Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case

[4RunnerAquasport]

So I'll post my response that I just sent you so other people can see the difference in the TBs as well.

They are very similar, yes. But the 03/04 TB won't fit the plastic intake. I forget exactly why and of course didn't take a picture but there was some sort of interference or it was the bolt holes that didn't line up correctly.

First, this is how the 05+ TB would normally be installed. Unless you want to extend the TB wiring, it's simpler to just flip it upside down so your existing wiring harness will simply plug in.

Here are pics of each, side by side, mounted on the respective intakes. The TB on the plastic intake has bee flipped already and is how it's installed on my 4Runner right now.

There is also about a 12.5lb weight difference between the aluminum intake and the plastic, so the weight loss is a bonus with doing the swap.

You also need to get the fuel rails for the newer intake, or at least the front crossover pipe since the aluminum intake version goes under the TB and the plastic intake version goes over the intake. I tried fitting the alu intake version first and it wouldn't work. I think the fuel rails by themselves are the same but one side had different bolt hole locations. Best just to get the newer fuel rails and not have to fiddle with trying to make it work.

I highly advise replacing both fuel regulators on the fuel rails with new ones while you are doing the swap. Also a good time to check out the starter while you have access. Fuel injectors can be reused or you can spend the extra and replace them with 12 hole injectors like I did. I didn't see any performance or mpg gain with the new injectors tho.

I have a lot more pictures and details in my build thread on tacomaworld but feel free to hit my up with any other questions about doing the swap.

My daily driver 2003 4Runner Limited 4wd V8 | Page 2 | Tacoma World

Thanks Todd! Love this community!!
I am wondering if the 12 hole Inj might be taken advantage of with my headers and a URD fuel pump. Thinking about swapping in an FJ 19 gallon tank to free up some travel on my drivers side upper link, and could put the new fuel pump in then. Also ordered a +3.5" DK LT kit, so I've gone completely out of my mind now. By the way my 1st gen is up for sale to help pay for all of this, so anyone in Florida.....

 

[montijo505]

Subbed for komodo dragon stance on the 4R with the new DK kit. With a roll of napkins to clean up the drool.

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[Inv4drZm]

Subbed for komodo dragon stance on the 4R with the new DK kit. With a roll of napkins to clean up the drool.

Sent from my SM-G986U using Tapatalk

Yeah, now make the rear axle match width-wise. Only way to roll.

 

[montijo505]

[MENTION=130999]Inv4drZm[/MENTION] flexin a bit lol. Seriously though two of my favorite 4th gens on the forum.

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[Inv4drZm]

[MENTION=130999]Inv4drZm[/MENTION] flexin a bit lol. Seriously though two of my favorite 4th gens on the forum.

Sent from my SM-G986U using Tapatalk

What the point of going to the gym if I can't show it off?

:rofl:

 

[4RunnerAquasport]

[MENTION=130999]Inv4drZm[/MENTION] flexin a bit lol. Seriously though two of my favorite 4th gens on the forum.

Sent from my SM-G986U using Tapatalk

Thanks!! So far I have nothing on the flexing Kansan though. He wins big time in the mod and adventure categories. I might be in the running for the "oldest owner" category.

Yeah, now make the rear axle match width-wise. Only way to roll.

No I won't be able to match that one. But I am getting 4:56s w an ARB, and with spacers My WMS to WMS will be 67" with this axle I bought of a guy in San Diego, and he is giving me his front gears once he pulls them out. What is your rear length by the way? I can't remember.

 

[Inv4drZm]

No I won't be able to match that one. But I am getting 4:56s w an ARB, and with spacers My WMS to WMS will be 67" with this axle I bought of a guy in San Diego, and he is giving me his front gears once he pulls them out. What is your rear length by the way? I can't remember.

69.895" WMS. Have you regeared yet? If not you will like the new ratio.

 

[4RunnerAquasport]

69.895" WMS. Have you regeared yet? If not you will like the new ratio.

No I haven't, looking forward to it. Still haven't bought shocks for the front, and I would like to get new rear shocks to gain more travel, so I am trying to come to grips with that expense as well. I think I need to be committed.

