PK's "accidental" '95 2nd gen build thread

Peevedkitten

New member
Warning, long story before build info. Feel free to skip down to the next post for the actual build guidelines.

I've been lurking and doing research for months on 96-02 T4R's. Thursday (7/24) afternoon my wife texts me a craigslist posting for a '96 4runner for $1k. The catch is, it's 500 miles away. I call the guy and he still has it and I convince him that I will buy it and to pull the ad.

He tells me it's got a bad fan clutch bearing and it needs a battery. I figure it's no big deal and picked up a replacement fan clutch and a battery from the parts house. I figure at $1k if I don't hurry he might sell it before I get there. I left work an hour early to hit the parts house on the way home. So, my wife and I load a bunch of tools in the car along with our 2 dogs and hit the road. The plan was to just turn and burn, get up there swap the fan clutch and get home.

The plan went horribly awry!
What was supposed to be about a 5 1/2 hour trip each way turned into a brutal 9 hour one way death march. The dogs were extremely unruly, the wife had to pee every 5 minutes and we hit a ton off construction and traffic. We left home by 5pm and arrived at 2 am. Luckily the seller had plans to be up and awake extremely late so he was fine with us coming in so late. Unfortunately for me by the time we got there I was so tired I wasn't thinking clearly.

When we got there things went from bad to worse. It wasn't the fan clutch (I may have misunderstood the seller) It was the fan pulley bracket and it was bad. The fan was wobbling probably an inch off center back and forth. There was no way I was driving it home without fixing it first. I should have waited and come back the next day before deciding to purchase it, but I was so exhausted I just wanted to get it done. I put the money down, he signed over the title and I agreed to come back the next day to get it.

We drove to the nearest town and found a hotel, I'm pretty sure as we were checking in somebody got shot across the street. It was pretty damn sketchy but by this time it was 4 am and I had just shut off mentally. The dogs did not do well being in a hotel and I got maybe 45 minutes worth of sleep. I got up at 8 and started calling shops and parts places. By 10am I knew I was in deep trouble, nobody had the part and I had no way to get the runner home.

I called my buddy back home and told him what was going on. He is eternally my hero, he dropped what he was doing and agreed to drive 400+ miles right then and tow it home for me. We just had to rent a tow dolly and wait for him to show up. Since we had several hours to kill it seemed like a good idea to take care of what we could before picking it up. So we decided to go to the DMV and take care of the title transfer...

When I started filling out the pink slip I realized I had screwed up. It wasn't a '96 as advertised, it was a '95. If I hadn't been so tired and had some light to check it out I would have noticed. It was to late for that, I own it now. I get into the DMV and find out the registration is past due and it cost me double was I was expecting to transfer the title.

My buddy shows up around 4pm and we rent the dolly, which was a horrible experience by itself. The U-haul site had no issues giving us the dolly but the system at the rental place showed we couldn't tow it with my buddy's truck (V8 F150 with a 10k hitch). We had to call corporate and get them to approve it so the dealer would rent us the dolly, that took almost an hour and a half. We get to the guys place, load the runner on the dolly and start heading home around 6:30 pm. Traffic and construction are horrid, the dogs and wife are exhausted, whiny and I'm awake only through the sheer power of caffeine. About 150 miles from home my buddy calls me and says he's to tired to keep going and is only 45 minutes from home. He says he'll head home and bring the runner to my place tomorrow.

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He heads home and about half an hour later I have a blowout on my Driver side rear tire. It's 12:30am and we're 120 miles from home in the middle of nowhere. Roadside couldn't get anyone that had the capacity to carry both of us, the dogs and the car. The tire is (luckily) a run-flat, so we limp it to a truck stop 5 miles down the road and call my brother in law who came and took us home.

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We took my truck over there today and ended up having 2 new rear tires put on the car. My buddy had to work and said he'll bring the runner over tomorrow (7/26). So now, I'm the extremely tired owner of a pretty beat to hell '95 4runner. All of my research over the past couple of months has been pointless since I was only considering 3rd gens and haven't read into 2nd gens at all.

I apologize in advance for the plethora of questions I'll be asking. I promise I will try and search out all the info I can before I ask about things. Let me start out with this though;

Does anyone have the part # or a link to the damned Fan pulley bracket? I need to fix that so I can get this thing smogged.
 
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Ok so my plan is coming together slowly but surely. This is not going to be a daily driver. This is my fishing, offroading, camping and expedition vehicle.

