Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case
- Thread starter 4RunnerAquasport
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4RunnerAquasport
Senior Member
T-case swap
Got the t-case in and waiting on drive shafts now. Like to thank everyone who has done this mod and posted all the pics and info: [MENTION=65653]aha2988[/MENTION] [MENTION=133326]ryanking61[/MENTION] [MENTION=459231]xtremewlr[/MENTION] [MENTION=4242]mysticz[/MENTION]. If I missed anyone sorry about that.
I pretty much copied everyone else right down to the shifter boot from Autozone. Why change something that works perfectly. I put the ground for the dash indicator lights inside the cab to resist corrosion, and I didn't pass the A/C duct back to the rear as I plan on pulling my rear seating anyway. I also added a Marine cig outlet to the console to replace the one that gets taken out in the coin slot.
Got the t-case in and waiting on drive shafts now. Like to thank everyone who has done this mod and posted all the pics and info: [MENTION=65653]aha2988[/MENTION] [MENTION=133326]ryanking61[/MENTION] [MENTION=459231]xtremewlr[/MENTION] [MENTION=4242]mysticz[/MENTION]. If I missed anyone sorry about that.
I pretty much copied everyone else right down to the shifter boot from Autozone. Why change something that works perfectly. I put the ground for the dash indicator lights inside the cab to resist corrosion, and I didn't pass the A/C duct back to the rear as I plan on pulling my rear seating anyway. I also added a Marine cig outlet to the console to replace the one that gets taken out in the coin slot.
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4RunnerAquasport
Senior Member
FJ Fuel Tank Swap
So I learned last year from a 4th gen guy out in San Diego, that the 19 gal FJ fuel tank will bolt right up with a few mods to the straps and plumbing. He then installed an aftermarket FJ fuel skid and called it a day. I am going to see if I can modify the OEM 4th gen skid and make it work.
Now you might say what is the point? Thats LESS fuel capacity. A valid concern for those that DD or have Overlanding Wanderlust.
I however am in pursuit of more travel, and not the overlanding type. Here is a picture of the two to explain what I'm after. The OEM 4th gen tank is on top which is pretty much maxed out on down travel with the upper link and spring in contact with the tank, and the FJ tank on the bottom allows a few more inches of clearance. Which I believe will equate to several more inches of down travel at the wheels, once I get my pinion angle sorted out and LT shocks in there. If you use the frame mount for the upper link as a reference, you can see how much shorter the FJ tank is.
The lower links are the restricting factor in the pic on the bottom, so with the pinion angle raised several degrees, this will allow even more droop and then I'll strap it to a safe limit. But, the FJ tank will not be in play as much as the OEM 4th gen.
So I learned last year from a 4th gen guy out in San Diego, that the 19 gal FJ fuel tank will bolt right up with a few mods to the straps and plumbing. He then installed an aftermarket FJ fuel skid and called it a day. I am going to see if I can modify the OEM 4th gen skid and make it work.
Now you might say what is the point? Thats LESS fuel capacity. A valid concern for those that DD or have Overlanding Wanderlust.
I however am in pursuit of more travel, and not the overlanding type. Here is a picture of the two to explain what I'm after. The OEM 4th gen tank is on top which is pretty much maxed out on down travel with the upper link and spring in contact with the tank, and the FJ tank on the bottom allows a few more inches of clearance. Which I believe will equate to several more inches of down travel at the wheels, once I get my pinion angle sorted out and LT shocks in there. If you use the frame mount for the upper link as a reference, you can see how much shorter the FJ tank is.
The lower links are the restricting factor in the pic on the bottom, so with the pinion angle raised several degrees, this will allow even more droop and then I'll strap it to a safe limit. But, the FJ tank will not be in play as much as the OEM 4th gen.
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xtremewlr
Member
So I learned last year from a 4th gen guy out in San Diego, that the 19 gal FJ fuel tank will bolt right up with a few mods to the straps and plumbing. He then installed an aftermarket FJ fuel skid and called it a day. I am going to see if I can modify the OEM 4th gen skid and make it work.
Now you might say what is the point? Thats LESS fuel capacity. A valid concern for those that DD or have Overlanding Wanderlust.
I however am in pursuit of more travel, and not the overlanding type. Here is a picture of the two to explain what I'm after. The OEM 4th gen tank is on top which is pretty much maxed out on down travel with the upper link and spring in contact with the tank, and the FJ tank on the bottom allows a few more inches of clearance. Which I believe will equate to several more inches of down travel at the wheels, once I get my pinion angle sorted out and LT shocks in there. If you use the frame mount for the upper link as a reference, you can see how much shorter the FJ tank is.
The lower links are the restricting factor in the pic on the bottom, so with the pinion angle raised several degrees, this will allow even more droop and then I'll strap it to a safe limit. But, the FJ tank will not be in play as much as the OEM 4th gen.