 

[4RunnerAquasport]

[MENTION=459231]xtremewlr[/MENTION] Hey Todd, Your truck is looking Great!
I finally might have some time to do this intake swap. Going through all the parts and comparing to your posts. I noticed two vacuum ports on the underside and see where you have them routed. The one in the rear loops out to the runner diaphragm and the other looks like it goes to the pressure regulator. Included some pics.
Just want to make sure where these hoses need to terminate. I see the regulator hose goes to the intake on my aluminum, and it looks like yours does also in one of your other pics.
Gonna go back and look at your thread on TW to make sure again what I'm looking at.

Also tried to find some diagrams in the service manual without any luck.

 

[xtremewlr]

[MENTION=459231]xtremewlr[/MENTION] Hey Todd, Your truck is looking Great!
I finally might have some time to do this intake swap. Going through all the parts and comparing to your posts. I noticed two vacuum ports on the underside and see where you have them routed. The one in the rear loops out to the runner diaphragm and the other looks like it goes to the pressure regulator. Included some pics.
Just want to make sure where these hoses need to terminate. I see the regulator hose goes to the intake on my aluminum, and it looks like yours does also in one of your other pics.
Gonna go back and look at your thread on TW to make sure again what I'm looking at.

Also tried to find some diagrams in the service manual without any luck.

Sorry for the slow response. Just got home from a weekend of wheeling and camping in norther AZ and up into southern Utah for a minute.

The rear vacuum line is exactly as I show in that pic there. The front one I ended up running the the vacuum port on the front passenger side below the intake. There's a dual vacuum port switch thing there (forget what it actually is right now) that has one line to the intake tube and another to the intake manifold. The regulator I used the stock vacuum port on the intake tube.

Edit: That S shaped hose on the top of the intake was only used until I got vacuum caps that fit.

 

[4RunnerAquasport]

Sorry for the slow response. Just got home from a weekend of wheeling and camping in norther AZ and up into southern Utah for a minute.

The rear vacuum line is exactly as I show in that pic there. The front one I ended up running the the vacuum port on the front passenger side below the intake. There's a dual vacuum port switch thing there (forget what it actually is right now) that has one line to the intake tube and another to the intake manifold. The regulator I used the stock vacuum port on the intake tube.

Edit: That S shaped hose on the top of the intake was only used until I got vacuum caps that fit.

No worries, I figured you were out on the prowl this weekend. It's been way too long for me, but I'm glad to have a full schedule again.

OK I wasn't sure those were vacuum ports under the intake or not. The dual port switch on the front pass side is for the power steering power up feature I believe.

I spent the day with a dryer vent brush and some purple power cleaning the carbon build up out of the runners. Got it mostly smooth in there now. Had to gather up a couple more parts I forgot about, crush washers for the banjo fittings and an O ring for the coolant tube.

I might get this done sometime this year.........Gears, T-Case and LT are later this summer/fall hopefully. Still gotta find a Drive shaft guy as well.

Hope you had a good trip this weekend,

Thanks Todd!!!

 

[4RunnerAquasport]

Intake swap

Got the intake pulled. About a pound of sand under there.

Took awhile to get the starter out, serious PIA. Toyota engineers were gettin cussed this afternoon.

Never have seen an intake gasket like this one. Composite sandwiched between two metal pieces.

Noticed that the 05' Throttle body opening is almost 5mm larger in diameter than the 03'. Hope that equates to some Torque on the low end.

 

[4RunnerAquasport]

DUHHHH, ordered the 270cc injectors from Dirty Deeds w out getting the adapter connectors, so I won't hear it run for awhile lol.
Spoke w Keith just now and he confirmed the adapters will work w the 270cc on the 03'.

SMDH

 

[xtremewlr]

DUHHHH, ordered the 270cc injectors from Dirty Deeds w out getting the adapter connectors, so I won't hear it run for awhile lol.
Spoke w Keith just now and he confirmed the adapters will work w the 270cc on the 03'.

SMDH

You can run it with your stock injectors until the others come in.

Why the 270cc injectors? Boost? I have the 250cc ones from DD and they are a direct swap, no adapter required.

 

[4RunnerAquasport]

You can run it with your stock injectors until the others come in.

Why the 270cc injectors? Boost? I have the 250cc ones from DD and they are a direct swap, no adapter required.

I'm going on the road for 3 weeks so I don't need to drive it and still have the 13 mpg 5th gen lol.