Unfortunately everything is on hold until I can sell my BMW. Once the car is gone I should have a $7,500-$10,000 budget for the runner. A solid $3500 of the budget will be going to tools. There are few things I've been wanting for quite a long time and the budget will finally allow for them. A lot of this project is going to be home brew and hand built. I'm going to try and keep my costs down by using junkyards and craigslist for parts.

My budget

First order of business is maintenance!
New plugs
New wires
New oil filter
New air filter
Oil change
Transmission fluid change
Coolant flush
Rear diff input seal replace
Front & rear diff fluid change
Transfer case fluid change
new passenger side front blinker
New accessory belts
Possibly a new PS pump, at least new fluid
Brake fluid flush
Inspect brakes and replace pads if needed
replace vacuum hoses (I hate vacuum hoses so very very much)
Replace battery cables (mine are shot!)
A full energy suspension refresher kit (this will go on with the lift I'll be doing)

Cleaning and refreshing is next:
Pull out the carpet and scrub/wash it clean
scrub the dash and consoles down, BECAUSE THEY'RE STICKY....
Hunt down any rust and grind, por15 and paint it (it's a central California valley vehicle so I'm hopeful rust is minimal)
Hammer out my fenders and try to pop the door dents out (this honestly doesn't matter to me and I may never actually do it...)
Replace my busted sun roof

Next up are purchasable upgrades:
4-5" rough country suspension lift
17" rims (going to try and find some sequoia oem take-offs)
Tires I'll probably do 33x12.5 and replace them eventually with 35's once I can re-do my gearing later on.
Blue sea fuse box
Front speakers and a full stereo system re-wire (the rear already has good speakers and my wife is an audio nut)
2 Corbeau Baja XRS suspension seats with wedge brackets for the driver/pass
Ditch and trail lights with otrattw switches in custom brackets
CB radio mounted in the ash tray spot
Eventually a HAM setup (I need to study and take my test)
Onboard compressor for tires & possibly air lockers (if anyone wants to chime in with ideas or opinions please do!)
Warn M8000 or 9.5XP winch



Custom upgrades:
raised full length deck/bed in the back with storage and a slide out stove (With the gate down and swing-out table down it should give me a full camp kitchen at my fingertips)
A custom built full length roof basket that will sit in the tracks not on the rails
Custom front plate bumper with winch mount
Custom rear bumper with swing-out tire carrier, jerry can holder and drop down table made of 1/2" HDPE (cutting board) on the back.
Custom skid plates
Custom rock sliders

That's my immediate plan. Long term I would love to do an SAS and just go crazy with it, but I need to work within my budget for now and see how it goes. I also need to see what kind of off roading I'm actually going to be doing, this build may already be overkill. Only time will tell!
 
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Lol

I had no intention of buying a 2nd gen either..... but with only $1000 total to spend on replacing my totaled "really nice condition first gen" (estamated value of $5000+) & little time to find a replacement or any extra $ /way to bring home one that didnt rI un & swap in my new motor, there was just no way could get another first gen.

So for now, Im the unhappy owner of a 93 second gen beater . same deal.. I was to tired & hungry (so was my wife & daughter) to really check it over/test drive. but on the way home I found out the brakes were completely shot & rotors warped..... The front shocks are so bad that that I hit a bump on thew freeway & almost lost controle of it & crashed. (it bounced up & down, then the body began to role side to side at the same time. VERRY SCARRY AT 65 MPH!) next morning I see its leaking like crazy... & I find that its low on antifreeze.. Not leaking anywhere that I can see, so most likely a head gasket leak. Oh & it was suppose to be a 92. but in 93 they came with ABS so cant even change over my new brakes... + I assumed the motor would be a direct swap & it isnt... The 93 has different sensors & wireing connectors, etc.....

SO I have an idea where your coming from.... Good luck with getting it all fixed up..
 
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Well, she showed up today with my buddy. She's rough but I think I can work with her. I've already ordered the fan pulley bracket as well as a Chilton manual, the truck came with a Haynes. I'm still doing research on how I want to build it, but a SAS is looking likely.

Here's what I ended up with:
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I went ahead and pulled the fan pulley bracket.I have another on order but I wanted to get it out and make sure I didn't need anything else parts-wise. I looked all over and couldn't find a write up on this so I figured I'd do one myself.

Tools needed:
  • 10, 12 and 14mm sockets and wrenches
  • A 3" and 6" socket extension
  • A pulley holder (I used a tire iron wedged against the body and the pulley)

This isn't a complex install, the only thing I can see that could be an issue is that the pulley bracket holds the timing belt tensioner. As long as you're careful it shouldn't be a problem.