Nice work on the tcase! Have you had a chance to try it out yet?
Great information about the FJ fuel tank. Right now, the 4runner is still my daily but that will change soon enough. Since I run the spare out back instead of underneath now, there is a ton of room for a 2nd fuel tank to get some of that capacity back and still have room for suspension travel. Something to think about if you need that extra capacity at some point.
4RunnerAquasport
Senior Member
FJ Fuel Tank Swap Cont'
So with the 4th gen tank removed, I put the FJ tank in and shuffled things around. The fuel pump housing for the FJ tank pretty much sits in the same position as the 4th gen tank. So I will swap out the main feed and return lines going to the engine from the 4th gen, and the electrical connection will not need altering.
So with the 4th gen tank removed, I put the FJ tank in and shuffled things around. The fuel pump housing for the FJ tank pretty much sits in the same position as the 4th gen tank. So I will swap out the main feed and return lines going to the engine from the 4th gen, and the electrical connection will not need altering.
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4RunnerAquasport
Senior Member
4RunnerAquasport
Senior Member
FJ Fuel Tank Swap Cont'
I wish I could figure out how to insert pics and text like [MENTION=429038]y=mx+b[/MENTION], so as not make so many posts, but that's for another day lol.
Now for the retaining straps. I am blessed with a relatively rust free undercarriage so this wasn't too bad of a job.
The forward strap fits in the same place, I just had to shorten and bend it to fit the smaller profile of the FJ tank. I decided to bolt it into the hole where the skid bolts in, so it will share this mounting point with the skid.
The rear strap was a bit of a brain tease at first, as it does not line up with any of the mounting points. So I got the band saw and welder out (don't look to close at those welds lol), fabbed up a little bracket, then drilled and tapped it for the outside frame mount. Then I put a sleeve and bolt in for the inboard mounting point and I think it will be pretty secure.
So now I can bring it back down, put the FJ fuel pump housing in, paint everything, and start work on modifying the 4th gen skid to fit.
I wish I could figure out how to insert pics and text like [MENTION=429038]y=mx+b[/MENTION], so as not make so many posts, but that's for another day lol.
Now for the retaining straps. I am blessed with a relatively rust free undercarriage so this wasn't too bad of a job.
The forward strap fits in the same place, I just had to shorten and bend it to fit the smaller profile of the FJ tank. I decided to bolt it into the hole where the skid bolts in, so it will share this mounting point with the skid.
The rear strap was a bit of a brain tease at first, as it does not line up with any of the mounting points. So I got the band saw and welder out (don't look to close at those welds lol), fabbed up a little bracket, then drilled and tapped it for the outside frame mount. Then I put a sleeve and bolt in for the inboard mounting point and I think it will be pretty secure.
So now I can bring it back down, put the FJ fuel pump housing in, paint everything, and start work on modifying the 4th gen skid to fit.
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4RunnerAquasport
Senior Member
No I haven't tried it out yet. I just dropped the drive shafts off today and it will be awhile before the front diff matches the 4:56 gear in the rear end anyway.
I plan on running the Currie Anti Rock sway bar back there, so I don't know about adding an aux tank. But your right, there is a shit ton of room back there. I may try to fab up a hitch carrier for my spare one day, but right now it takes up most of the cargo space.
I plan to take the back seats out and may have to bust through the rear fender well to get these 14" triple bypasses to work back there. I'm in over my head for sure lol.
montijo505
Senior Member
Damn. I’ve been off the forum for a while. Taking this beast to the next level, I love it!
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
4RunnerAquasport
Senior Member
The front of the tank is definitely tucked up tighter. Didnt measure it, but its over an inch. You might be right, Pic I found of a BudBuilt 07 -09 FJ skid looks to be well over an inch in that front area. Might help a little with your break over clearance in the middle of your wheel base.
Im not sure if the rear of the tank tucks up any higher or not.
FJ tank is just mocked up for now, so I can compare the two later when I pull it back down.
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4RunnerAquasport
Senior Member
FJ fuel tank swap cont
Found my first oversight on this job. The 4th gen has a vapor pressure sensor tied into the evap system. The FJ fuel pump housing doesnt have that port, so I will have to drill one out and put a bushing in to hold the sensor. Hoping for the best. EVAP DTCs are not our friends.
Found my first oversight on this job. The 4th gen has a vapor pressure sensor tied into the evap system. The FJ fuel pump housing doesnt have that port, so I will have to drill one out and put a bushing in to hold the sensor. Hoping for the best. EVAP DTCs are not our friends.
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xtremewlr
Member
They look roughly the same size from the pic. The 4runner one won't swap over to the FJ tank?
