Nelsonmd's Build Thread

[Nelsonmd]

2000 SR5 Sport E-Locked
Boston MA

Mods:
Field Monitor Unit
Pioneer HU and front speakers - JL Sub Amp - Alpine 12" sub in sealed enclosure
265/75-16 Duratracs for winter/wheeling, 265/70-16 Firestone Destinations for fairweather commuting
Ironman 1.8 front lift, OME 906 rears with procomp shocks
B&M 70268 Tranny cooler in bypass
Satoshi Grill mod - Part 2
Auto up via remote for rear window
Auto-close Sunroof - Part 2
ABS disable mod - Half Done
ScanGauge II
Tan Husky Liners in front
Aftermarket Mud Guards

Maintenance:
Swapped rear axle - old one rusted out
Passenger side Axle seal replaced
New spark plugs and wires
POR-15 on rust
Cleaning/Painting seized parking brake hardware
New fuel filler pipe
Energy Suspension PU Steering rack bushings
New steering rack guide
New front sway bar/bushings/mounts
Replaced rear hatch handle
Replacing the factory gas tank skid plate (with another stocker - used)
Tundra Brake upgrade
New LBJ's and TRE's
New Steering Knuckles (from a part out, less rust)
Stainless steel brake lines
Highland Contura front mud guards
New Napa (A1 Cardone) steering rack

Coming Soon...
Fuel Filter

Current Pic...

And here are some links that I have found useful, or have written myself.
http://www.toyota-4runner.org/3rd-gen-t4rs/97006-drive-prop-shaft-greasing-guide.html
ABS Disable Reference Thread

 

[Nelsonmd]

Reserved for future use...

 

[Nelsonmd]

Got my first big project ahead of me, so it's time to start a build thread.

My first project was replacing the fuel filler pipe that had completely rusted through.

I squeezed the pipe a little bit, and my finger went right through it...

There was a ton of dust that had gotten up in there, and the pip was rusted all th way to the top.

When taking the rusty one off, the bolt holding the bracket in the above pic to the cross beam on the body just above it broke off. This was a big pain because it was almost directly above the rear axle, so I couldn't get a drill in there. I had to buy a 14" drill bit to drill it out, and that was just barely long enough.Then of course I have to tap new threads into it, which required a really long extension and a jerry-rigged tap holder...

Close up of the tap mount...

That is little bits of a hack saw blade I had laying around that I cut up to fill the gaps.

Finally, after a couple hours and some tricky finagleing, the new pipe was in.

All in all, this was not too tough a fix, just time consuming with that broken bolt.

The filler pipe was $124, with just a couple bucks more for bolts, long drill bit, etc.

My next project was a field monitor unit. As soon as I saw this on yotatech, I knew I had to have it, so I got it from JDMNZ. I won't post the details of the install because others have done such a good job of documenting it already.

Blcktpgsr: FIELD MONITOR UNIT - update w/ pics - YotaTech Forums
Rock Slide: Hilux Surf Field Monitor installed in a 3rd Gen Write-Up *PICS* - YotaTech Forums

So here is the final product.

I used SEM Color Coat, Saddle Tan for the paint. It matches extremely closely to the color of the original console.

I moved my Pioneer head unit from my old car to my new one with a new install kit.

I also added an aftermarket tranny cooler (B&M 70268). I won't post any pics of that because I did exactly what was done in the link from Ksroqclimber's reference page.

http://www.toyota-4runner.org/3rd-gen-t4rs/69744-tutorial-documentation-reference.html

At the same time, i also replaced my spark plugs, spark plug wires, air filter, PCV valve, cleaned the MAF and throttle body. No pics of those either since they are just maintenance.

 

[Nelsonmd]

My next project is a big one... I am swapping out the entire rear axle for a less rusty one.

So the dealer I bought it from definitely didn't disclose all the problems with it, and the axle housing was rusted through in a couple places. When I chipped off the big flakes of rust, I found this

I patched it with some JB weld putty. I used the putty instead of the 2 part stuff in order to prevent any of it from dripping inside and onto the diff. It was pretty easy, but required good cleaning to get all the oil off.

I tried putting rustoleum rust converter on it but the stuff just flaked off.

While the patch is working, I don't see it as permanent, so I wanted to replace the housing. Every salvage housing here in New England was rusty, so I bought a rear axle off Topdownrunner from this forum. After arranging a craigslist rideshare for shipping from florida to Boston, it arrived this weekend.

It didn't come with any brake hardware, so that will all have to be swapped over

The locker looks to be in great condition

The breather tube was cut though. Anyone have any ideas how to attach a new tube to extend it up to a good position? It doesn't look like I can disconnect it from the locker.

 

[StreetKill831]

I was trying to buy that axle from him but you beat me to it.. lol no hard feelings. Anyway, I'm confused as to what you mean by the diff breather being cut.. as in the pictures it looks to just be an OEM breather. It unscrews, I believe you need a 10mm or 12mm to get it off. I just did the extension mod to my breather a few weeks ago.

*edit
I think what you are referring to is the "tube" coming out of the third member, which is part of the wiring for the e-locker.

