Lindenwood's 2002 SR5 Build Thread

[Lindenwood]

So, recently I took my rig in for a re-alignment, and they discovered that a previously-botched install (reinstall) of the steering rack caused the rack body to get pinched under the passenger u-shaped mount. The bushing was also pretty worn and flaking, so he recommended replacing it. I swapped in a new bushing, and noticed a hairline crack where it had been pinched under the bushing. It had been leaking a few drops a day from this location for a while now, but I was putting it off until I could make time to refresh the whole front end. And, given the pending weather, I accepted pressing for another week or two at least.

Shortly after beginning our evac for Hurricane Michael this morning, despite topping off the fluid, I felt my steering get heavy. I pulled into a parking lot and look under the rig while turning the wheel, and it's pissing fluid. So, I just pulled the PS belt so I could continue on without damaging the pump.

Just ordered a new OEM rack with OEM OTRs for $640 from www.mcgeorgetoyota.com , and an Energy bushing set. Not sure Ill have time to do it myself for a few weeks, so Im just going to drop it off to one of the shops Ive come to trust.

Oh, I have been running with my front sway bar disconnected for a couple hundred miles now. I go back and forth. I did some quick math and estimate something like a 5% increase in rollover probability--or, perhaps it can be better stated as a 5% reduction in rollover resistance. I am actually kinda tempted to make some quick disconnects.

 

[Unner]

So, recently I took my rig in for a re-alignment, and they discovered that a previously-botched install (reinstall) of the steering rack caused the rack body to get pinched under the passenger u-shaped mount. The bushing was also pretty worn and flaking, so he recommended replacing it. I swapped in a new bushing, and noticed a hairline crack where it had been pinched under the bushing. It had been leaking a few drops a day from this location for a while now, but I was putting it off until I could make time to refresh the whole front end. And, given the pending weather, I accepted pressing for another week or two at least.

Shortly after beginning our evac for Hurricane Michael this morning, despite topping off the fluid, I felt my steering get heavy. I pulled into a parking lot and look under the rig while turning the wheel, and it's pissing fluid. So, I just pulled the PS belt so I could continue on without damaging the pump.

Just ordered a new OEM rack with OEM OTRs for $640 from www.mcgeorgetoyota.com , and an Energy bushing set. Not sure Ill have time to do it myself for a few weeks, so Im just going to drop it off to one of the shops Ive come to trust.

Oh, I have been running with my front sway bar disconnected for a couple hundred miles now. I go back and forth. I did some quick math and estimate something like a 5% increase in rollover probability--or, perhaps it can be better stated as a 5% reduction in rollover resistance. I am actually kinda tempted to make some quick disconnects.

That sucks about the rack. Stay safe during the storm! Hopefully it doesn't do too much damage.

 

[Dezert4Runner]

I ran 99 talls with Taco 5100’s on the middle notch (22.5” hub to fender) a few years ago, and no sway bar was too sketchy on the highway. I felt like the rig was leaning way too much taking a certain freeway junction loop every day and decided to keep it on.

As soon as I switched to a set of coilovers with a 650lb coil, I took off the sway bar again and it was like driving the previous setup with the sway bar still attached. I know you’re on a softer front setup now, and imagine the sway/ lean is pretty noticeable after having the 620lb Eibachs on the front. A set of disconnects might be in my future once I drop down to a 550-600lb coil sooner rather than later.

Stay safe and good luck on the steering rack swap!

 

[Lindenwood]

Yeah, it is noticable, though I observed no stability issues during normal driving, even on the interstate. I mostly only notice the modest increase in body roll on tighter city street corners, though I drive pretty conservatively. Of course, where it really matters is the rare emergency evasive manuever, which is why I am looking into quick disconnects.

I will have to make some time to sit down and sketch it all out. I bet I can get a little closer than my 5% estimation (I used to teach physics before joining the AF, but only did the math half in my head while sitting out in the woods with my dogs).

