my poor 4runner thread

[darkfader]

now that spring is here, and my yota is my main project for the summer, i figured i would start a mod/build/maint/pic thread. i'll keep it updated as i complete various projects i have planned for it.

i bought this 4runner last year from northern Ohio. i'm the second owner. they must really throw the salt down on the roads up there in the winter because this one has some serious rust underneath. sad really. so priority number one is getting this corrosion slowed down. you guys have the E-locker, well, i have the 'E-leaker". the rear diff rusted so bad that it just started leaking through. for now, JB weld is keeping gear oil in the rear, but a new-to-me rear end is on the short list of to-do items. won't bore you with rust pics, i think it's safe to assume we all know what a rusted rear diff looks like.

we had over 200 inches of snow this year, and it finally all melted off and gave way to spring time temps a week or two ago, so i figured i should get to work. i started with some typical maintenance including plugs and wires(still had original wires dated 1996), did an oil change, and cleaned the MAF sensor, throttle body, and treated the K&N air filter, and treated crankcase and fuel system with seafoam. it's got a smoother idle, more power, cleaner throttle response, and even seemed like i used less gas getting to work today. i'm happy with the tune up.

today, i put the truck up on the trusty homemade ramps with the intention of 86'ing the rusty OEM running boards. here's a pic or two:

before:



after:



and i'd love any suggestions or advice on my best plan of action to repair this spot. cursed rusted rockers. do i cut this out and tack in some new steel, use fiberglass, bondo? if there's a comprehensive thread on body repair, i'd love a link. this makes me sad:



i also have a spot i'd like to fix under the passenger tail light, suggestions are welcomed:



running boards and etc. gone and i like the look, but want to invest in some kind of nerf bars in the future, simply because i like having a step.



i most certainly prefer the look without the fender trims:



here's what can happen when a big fat whitetail deer steps out in front of you at about 60mph:



no worries though, it was an excuse to get some '99 headlights, corners, and turns. and parts to do nose surgery should all arrive this week.

and a shot of my lovely rear bumper, also on the soon to be replaced list.

 

[darkfader]

my short list includes wire wheeling undercarriage and slathering the POR-15 on there. looks like the frame rail under the drivers floorboard may need a wrap sooner than later. and as previously mentioned, i'll need a new rear end pretty soon as well.

after all that, i want to begin replacing bushings with poly, and new shocks all the way around. haven't made my mind up on how i should upgrade. i don't really need a lift as this is my DD.

rust is my main concern at this point. once i have that somewhat under control, i'll move onto the mods that are just 'wants' and not 'needs'. that list is long and distinguished like my..... nevermind. eventually, i'll pick up a scooped sport hood, paint the exterior, and rhinoline(or similar) the rockers all the way around. factory audio desperately needs to be upgraded, and i must have LED dash and console lights. :guitar3: my problem is i keep reading the build threads on this site, and my runner gets jealous. you folks are gonna put a hurtin' on my bank account.

comments and suggestions are the reasons why i started this thread, so don't be shy to post. i'd really like to get this yota restored.

:thanks: Oyea, 230k and climbing on the clock BTW, and i've only got tundra brakes and 99 headlights to show for it. :thumb3:

 

[nissanh]

I love the ramps....

I think for the rear dent by the right tail lamp, you have to remove the tail lamp and then you can access the dent from that opening. Remember to give a small push outwards (not to the rear but to the side) to pull the tail lamps.

 

[Stick Figure]

While I commend you for wanting to keep it on the road and rebuild it. I think you could buy a 99+ 4x4 for what it would cost for the new front components, rear bumper, and rust repair. + you could offset the cost by parting that one out. Sad to do, but makes more financial sense to me.

 

[darkfader]

i've got less than $100 dollars in the tune up, less than $250 in front end. i've always done my own wrenching, and saving tons there, so i'm going to keep going on it for now. i'll be keeping my eyes open for a '99 though. i've had a 93, 95, and now this 97. might as well keep the streak going and pick up a 99. thanks for the suggestions fellas. :car:

 

[cjf_351]

Looking forward to seeing the progress! My 4runner is in similar shape. I bought mine in Connecticut and lived in Maine until about a year ago when I moved to Florida. I am fortunate to have found a pick and pull that has a couple rust free runners (milkshake victims i think) that I have been pulling parts from.
Give her a bath and a coat of wax! Please!

 

[gornish_hick]

Tinker Away at er and you'll have it looking like new in no time. Im just in the home streach of repairing my rocker panels which were wayyyyyy worse then then yours. I got new ones bent to fit and welded them on, body filled the cracks. If you plan to body fill your cancer holes just remember to grind off alll the rust, get it down to good bare metal or 4 months down the road your gonna see rust forming through your paint!

 

[darkfader]

Looking forward to seeing the progress! My 4runner is in similar shape. I bought mine in Connecticut and lived in Maine until about a year ago when I moved to Florida. I am fortunate to have found a pick and pull that has a couple rust free runners (milkshake victims i think) that I have been pulling parts from.
Give her a bath and a coat of wax! Please!

it's tough to find northern vehicles without cancer. i bought my 95 limited in miami and it was so clean underneath. wish i would've held on to that one. and no worries, today i buffed it out with rubbing compound and will get some wax on it tomoro.

Tinker Away at er and you'll have it looking like new in no time. Im just in the home streach of repairing my rocker panels which were wayyyyyy worse then then yours. I got new ones bent to fit and welded them on, body filled the cracks. If you plan to body fill your cancer holes just remember to grind off alll the rust, get it down to good bare metal or 4 months down the road your gonna see rust forming through your paint!

roger that! i figure i will just cut out the bad spot on the rocker and under the pass tail light and weld in some new steel. then finish and paint. plus i love to tinker.