 

[Nelsonmd]

I was trying to buy that axle from him but you beat me to it.. lol no hard feelings. Anyway, I'm confused as to what you mean by the diff breather being cut.. as in the pictures it looks to just be an OEM breather. It unscrews, I believe you need a 10mm or 12mm to get it off. I just did the extension mod to my breather a few weeks ago.

*edit
I think what you are referring to is the "tube" coming out of the third member, which is part of the wiring for the e-locker.

Yeah, the tube coming off the locker. I read somewhere that this is the locker breather tube. It is a small diameter tube with a rubber jacket around it. I don't really know how to attach a new tube to one so small.

I will have to check mine out see where it goes. I didn't know it existed until the axle came in.

 

[StreetKill831]

That's the wiring for the e-locker. try cutting back some of the tubing to reveal the cut wires. The 3rd member(e-locker) and axle housing all have the same breather which is the little nub sticking out on top of the axle.

 

[StreetKill831]

Just did a little more research and I guess i could be wrong, but I don't think so.

 

[xskydivingdudex]

looks good dude and well u seem to have done a few things i need to such as bypassing the tranny cooler... if u dont mind me asking, how much did u get ur FMU for? ive been looking for one but havent had any luck yet. Saw one a while back on ebay but it was around $400+

 

[blcktpgsr]

Nice install on the overhead unit and let me welcome you to the FMU club like I'd been welcomed before. Good luck on the factory locker build as well, you're gonna have lots of fun wheeling with it just as much as the Field Monitor Unit.

 

[blcktpgsr]

looks good dude and well u seem to have done a few things i need to such as bypassing the tranny cooler... if u dont mind me asking, how much did u get ur FMU for? ive been looking for one but havent had any luck yet. Saw one a while back on ebay but it was around $400+

I also got mine from Henry from New Zealand.
JDM Toyota - JDMNZ

 

[Nelsonmd]

looks good dude and well u seem to have done a few things i need to such as bypassing the tranny cooler... if u dont mind me asking, how much did u get ur FMU for? ive been looking for one but havent had any luck yet. Saw one a while back on ebay but it was around $400+

Blcktpgsr, you beat me to it...

Henry's definitely the best place to get one. It is relatively cheap ($150 +$20 shipping), and he shipped very quickly. He only has grey's, but they can be painted. Great source there.

Nice install on the overhead unit and let me welcome you to the FMU club like I'd been welcomed before. Good luck on the factory locker build as well, you're gonna have lots of fun wheeling with it just as much as the Field Monitor Unit.

Thanks. Your rig is on my top 3 list that I have seen here. The next looks mod I want to do is the satoshi mod, I love the way you integrated the lights in yours. I would love to be able to do th same thing, but my money has to go into performance mods for now.

 

[topdown4runner]

Glad you like the axle. It is definately cleaner than the one on my own truck
I should have swapped them out and sold the one from my '99 instead. :crybaby:
Oh well. Enjoy :bluejump:

As to the "tube" coming out of the axle, there are no wires in it. The wires connect to two different "connectors" on top of the housing. This wrapped tube is new to me too. What about connectors for air shocks? Looks to be about the same diameter tubing. Just some thoughts....

 

[fightman80]

Got any pics of the exterior of your truck man?? Looks like you're doing alot of work to get rid of the rust issues.......I deal with Road Salt here in Ontario Canada....I just coat everything with Oil and Grease....

 

[xskydivingdudex]

wow i just sold my brush guard and ive been debating on wat to do with money so now the FMU is on the list of potential items to buy with that great price... best thing of all is my interior is grey!

 

[SkidPalace]

That rear end looks good. I just shot you a PM about helping with the install.

 

[Nelsonmd]

That rear end looks good. I just shot you a PM about helping with the install.

Got it. I need to check with the rest of the guys that will help me if that date will work, so don't move your schedule around yet.

Anyone else here in Boston want to help? This would be Saturday 10/30 in brighton.

I just bought a ScanGauge, should be here tomorrow. I figure it will be worth the price just to give me an accurate gas gauge since the PO's didn't take it in for the TSB.

 

[brian2sun]

Good work! Seeing all that rust makes me glad for a split second that I live in CA. Nice score on the elocker too!

 

[Nelsonmd]

So does anyone know where the breather tube for the e-locker goes? I found that it is 1/8" vacuum line, and I can attach a new one to it using vacuum line connects that are just rubber sleeves that fit around the ends. I need to know how much more vacuum line I need and where it goes. I havn't had a chance to crawl under there and try to follow it. Also, anyone know if there is a breather plug or the like at the end of it?

 

[SkidPalace]

I think you may be confused still. There is no special breather for the locker. It is the same breather as the regular axle housing. It's the little button doo-hickey on the top of the pumpkin (to the right of the cut wire on your pic). That's the thing that people relocate to higher ground in order to prevent mud and water from getting into your diff.
The black tube in your pictures is the electrical wiring harness that actuates the locker. It was just hacked off by the salvage company. You should be able to take that off completely and re-attach the harness from your truck.