John's 99 4runner rebuild/build

[mmml4]

Started with this in August of 2007.

1999 4Runner, 2wd, 3.4 v6, auto. Killed in head-on collision.

Rebuild/build specs:
Replace frame, damaged body panels, damaged engine compartment components.

Front:
SAS with 80 series Land Cruiser axle and coils
3 link with panhard
Ballistic Fab adjustable coil buckets
IFS steering box

Rear:
80 series Land Cruiser axle and coils
3 link with panhard

Engine:
3.4 liter 5VZ-FE

Transmission:
80 series Land Cruiser A343F & transfer case running Slee Offroad part time 4 wheel drive kit and manual hubs
Tiptronic type manual transmission shift control

and a whole bunch of other stuff I haven't figured out yet

 

[mmml4]

Swapping in the new frame.

It started out on leafs but I could'nt find a good steering solution.

 

[mmml4]

Fitting the new wheel well and core support.

 

[mmml4]

After seam sealer, primer and paint. I searched and searched but could not find a really good match on the engine compartment paint.

 

[mmml4]

Your basic frame plating, instead of plugging all the factory holes or plating over them I just cut mine to match so the space between the frame and the plate would be sealed.

 

[mmml4]

IFS steering box, frame is sleeved with 3/8" stainless pipe.

 

[mmml4]

Coil buckets tacked in place.

 

[mmml4]

My first attempt at building links.

Lower links:
I used 1-1/4" Johnny Joints (18mm thru hole) at the frame, custom sleeves with cruiser bushings (18mm thru hole) at the axle, 1-1/4" ladder bar adjuster for fine tuning and a custom square insert 6" long drilled and tapped 1-1/4" left hand thread 4" deep. Tubing is 2x2x1/4" wall.

 

[mmml4]

Lower links and frame mounts, not finished with the frame mounts.

 

[mmml4]

Coil spring stuff.

 

[mmml4]

Got the engine back in and found the DS engine mount is bent about an inch.

 

[mmml4]

Upper link:
I used 1-1/4" Johnny Joints (18mm thru hole) at the frame, custom sleeves with a cruiser bushing (18mm thru hole) at the axle, Ballistic Fab 1-1/4-12 righthand chromoly insert.
Tubing is 1-3/4" OD x .120" wall DOM.

 

[mmml4]

Picked this up and now I got a rear to match my front .
97 Land Cruiser
70,000 miles
full floater
disk brakes
9 1/2" ring gear
63 1/2" wms to wms

 

[mmml4]

Well I got my upper link tacked in place. I ended up with about 5" of separation at the frame and about 6" at the axle. My next step will be to fit the panhard.

Reusing the Cruiser coil perch.

 

[mmml4]

Here are a few flex pics. Looks like I got lucky, no interference or binding.

 

[steezemcqueen]

Looks good!

That a HH140 welder i see?

 

[mmml4]

Here is how it sits now, still got a long way to go.

 

[mmml4]

As for the steering, stock power steering pump, IFS steering box, Marlin Crawler pitman arm, LC drag link. I wish I had taken pictures of fabricating the steering shaft but I didn't.

FIREWALL PLATE:
I cut the outer edge (about 1" wide strip all the way around with the bolt holes in it) off of the existing firewall plate where the steering went down to the R&P, I cut the piece with the shaft seal in it off also.

I then took a piece of 16 gauge sheet metal and formed it to fit the piece with the bolt holes and welded them together. I pulled a piece of string from the steering wheel to the steering box and took some measurements so I could fit the shaft seal piece to the new firewall plate.

Then I cut a hole for the shaft to go thruogh and then fit the seal.

STEERING SHAFT:
I cut up the steering joint that turned at the firewall and went down to the R&P so it would work as a u-joint, I used this joint at the steering wheel. I cut the splined section off of the factory shaft that the came with the IFS box and used a piece of 1/2" schedule 40 pipe to bring the shaft to length.

 

[NachoPitt]

Amazing work - one of my favorite threads here.

 

[mmml4]

Looks good!

That a HH140 welder i see?

Thanks and yes it is and has done a really good job so far.