 

[darkfader]

a few more pics.

buffed out with rubbing compound but still needs work. i was doing it during downtime at work yesterday:



with some more elbow greese, i think i can still bring the 16 year old paint back out to nice shine:



did the ISR mod today, too easy, and cleaned it up nicely.

nasty clamps



much cleaner:



got a deck plate from ebay. should be here soon. i have a new muffler to put on but not in a huge hurry to get it done. :sleepy:

 

[afg10000]

That always sucks when you take the RB's off, you see all the rusty underside. They are quite generous with their salt budget where I live and very liberal applying it. My auto body friend really says that no matter what you do under there, the rust will happen. I'm told to just keep up on washing the truck very often in winter is the best rust prevention. My fuel tank skid plate and LCA brackets look just just like yours. Got a skid plate off craigslist that came from AZ for $80. I somewhat in agreement with you on restoring this one rather than buying another. If you really like it and want to go that route it's truly your decision. props -

 

[darkfader]

thanks afg10000, at this point it's solid enough for me to get plenty of miles out of it as long as i stay on top of things. i have never been afraid to tear into a job or project. tomoro i'll be measuring up a nice wrap for the driver's frame rail. i'll save plenty in sweat equity on fixing this one up IMO. one day at a time, one part at a time. :lol:

 

[darkfader]

some of my parts that i ordered last week came in today.:banana::banana: deck plate, chrome bumper, bumper brackets, tranny cooler, and head light filler panels all came today. i'm just waiting till a new grinder gets here to do the muffler so i can clean the frame and paint near the muffler when the old one is out. figured i'd try that thrush muffler because it was inexpensive and seemed heavy duty. i'll just weld it in.




still waiting for a radiator, ac condenser, grill and valance to arrive. i also ordered materials to complete an 0/1 AWG 'big three' upgrade.

once i rip the front end off, i'll hit all the rust i can reach with the grinder/wire wheel, and paint as i go. i'll be replacing engine belts, and rad/tranny hoses with new also. i recently burnt up my old grinder, so i'm waiting on a new dewalt to arrive. once i have all the stuff i need, i'll tear into it. really looking forward to having a straight front end.

i just did the deck plate mod today since it was fast and easy. just used a hole cutter on the cordless drill and some sensor safe sealant. i need to get a small piece of cable to attach the cover so i can leave it in the engine bay when not in use. you guys all know what that looks like so i didn't bother with pics. it's black. lol

after this is done, i'll concentrate on the under carriage. wire wheel and paint. I need shocks on all four corners, and will replace all the bushings. i want to get to the point where i'm thinking about interior and sound system, but i think it's coming along nicely.

 

[darkfader]

i've been a busy man the last couple weeks. most of my parts came in for the ole runner. i got a lot done to it. new stat, belts, rad and hoses, tranny cooler, bumper and grill. they sent me the wrong valance so the proper one should arrive wednesday. i still need to get to the wiring upgrade and i decided to leave the AC condensor off for now. our two weeks of summer here when we get up to about 80*F, isn't really enough to justify spending more $ on AC parts at the moment. i may get around to it, but i just bought another toyota that blows really cold AC so we shall see. enough talk, moar pics:

some tunes, a little PB blaster, and some T4R.org for reference and i'm ready to tear into the project



one last pic of the catfish mouth grubbing for chicken livers :fishing:



out with the old



in with the new



as it sits now



i need whatever brackets hold the headlight filler panels on. must've lost those when i hit the deer

i also got two of these mounted, i'll get the other two next month



i still have some tweaking to do to get the lights lined up properly without the angled gaps, but this is a huge improvement IMO. i also plan on doing some kind of grill mod, i just haven't decided yet.

 

[darkfader]

dang near forgot to post a pic of the new-to-me toyota. it needs a little work, but it's pretty solid for it's age. i've wanted one of these since they came out and was in a position to get one, so i did. any of you guys have one of these?

1991 Toyota MR2 N/A 5-speed manual, 136,xxx on the clock



already replaced fog bulbs but failed to get a pic :der:





it's got TRD suspension with coilovers, TRD strut bars front and rear, 17x8 5Zigen in front, 17x9 in the rear, white gauge faces, cold air intake, NGK plugs and wires, blue leather interior, full stainless magnaflow exhaust.

it has a bad axle seal, and a leaky distributor. those parts are already ordered, and i just rec'd these to strap onto the front. then i'll take it for an alignment.

 

[darkfader]

bumpin it up for a new valance! the right valance. :woot: still need to order the filler panel brackets. i was waiting to make a bigger order since i'd have to pay shipping on such an inexpensive part. the fitment isn't perfect on any of it yet, but not too bad for cheap crash parts IMO:



still debating what i want to do with the grill mod, but something will happen there soon. doing a few things to the MR2 as well, so there's a lot going on.



ETA - just wanted to say that i'm really pleased with the way it runs with the ISR, deckplate, and new muffler. sounds great, plenty of power, and seems to be pretty decent mpg, although i haven't really taken an accurate account yet. i learned all that stuff right on this site so thanks to all here.

 

[darkfader]

i'm hoping you guys can help me out a little bit. i've done a bunch of reading on the subject but i'm still a little confused. here's my situation:

as mentioned above, i need to swap out the rear axle housing for a less rusted one in hopes of keeping my gear oil in the diff. the rear diff doesn't make any noises and seems like the innards are working properly. i have kept the fluid in it topped off, and used some JB weld to try to keep it together while i search for a replacement. so my question is, can i use any rear axle housing from a 3rd gen if it has ABS 'holes' and swap my third member and axles into the new one if the gear ratio doesn't match what i currently have? i can get a rear axle housing that doesn't match my current gear ratio quite a bit cheaper than one that matches. thanks for any advice!