing as you! I do have to rebuild my power steering pump and replace the lines since it seems like there's a leak in that area. I'm bummed about my cracked dash so I'm on the lookout for a parts car in my area.

 

[f250ben]

I jus got an 03 SR5 as well and I'm going through the same thing as you! I do have to rebuild my power steering pump and replace the lines since it seems like there's a leak in that area. I'm bummed about my cracked dash so I'm on the lookout for a parts car in my area.

My steering pump actually whines a little bit too. I’m just assuming a fluid flush and getting the fluid at the correct level will fix it, then if that’s not successful I’ll be rebuilding mine too.

Also, a donor car with a good dash is TONS better. I just spent almost 800 bucks on a new one. Shipping alone from the Toyota wholesale parts place was 180ish because of the size of the package. But 4th gens NEVER show up in yards around here. They’re all still driving around.


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[f250ben]

Gathering parts together...

Parts started coming in yesterday and today. I’m not really starting on the work/installation for another month. I’ve got a metric ton of parts coming in, and I needed to get organized so I have a place to store and stage parts as they come in.

I had all the fluids I needed to do a semi-complete fluid change out on my Tacoma. Then I sold it. So here’s the fluids that are left, I’ll add to them whenever I get to that point in the project.

I’ve also always wanted to start a good detailed auto log with all receipts and jnvoices. So I’m doing that.

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[nuron]

My steering pump actually whines a little bit too. I’m just assuming a fluid flush and getting the fluid at the correct level will fix it, then if that’s not successful I’ll be rebuilding mine too.

Also, a donor car with a good dash is TONS better. I just spent almost 800 bucks on a new one. Shipping alone from rockauto was 180ish because of the size of the package. But 4th gens NEVER show up in yards around here. They’re all still driving around.


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Wow, didn't know rockauto had dashes in stock. I'm surprised to not see that many 4th gens for parts on craigslist myself. Think I'm gonna scour ebay next. Document your dash replacement when you do it!

 

[f250ben]

Wow, didn't know rockauto had dashes in stock. I'm surprised to not see that many 4th gens for parts on craigslist myself. Think I'm gonna scour ebay next. Document your dash replacement when you do it!

I lied...I’ve made too many orders to keep track of them. I ordered the dash from a Toyota wholesale parts website.

Also, I’m definitely documenting the dash replacement. From what I’ve read though, it’s not difficult just tedious.


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[f250ben]

Frustrating afternoon with the truck....

I was bored and I figured “hey I’ve got that head unit just sitting here, why not throw it in?”
Well. That would have been a 45 minute process, except the previous installer or my current craptastic unit cut 3 wires directly out of the oem harness, and rigged them into an old pac unit. Head unit works perfectly, sound only comes out of left speakers, and steering wheel controls don’t work at all.

Gonna call Crutchfield tomorrow and see if they can help me figure it out. If that doesn’t work, I’ll take it to a stereo shop, get them to help me fix the wiring and put it back together myself.


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[ThatSickRip]

Frustrating afternoon with the truck....

I was bored and I figured “hey I’ve got that head unit just sitting here, why not throw it in?”
Well. That would have been a 45 minute process, except the previous installer or my current craptastic unit cut 3 wires directly out of the oem harness, and rigged them into an old pac unit. Head unit works perfectly, sound only comes out of left speakers, and steering wheel controls don’t work at all.

Gonna call Crutchfield tomorrow and see if they can help me figure it out. If that doesn’t work, I’ll take it to a stereo shop, get them to help me fix the wiring and put it back together myself.


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Damn man, that sucks. My head unit was the first thing I replaced when I got mine (OEM). Prepping took more time than the install. When I was doing the install, I was amazed at how simple it was to take apart the dash components to do the swap and it definitely helped with the my confidence with working on the truck in the future.

 

[f250ben]

Yep. It’s mostly frustrating because of how simple it SHOULD have been. The console and dash trim is super easy to remove. And changing out a headunit with the correct adaptors is normally a peace of cake.

Oh well. This will force me to learn a bit about vehicle wiring, I’m pretty sure Crutchfield will be able to help me pretty simply.


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[trippyelephantx]

I think the fob case is from here: https://www.ajtdesign-llc.com/

Looking forward to the thread...

Sweet thanks

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[f250ben]

How I’m rolling today. [emoji107]


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[f250ben]

Small updates:

I’ve received almost all of my parts including my new OEM dashboard and the entire dobinsons lift kit (minus UCA’s because they’re back ordered)
That dash is GORGEOUS.

Fixed my headunit. Sony XAV-AX100. It’s awesome. Works great, steering wheel controls work perfectly. No buzzing or audio issues and CarPlay is great.

AC went out, Freon was low. Paid a garage next to my work 200 and they cleaned out the evaporator and replaced Freon. Hopefully there’s no leak and I don’t have this same issue in 6 months

Started building my workshop, which needs to be finished before I can start really working on the 4runner. Installed an attic ladder in my carport attic so I can access the attic while building the shop.

And for those who are interested, this is roughly what the shop will look like. The design has changed some since this rendering but this is the basic idea.

Yes my wife drives a fiat. Yes it’s a terrible car. And please for the love of God dont ever buy yourself one. But it’s cute and red so here we sit .


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