No not gonna boost it.
I might be dreaming but I'm hoping with the 05' intake, Headers and Y pipe w 4:56 gears I will be gaining some torque with bigger injectors. Keith actually thinks it might be running lean as well so there is that.

I also was thinking of getting a MAF Sensor Calibrator from URD and maybe getting a little more out of it that way.

I know cost wise boosting is really the way to get power out of these Toyotas, but trying to get decent power out of N/A appeals to me. I'm probably dreaming though lol.

 

[xtremewlr]

I'm going on the road for 3 weeks so I don't need to drive it and still have the 13 mpg 5th gen lol.

No not gonna boost it.
I might be dreaming but I'm hoping with the 05' intake, Headers and Y pipe w 4:56 gears I will be gaining some torque with bigger injectors. Keith actually thinks it might be running lean as well so there is that.

I also was thinking of getting a MAF Sensor Calibrator from URD and maybe getting a little more out of it that way.

I know cost wise boosting is really the way to get power out of these Toyotas, but trying to get decent power out of N/A appeals to me. I'm probably dreaming though lol.

No, that makes sense. I forgot you had a real exhaust. I'm still running stock shit for now.

Can you post some pics of how the Antirock sway bar in the rear is mounted? It's something I've been considering doing to mine. Also, what length arms and width is it?

 

[4RunnerAquasport]

No, that makes sense. I forgot you had a real exhaust. I'm still running stock shit for now.

Can you post some pics of how the Antirock sway bar in the rear is mounted? It's something I've been considering doing to mine. Also, what length arms and width is it?

The picture above is of the axle I bought off Race Dezert from a super good guy in San Diego. It has Nitro 4:56s and an ARB locker in it with modified link tabs and lower shock mounts all set up for what I want to do with the LT. He made me a deal and got me a great price with his shipping dept at work. So I couldn't pass it up.

That pic is actually when it was still on his 4th gen, but he kept his anti-rock for the new custom build he was getting from Currie. He said the FJ anti-rock bolts right up.
Other than that I got nothing, except the part# label off the one I bought from Trail Gear. I hope to start this axle swap soon, but you know how time gets away from us. I'll try to keep you posted on how the Anti- Rock goes together, but hell the way you move, you might get to it before me.

 

[xtremewlr]

The picture above is of the axle I bought off Race Dezert from a super good guy in San Diego. It has Nitro 4:56s and an ARB locker in it with modified link tabs and lower shock mounts all set up for what I want to do with the LT. He made me a deal and got me a great price with his shipping dept at work. So I couldn't pass it up.

That pic is actually when it was still on his 4th gen, but he kept his anti-rock for the new custom build he was getting from Currie. He said the FJ anti-rock bolts right up.
Other than that I got nothing, except the part# label off the one I bought from Trail Gear. I hope to start this axle swap soon, but you know how time gets away from us. I'll try to keep you posted on how the Anti- Rock goes together, but hell the way you move, you might get to it before me.

This works just fine!

Things have slowed down for me. A little burned out on doing stuff to the 4Runner right now. I just want to enjoy it for a while and find what it really needs going forward. Like exhaust. The stock exhaust has been slowly ticking on cold start and seems to be getting slowly worse so I need to start thinking about the DT headers down the road. And gearing. And a rear locker. And a winch. And .........:lalala:

 

[4RunnerAquasport]

Intake swap

Got Home Tuesday from 3 weeks out working, and the Injector connector extensions had arrived so I finished up yesterday.
Threw a P2103 code and it went into limp mode after a couple of minutes of idling-Throttle Actuator Control Motor Circuit.

I did not reinstall the coolant pass through that goes into the throttle body housing and had left the two ports open. So I capped them (red and yellow caps) and tapped lightly on the motor housing, thinking that the motor might have been stuck from sitting for several months.

The code was still registering in the ECU, but the engine had recovered from limp mode, so I had Torque Pro clear the code and went on a 15-20 mile drive and it seems OK for now. Will drive it for a couple days before I leave again.

Pretty generic picture because with a lack of time at home, and not much attention to detail like [MENTION=459231]xtremewlr[/MENTION], I didn't paint anything like his great looking valve covers lol. This truck has always been more about function than form anyway. It takes quite the beating when I get out on the trails, so I just clean it mostly for maintenance purposes.

 

[4RunnerAquasport]

Finally got rid of the SR5 rims that came on the truck.
SCS Stealth 6 and some new KO2s.