FWIW, I dont have a rear sway bar because 3 of the 4 bolts in the axle were rusted and broke off when I did my first lift, and I havent had time to drill them out.

 

[Lindenwood]

Though, we did make it! My wife found a pretty sweet deal for us. This AirBnB was about as much as hotels that would accept large dogs, except here we have more privacy, get a little taste of the outdoirs, and the dogs can run around freely!

#Evac'ation *rolleyes*

 

[Hammit]

Hey that's a cool cabin, looks like you guys are making the best of it!

Your build is looking really awesome, I'm new here and getting tons of inspiration, but I especially enjoy guys like you who would rather build than buy!

 

[Lindenwood]

Haha thanks! Yeah I am kindof a cheap SOB heh. I also have lots of engineers and tinkerers in my family so I have a long-developed tendency to figure out the simplest way to accomplish things, rather than just the fanciest heh.

Oh! I never posted it up, but maybe 2 months ago I bought a Dometic CC-40 fridge. It is from their entry-level lineuo that uses a smaller compressir, and lacks some nicer features like a basket or separate "freezer" section. But, it has kept cold drinks in the truck so far! Given my short commute (about 2 miles / 9 minutes) and the Florida heat, it will run the 2nd battery dead in a couple days without supplementing its power with an extension cord through the back window.

However, once Hurricane Michael intensified from a tropic storm to a Cat3, I set the fridge to 10 degrees and it has been keeping about 6 months worth of my wife's frozen breast milk. I would certainly call that a very pragmatic win! We drove it up here in my vehicle and then plugged it up to the cabin's AC--if we lose power here (slight possibility) Ill just move it back to my truck and run the truck maybe 10 minutes every hour to ensure it stays powered (just to be sure--if it thaws at all, it can't be used again).

 

[Lindenwood]

I'm glad I took the rig to the shop to have the rack replaced. They already had to replace one of the hardlines going to the rack, as well as the rag joint, because they were seized onto the rack to the point of being unremovable without damage. They also had to cut off the old OTRs (NBD since I bought new OEM ones) to remove them. It is costing me a good bit of money (about $1300 so far), but I have far less time than money these days.

I think I might have them replace the fuel pump and all its associated lines soon, as well. That is honestly about the last thing on the rig that has even a small chance of leaving me stranded, outside of a mechanical failure like a CV. And, that said, I might look into swapping a new set of CS in, if for nothing else so somebody else can break loose all these rusted bolts before I have to do it in the future .

 

[Lindenwood]

Well, with a new OEM rack, all tie rods, new bushings, and new PS pressure line, it steers like butter! I am having the tires re-balances today (I have lost a couple of balance weights since the original install) to smooth out the ride.

Maintenance-wise, the last things on the truck that could potentially leave me stranded are the fuel pump and starter. The shop recommended against messing with the fuel pump as PM because of the likely rust-damaged lines. But, we'll see.

 

[TonyB66]

Haha thanks! Yeah I am kindof a cheap SOB heh. I also have lots of engineers and tinkerers in my family so I have a long-developed tendency to figure out the simplest way to accomplish things, rather than just the fanciest heh....

From my experiences, "cheap SOBs" are quite often some of the most creative, out-of-the-box thinkers and doers. This build is testament to that, so kudos to you.

As far as the FP goes, I have not done so either. A related thread that I'll share, in case you have no seen it:

http://www.toyota-4runner.org/3rd-g...ump-failure-any-advance-warning-symptoms.html

As for me, I ran Seafoam through the fuel system (and elsewhere), then changed the fuel filter...

Glad I found this build.

 

[Lindenwood]

From my experiences, "cheap SOBs" are quite often some of the most creative, out-of-the-box thinkers and doers. This build is testament to that, so kudos to you.

As far as the FP goes, I have not done so either. A related thread that I'll share, in case you have no seen it:

http://www.toyota-4runner.org/3rd-g...ump-failure-any-advance-warning-symptoms.html

As for me, I ran Seafoam through the fuel system (and elsewhere), then changed the fuel filter...

