Octanejunkie's T4R project - 99 SR5 4WD 5-speed

[octanejunkie]

Are they any good? Lots of folks have had serious issues with aftermarket flywheels for years. Maybe they are fine.

I just know I wouldn't want to change a clutch/ flywheel and have the starter bind in the teeth or have the surface not true enough that you have to redo it again.

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We are going to find out lol

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[brillo_76]

We are going to find out lol

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LOL.. Nice.. Yes, I guess we will.. :driving:

 

[Unner]

Nice tires, I loved my skinny ST Maxx. I just put 285 Cooper AT3 XLTs on. Time will tell if I like them as much. So far MPG seems to have taken a good hit. I had like 70k miles on my ST Maxx and they still have life left.

How did your spindle gussets fit? I know jziggy had to trim some on his to get good fitment. I've been looking at those same ones.

 

[octanejunkie]

Nice tires, I loved my skinny ST Maxx. I just put 285 Cooper AT3 XLTs on. Time will tell if I like them as much. So far MPG seems to have taken a good hit. I had like 70k miles on my ST Maxx and they still have life left.

How did your spindle gussets fit? I know jziggy had to trim some on his to get good fitment. I've been looking at those same ones.

Compared to the worn out discoverers that I switched from, that still have life technically, the St Max is a different ride completely.

We did minimal fitting of the gussets, depending on how you align them and variation in your spindles, we did do a little bit of grinding but not much.

Not sure if I'm going to use an extension tab for the brake line like Jordan did or come up with an alternate mounting point.
I will be sourcing another set of brackets to secure the ABS wiring in the stock location.

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[octanejunkie]

Weekend Update 249,298 miles

Clutch replaced by local shop

Dropped the truck off on Tuesday with the understanding that they would work it into their rotation, they called me at 4 PM today, Friday, that it was ready so I promptly went to get it.

The Aisin kit came with an NSK (日本精工株式会社, Nippon Seikō Kabushiki-gaisha, Japan Precision Company) throwout bearing, so we used that. I'll return the Timken.

Install went smoothly, but I forgot to give them the Marlin Crawler shifter bushings so I'll have to do that myself.

The only notes I got back was play in the driver side ITRE so I will plan replacing both ITREs soon.

I'll take it easy for the next 500-700 miles to properly break it in but so far no issues/vibration at any RPM with either street or highway driving.

Next project, installing the manual hubs, spindles and CVs.



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[brillo_76]

Weekend Update 249,298 miles

Clutch replaced by local shop

Dropped the truck off on Tuesday with the understanding that they would work it into their rotation, they called me at 4 PM today, Friday, that it was ready so I promptly went to get it.

The Aisin kit came with an NSK (日本精工株式会社, Nippon Seikō Kabushiki-gaisha, Japan Precision Company) throwout bearing, so we used that. I'll return the Timken.

Install went smoothly, but I forgot to give them the Marlin Crawler shifter bushings so I'll have to do that myself.

The only notes I got back was play in the driver side ITRE so I will plan replacing both ITREs soon.

I'll take it easy for the next 500-700 miles to properly break it in but so far no issues/vibration at any RPM with either street or highway driving.

Next project, installing the manual hubs, spindles and CVs.



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So the flywheel is good. That's good to know.

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[Scramble]

You should convert this rig to an A/T and RWD! It would be a forum first! :bravo:

Edit: I guess its too late now but the Marlin Crawler HD Clutch is bad ass. Feels just like stock except it grabs a little better. Which is exactly what I wanted for towing by boat up hills. My flywheel looked good but for only another $50 I went with the Marlin FW so there weren't any issues.

 

[brillo_76]

You should convert this rig to an A/T and RWD! It would be a forum first! :bravo:

Edit: I guess its too late now but the Marlin Crawler HD Clutch is bad ass. Feels just like stock except it grabs a little better. Which is exactly what I wanted for towing by boat up hills. My flywheel looked good but for only another $50 I went with the Marlin FW so there weren't any issues.

That's what's going to go in my 5 speed is a marlin crawler clutch

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[octanejunkie]

You should convert this rig to an A/T and RWD! It would be a forum first! :bravo:.

Jaysus, man

Edit: I guess its too late now but the Marlin Crawler HD Clutch is bad ass. Feels just like stock except it grabs a little better. Which is exactly what I wanted for towing by boat up hills. My flywheel looked good but for only another $50 I went with the Marlin FW so there weren't any issues.