First step is to loosen the 3 accessory belts. I got pictures of the first 2 but forgot to grab a picture of the last one. It's easy to see but requires you to be underneath the vehicle.

I released the alternator first, the 2 bolts are circled in red. The top bolt is the pivot bolt, the bottom bolt is the slide. Don't remove the bolts, just loosen them.

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The power steering pump is next. The first bolt is the pivot. The second bolt is the slide bolt, it's undone on the back side. Remove the slide bolt entirely but leave the pivot bolt loose.

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Undo the four bolts on the face of the pulley. I used a wrench to hold one of the bolts while I broke the rest loose. For the final bolt I used a tire iron wedge in between a stud and braced against the body. I would recommend using the proper tool if you have one. Once all the bolts are removed the fan will come off along with the pulleys.

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From here undo the timing belt tensioner on the side of the fan pulley bracket. I didn't get a shot of it inside the bay, but here it is on the bracket after being removed.

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Disconnect the radiator hose going into the top of the motor. (I took this picture after removing the timing belt cover)

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Now remove the timing belt cover, it should come off fairly easily. If you're pulling and it doesn't come off with minimal force you missed a bolt or 2.

Unbolt the slide bracket for the power steering pump. Be careful because if you let it drop it will fall out of the bottom and onto your foot...

Once it's removed unbolt the fan pulley bracket and just slide it out. Be careful not to bang it into your radiator while you're removing it.

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That's as far as I've gotten since my part hasn't shown up yet. Installation is just the reverse, make sure to use lock tite and do not over-tighten the bolts. I hope this helps somebody.
 
Got my plan together (2nd post), it will evolve as the build progresses I'm sure. I'm on the fence about the lift kit though, anyone have advice or opinions?
 
Interesting way to get started, but I like the plans you have for the build. Sounds similar to mine. I haven't got that far in planning lift and tires, but the rest... ditto. My ride is a 1992. Lost the tranny pretty quickly (auto), and threw in a used one from the wrecking yard. Sunroof was shattered, so that was replaced from the wrecking yard. Here's a tip: around here, there's a Tear-A-Part, and Pick-N-Pull that both list what vehicles are in and when they got there. I've used that to time my trips to look for odds and ends (I keep a list on my phone so I remember the random items I want). There's also Car-Part.com--Used Auto Parts Market which will help to know what years interchange and where the used goods are at.
My interior is looking real good. But I lost a head gasket, and haven't been able to get that job done just yet. My wife wanted a new pergola and patio this summer. Enough said.
But good luck with yours! I really like mine, when I can actually drive it :)
 
Got my plan together (2nd post), it will evolve as the build progresses I'm sure. I'm on the fence about the lift kit though, anyone have advice or opinions?

I'm thinking long travel shocks and the blazeland IFS lift kit up front (kit has good resale value when you go SAS), bolt on/off and requires a lot less labour than 4 inch) and up the rear landcruiser coils and a weld in panhard rod centre extension plug would be a better option. Putting the new length front driveshafts is the only messy part, but easy for a shaft/joint shop.
 
I'm thinking long travel shocks and the blazeland IFS lift kit up front (kit has good resale value when you go SAS), bolt on/off and requires a lot less labour than 4 inch) and up the rear landcruiser coils and a weld in panhard rod centre extension plug would be a better option. Putting the new length front driveshafts is the only messy part, but easy for a shaft/joint shop.

I'm not sure what you mean about the drive shaft. Do you have to lengthen the drive shaft for the blazeland kit?
 
I'm not sure what you mean about the drive shaft. Do you have to lengthen the drive shaft for the blazeland kit?

My oops - meant drive axles - T100 drive axles are used as they are longer than 4runner axles, and the cv's at each end must be swapped onto the longer axles. Lift comes from lengthened upper & lower A Arms
 
My oops - meant drive axles - T100 drive axles are used as they are longer than 4runner axles, and the cv's at each end must be swapped onto the longer axles. Lift comes from lengthened upper & lower A Arms

Ok, I gotcha. You have to change the splined ends on to the longer t100 shafts is what you're saying.

I've got to see how the budget works out before I can look at something like the blazeland The money I'm saving by doing my own fab work is being spent on the tools to do the fab work lol. Blue welders aren't cheap!
 
Need advice

I am at a bit of a cross-roads and could use some advice.