Glad I found this build.

Thanks for the kudos! I really do appreciate the thought .

I did a complete seafoam treatment and replaced the fuel filter when I got the rig, so this is again just some potential PM. I am about half way through [MENTION=120071]mtbtim[/MENTION] 's video on removing the tank which, so far, has actually been kinda encouraging! I will probably have to take a couple days leave to do the tank, but one of the biggest benefits will be that I'll have the opportunity to really clean and repaint a big area under the rig.

And, I actually found that thread yesterday! Thanks for the link, though!

Finally, I had my tires rebalanced today. She's really runnin' smooth now!

 

[Unner]

Has your starter never been rebuilt or replaced? If not it's a ticking time bomb waiting to fail. It doesn't hurt the truck when it fails, but you will be left stranded. I'd put new contacts in it if it's never been done. They're cheap and easy. If the starter has been replaced by a previous owner see if they put a cheap Chinese one in there. If so pull it out and replace it with a Denso. See my starter failure as evidence on why the Chinese ones are garbage.

As for the fuel pump, I'd replace it unless you've got some crazy rust. It's pretty easy. Pop the plastic fuel line clip things in front of the gas tank, get sprayed with gas, disconnect the connections on the tank, drop the tank and pull the pump hanger out and replace the pump. A new Denso is under $100. I did mine at 220,000 as preventative maintenance because I didn't want to be stranded somewhere if it fails. Good peace of mine.

 

[TonyB66]

...As for the fuel pump, I'd replace it unless you've got some crazy rust. It's pretty easy. Pop the plastic fuel line clip things in front of the gas tank, get sprayed with gas, disconnect the connections on the tank, drop the tank and pull the pump hanger out and replace the pump. A new Denso is under $100. I did mine at 220,000 as preventative maintenance because I didn't want to be stranded somewhere if it fails. Good peace of mine.

Thank you for sharing that Unner. I currently have the factory gas tank skid off awaiting an aftermkt one, and you now have me thinking that I might want to tackle this now... I imagine it's desirable to do this when the tank is near empty (lighter).

 

[Lindenwood]

Has your starter never been rebuilt or replaced? If not it's a ticking time bomb waiting to fail. It doesn't hurt the truck when it fails, but you will be left stranded. I'd put new contacts in it if it's never been done. They're cheap and easy. If the starter has been replaced by a previous owner see if they put a cheap Chinese one in there. If so pull it out and replace it with a Denso. See my starter failure as evidence on why the Chinese ones are garbage.

As for the fuel pump, I'd replace it unless you've got some crazy rust. It's pretty easy. Pop the plastic fuel line clip things in front of the gas tank, get sprayed with gas, disconnect the connections on the tank, drop the tank and pull the pump hanger out and replace the pump. A new Denso is under $100. I did mine at 220,000 as preventative maintenance because I didn't want to be stranded somewhere if it fails. Good peace of mine.

Thank you! I don't believe the starter was ever touched either, so Ill make sure to get on that as well!

I just finised the fuel tank video! Honestly it doesnt seem bad. I will probably buy all new lines and hoses for the tank since I expect a lot of corrosion and brittle rubber. This will serve the dual purpose of simplifying the removal since I can just cut all the hoses, and also pre-position me for a quick reinstall without having to track down special tank hoses. And, it will prevent any leaks down the road since rusted and brittle lines are more likely to develop cracks from manipulation.

 

[Unner]

Thank you for sharing that Unner. I currently have the factory gas tank skid off awaiting an aftermkt one, and you now have me thinking that I might want to tackle this now... I imagine it's desirable to do this when the tank is near empty (lighter).

Definitely much easier to do with a nearly empty tank.

Thank you! I don't believe the starter was ever touched either, so Ill make sure to get on that as well!