That is a good looking flywheel for $110 @ 23.2#
The Sachs flywheel I installed was just under 25#

That's what's going to go in my 5 speed is a marlin crawler clutch

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Marlin clutches were out of stock, I went Aisin. Next time MC or LC, similar specs.

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[Scramble]

That is a good looking flywheel for $110 @ 23.2#
The Sachs flywheel I installed was just under 25#
Marlin clutches were out of stock, I went Aisin. Next time MC or LC, similar specs.

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The Aisin's are good, that would have been my second choice. If I remember correctly the stock clutch is 900lbs and the Marlin is 1200lbs. I think the Aisin is around 900lbs also. I replaced the master cylinder with OEM too. The only thing I didnt fix was the squeaky spring on the clutch pedal. It's been squeakin' for well over 10 years I dont even notice it anymore. LOL

 

[brillo_76]

I could be wrong. I think Marlin has asin make a clutch that's 33% stronger then Oem yet has the same feel as factory.

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[octanejunkie]

The Aisin's are good, that would have been my second choice. If I remember correctly the stock clutch is 900lbs and the Marlin is 1200lbs. I think the Aisin is around 900lbs also. I replaced the master cylinder with OEM too. The only thing I didnt fix was the squeaky spring on the clutch pedal. It's been squeakin' for well over 10 years I dont even notice it anymore. LOL

I replaced the pedal spring early on, the squeaking was half solved by that and the rest of it was cured probably when the throwout bearing went south.

If i have to do a clutch again anytime soon I'll keep eyes on Marlin Crawler. Maybe they'll have clutch in stock when they have alignment tab gussets in stock for 3rd gen 4Runners.

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[octanejunkie]

I could be wrong. I think Marlin has asin make a clutch that's 33% stronger then Oem yet has the same feel as factory.

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They have two options under the clutches for the 5VZ engine, both were out of stock, one was Aisin

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[brillo_76]

They have two options under the clutches for the 5VZ engine, both were out of stock, one was Aisin

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I am not in a hurry. I can wait a while. As my frame repair isn't done on my 5 speed. I am waiting till I get my car lift installed then my 5 speed will be a higher priority to get completed.

The winter rides are more pressing now then my 5 speed.

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[octanejunkie]

Ordered a pair of inner tie rod ends 45503-39075 from Amayama, waiting to see if they'll accept my order

 

[octanejunkie]

Weekend Update 249,468

Installed manual hubs/spindles and Taco CVs aka Stage 1 on Saturday and drove it around. You can actually notice a difference between hubs locked and unlocked.

Updated to black lugnuts, too
https://a.co/d/fCtjFGb

Today I adjusted camber via the UCA and prepped a pair of center caps with a 3-1/2" hole saw and some sand paper.

They will get a coat of primer and then painted to match the rims.

EDIT: the final product

Regarding fit, and there's at least 1/2" of clearance between the spindle gusset and the rim/tire. Maybe I'll clearance the gussets a bit more, not sure yet

While I had the skid plate off I swapped out the stock drain and fill plugs on the front diff for Lexus plugs and refilled with Lucas 75w 90

Next steps:
Taco brake lines to eliminate the caliper hardline

New pads and rotors

Install winch (finally)

New-to-me front coilovers


I'm calling this Stage 1 because I'm making changes in phases to ensure issues can be easily isolated if any occur.

 

[habanero]

Very nice work on the center caps, thanks for the inspiration.

 

[G_Raw]

Welcome to the club. I didn't go the extra step of doing the center caps. Looks a bit cleaner your way.

What studs you end up using?

Also I didn't get around to pulling those studs as I'm still messing around with my gas tank/gauge issue after puncturing my old tank. Now that you got your hubs on do you even still want studs for reference?

 

[octanejunkie]

Welcome to the club. I didn't go the extra step of doing the center caps. Looks a bit cleaner your way.



What studs you end up using?



Also I didn't get around to pulling those studs as I'm still messing around with my gas tank/gauge issue after puncturing my old tank. Now that you got your hubs on do you even still want studs for reference?

I'm running the studs that came installed in the hubs for the time being. I am looking for a sample to compare without pulling one of mine out *hint hint

I have a set of studs from yotamasters but have not pulled one of mine to compare yet. They swear their's will work and are not too long lol

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[brillo_76]

Very nice work on the center caps, thanks for the inspiration.

I like that idea. Good idea on the center caps.. +1 for octane project.

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