I've got my build laid out on this sheet. My total budget will be around $8k I think. I really want to do a SAS and it seems like I can afford to do it but I'm not sure if I'm considering everything I need to do. Do I need to re-gear to 5.29 if I do an SAS and run 35" tires? I've been reading SAS swap threads and it seems like they're all doing it. I'm just trying to make sure I'm covering all my costs and see whether or not I'm being realistic.

Please feel free to critique my list in case I'm missing something or have things that aren't needed on it.
 
I am at a bit of a cross-roads and could use some advice.

I've got my build laid out on this sheet. My total budget will be around $8k I think. I really want to do a SAS and it seems like I can afford to do it but I'm not sure if I'm considering everything I need to do. Do I need to re-gear to 5.29 if I do an SAS and run 35" tires? I've been reading SAS swap threads and it seems like they're all doing it. I'm just trying to make sure I'm covering all my costs and see whether or not I'm being realistic.

Please feel free to critique my list in case I'm missing something or have things that aren't needed on it.

You're definitely going to want to regear, 5.29 or 4.88 will work, in my opinion, 5.29's are a bit much for 35's if you have the V6, but they work with the 22RE since it's a high strung motor anyways.

Luckily already set-up 8" Toyota diffs are plentiful (At least here they are), and can be found for 250-300 usually if you're patient.

And I'll just add, you can't have the welder and plasma be part of the project budget, that's just silly.
 
You're definitely going to want to regear, 5.29 or 4.88 will work, in my opinion, 5.29's are a bit much for 35's if you have the V6, but they work with the 22RE since it's a high strung motor anyways.

Luckily already set-up 8" Toyota diffs are plentiful (At least here they are), and can be found for 250-300 usually if you're patient.

And I'll just add, you can't have the welder and plasma be part of the project budget, that's just silly.

Thank you for the info. The welder and the plasma cutter are either part of the budget or the budget gets reduced by the cost of the two. That being the case it just makes sense to budget for them. My current welder is a cheap harbor freight PoS and will not work for what I want to do.

I'll keep an eye open for set up diffs, it'd be a lot cheaper. I think I can use a rear diff in the front axle as well. Am I wrong about that?

I wish I hadn't had to sell my 70's era industrial Hobart tig a few years ago.
 
Thank you for the info. The welder and the plasma cutter are either part of the budget or the budget gets reduced by the cost of the two. That being the case it just makes sense to budget for them. My current welder is a cheap harbor freight PoS and will not work for what I want to do.

I'll keep an eye open for set up diffs, it'd be a lot cheaper. I think I can use a rear diff in the front axle as well. Am I wrong about that?

I wish I hadn't had to sell my 70's era industrial Hobart tig a few years ago.

Just kidding with you. I haven't personally worked on a straight axle diff, but as far as I know the front's exactly the same as the rear.
 
Just kidding with you. I haven't personally worked on a straight axle diff, but as far as I know the front's exactly the same as the rear.

I did more research and the front & rear diffs will be the exact same, so if I can find some built diffs I'd be way better off.

Questions about lockers! Are grizzly lockers just LSD's? I have an LSD in my ranger and it seems to be pretty good. For rock crawling and such would Grizzly's be sufficient or should I try to go full air or electric?

I could probably do lockers later but since I'm going to have everything torn apart it makes sense to do it all at once. If I have to minimize costs to stay in budget I'd think the lockers would be the first thing to go, but I'd like to do them if I can make the budget work.
 
So the fan pulley bracket from Amazon came in and was the WRONG PART! After calling around I found out the Autozone down the street actually had one in stock. I went over there with my buddy (same guy that towed it home for me) and found out it was the same part # an everything. When they brought it out it was actually the correct part. We went back to the house and installed it. Then we changed the motor oil, diff fluid and made sure the transmission was full before taking it for a spin. For the most part everything was fine. We toopped the tank off and poured in a can of seafoam before going out to see how she behaved offroad. We did about 40 miles of trails, most of it was pretty mellow but some of it was kind of gnarly.

Here's it's first pics at the top of the mountain!
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As for what wasn't fine: The AC blower probably needs to be replaced and there's a very bad noise I need to look into. When I let off the gas I have an extremely loud gear scream. If I clutch in it goes away unless I'm in 3rd gear. It only happens on heavy decel when I'm completely off the gas. I'm concerned it's the transmission. It didn't do it at all while we were offroad, but the second we hit pavement it started again.

I'll do some research this week and see if I can figure it out, but if anyone has ideas I'd love to hear them.
 
After doing some research I'm thinking my loud noise might be a bad throw out bearing. I think I may just swap the clutch since as far as I know it's original.

Anyone have any thoughts?
 

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