4RunnerAquasport
Senior Member
It could, I test fit the 4Runner housing in the FJ tank, but there are physical differences in the lower part of the housing where the pump is located. And the sending units are a little different in how they're oriented.
The 4Runner sending unit might give false levels being calibrated for a 24 gal tank.
About a year ago I emailed Gadget over at URD, and he said there are differences that do matter.
I want to upgrade the pump with one of his high flow kits, but he recommends putting the FJ housing in the tank and run it for a few hundred miles to make sure the fuel system and sending unit are working properly.
Then when I put the upgraded pump in, I can address any problems there might be.
I dont think he has ever seen this swap as the vapor pressure sensor never came up. But, I trust his judgement when it comes to this type of mod.
It makes sense to eliminate any issues w the system before I drop the high flow pump in there. And I have time right now to cut a bigger opening where the access panel is under the back seat.
That will make pulling the housing out much easier, because they only give you enough room to disconnect the plumbing and electrical, the housing wont fit thru that opening.
My Son has a Dremel oscillating tool w a carbide blade that eats these floor pans up. So it wont take long.
4RunnerAquasport
Senior Member
[MENTION=130999]Inv4drZm[/MENTION] Yea Mason, the FJ tank is slightly smaller in a couple of ways. The overall design is really close, but thats what makes this swap doable.
Aside from the obvious length difference and the tighter profile top to bottom in the front, the 4Runner tank is about a 1/2" taller at the highest points of the design, so it may tuck up a little tighter in the frame.
Aside from the obvious length difference and the tighter profile top to bottom in the front, the 4Runner tank is about a 1/2" taller at the highest points of the design, so it may tuck up a little tighter in the frame.
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4RunnerAquasport
Senior Member
FJ fuel tank swap cont
Mock up #3. Just cut the opening and tested installing the housing. The float hangs down and away from the housing and you have to angle it into the opening, so you have to cut the floor pan quite a bit larger than the tank opening.
You can see the old cover and how much you need to cut.
I have a piece of Aluminum left from the T-case swap, so Im going to fab a cover and get some rubber sheet to seal it up.
Hopefully once it's permantly installed I'll never have to drop the tank again.
Mock up #3. Just cut the opening and tested installing the housing. The float hangs down and away from the housing and you have to angle it into the opening, so you have to cut the floor pan quite a bit larger than the tank opening.
You can see the old cover and how much you need to cut.
I have a piece of Aluminum left from the T-case swap, so Im going to fab a cover and get some rubber sheet to seal it up.
Hopefully once it's permantly installed I'll never have to drop the tank again.
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4RunnerAquasport
Senior Member
Got the rear axle and T-case installed, along with getting the FJ tank operational last week, the guage is not accurate tho. More work to be done there. Took a couple weeks for the driveshafts to get finished.
I pussed out on installing the bypasses for now. Too much work to be done on the front right now and I wanted to get started.
So I put new rod ends on the smoothies and reinstalled them.
The 4:56 gear is super responsive. Truck is pretty quick now. 2350 rpms @ 70 mph and the mileage might suffer, so the timing of the rise in prices sucks. ****ing politics.
Received my 200 Rack bushings from [MENTION=130999]Inv4drZm[/MENTION] Masons brother tho.
I pussed out on installing the bypasses for now. Too much work to be done on the front right now and I wanted to get started.
So I put new rod ends on the smoothies and reinstalled them.
The 4:56 gear is super responsive. Truck is pretty quick now. 2350 rpms @ 70 mph and the mileage might suffer, so the timing of the rise in prices sucks. ****ing politics.
Received my 200 Rack bushings from [MENTION=130999]Inv4drZm[/MENTION] Masons brother tho.
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4RunnerAquasport
Senior Member
Yea we'll see how it goes. I have to pull the diff to put the matching 4:56 in it, and the suspension will be completely torn down to install the DK +3.5. So there will be plenty of room to work on the rack.
I got a really good deal on a brand new 200 rack and McGeorge Toyota was honoring a free shipping special that corporate was promoting. So I jumped on it.
Took the fenders off this evening since the fiberglass is going back on after I'm done.
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4RunnerAquasport
Senior Member
Weather is not cooperating, so Im indoors prepping the 200 Rack.
Need offset bushings for the driver side mount to piggyback in the diff mount location. So the OEM bushing gets removed and the offset replaces it.
Also ordered new motor mounts to hopefully gain a little clearance for this behemoth under the pan. A high mileage mount can start to sag like old.....well you know.
Need offset bushings for the driver side mount to piggyback in the diff mount location. So the OEM bushing gets removed and the offset replaces it.
Also ordered new motor mounts to hopefully gain a little clearance for this behemoth under the pan. A high mileage mount can start to sag like old.....well you know.