I just finised the fuel tank video! Honestly it doesnt seem bad. I will probably buy all new lines and hoses for the tank since I expect a lot of corrosion and brittle rubber. This will serve the dual purpose of simplifying the removal since I can just cut all the hoses, and also pre-position me for a quick reinstall without having to track down special tank hoses. And, it will prevent any leaks down the road since rusted and brittle lines are more likely to develop cracks from manipulation.

Just don't cut the wires leading down there! There's also a hose going to a check valve on the tank for 01-02 4Runners. I couldn't figure out how to get that one off, so I just left the tank under the 4Runner and dropped the tank as low as I could without pulling on that hose too much.

 

[Lindenwood]

Long story short, starting next year, due to work, my wife and I will be living about 5 hours apart. Until the kid starts school, my wife will be splitting her time between both locations to keep the little one close to our families (she is a part-time yoga instructor, so her schedule is pretty flexible).

For a while now, we had been figuring we'd get a condo for me, and a small house for her (mostly for the garage and yard). But then she surprised me by proposing we get a travel trailer for me, with two caveats: It has to be big / nice enough for her to comfortably live in it for weeks at a time on a regular basis, and she wanted to travel a lot in it. I loved the idea.

We quickly saw that nothing we'd want to actually live in was light enough to be comfortably, safely, and reliably towed 10k miles a year by an offroad-oriented, 17 year old 4Runner . I originally pushed back and said if I sold the eunner, whatever trailer we get has to be pullable with a new Tacoma (~6400lbs max). I figured at least this would keep me close to my 4runner in trail capabilities. However, as we did more research on trailers, we kept coming back to models in the 6000-7300lb (loaded) range, which even at 6k lbs still seemed like a lot to pull with a Taco on a regular basis (especially after adding 1000lb of gear and armor ). Thus, I eventually warmed up to getting a Tundra after also checking out its competitors.

Unfortunately, for several reasons, the logistics of keeping the 4Runner even as a toy doesnt make a lot of sense for us. I couldnt just leave it parked in the RV park all the time, so Id need to spend probably $75/mo to put it (or even the Tundra) in one of those self-storage units. Even if I store it at the house with my wife, I would basically have to come home to play with my toys rather than to spend time with family, which is not a great long-term option. She does wheel with me from time to time in her own rig, but I know that wouldnt be how she'd want to spend our increasingly-valuable time together, when we could be going kn nice weekend trips with the travel trailer and still wheeling as a family in a Tundra around Colorado or Moab or whatever).

Bottom line, even if I do keep my rig, Id rarely get to use it. If anything, Ill probably sell it for a dual sport bike that not only fills a much different niche, but would pay for itself if I commuted on it just couple days a week.

Still, there is some hope for offroad fun! Pretty much right off the bat I expect to add wheels / tires, suspension, at least full skids and sliders, and likely 4.88s with an ARB. Unless I decide I need a winch right away, or I find front recovery options wanting, I'd probably just wait til I scrape up the bumpers to replace those.

Obviously, the wheelbase increases by 40%, it is almost a foot wider, and I am not sure I can get the suspension as supple as my 4Runner (relative to its wheelbase). Still, after finding a long list of videos and posts by few Tundra trailblazers, I am confident I'll be able to have plenty of fun with the Tundra.

It's been a blast, though! Hopefully whoever ends up with this thing enjoys it as much as I do! It had been about a decade since I had a vehicle I turned my head to check out in parking lots--hopefully the Tundra can get me there .

 

[Lindenwood]

Sold this morning to a good buddy at work! He needed a utilitarian vehicle that could carry his kayaks and enjoy offroading with his son.

 

[Lindenwood]

Just bought my F250 lol. Definitely a blank canvas! It already has a locking rear diff, but 37s on 17s, 4.88s, a Truetrac front end, and a 4" lift are going to be first up!

It's been a pleasure!

 

[Greenmachine86]

Very good looking 4runner. Like the ford to though