Project GG35

It's Wednesday night, my wife is working, and I'm feeling lazy. That can only mean one thing; It's update time!

The last week has been pretty busy as far GG goes. It's also been busy at work and home, so it's really nice to have a garage to get away to. A friend and I have been talking about a Moab trip in October so I've been using that as my motivator to get things done. I'm targeting the second weekend in September to get all the major stuff done. Why then if Moab isn't until October? My wife has a work conference every second weekend of September and while I usually take off for two days on the motorcycle while she's away, I'm thinking some close to home shake down in GG is in order this year.

As I previously posted, I all but took last Thursday off and replaced both CV axles with Napa units, then did the Tundra brake upgrade. All the parts went on without a hitch, but I suck at bleed brakes alone with just a hose and a soda bottle. So last Friday I took her to Brakes Plus to get them bled "professionally". They guy there was really cool and helpful, he even squeezed in GG when he had a full calendar then walked the key across the parking lot to Safelite where I had an appointment later that afternoon (more on this in a minute). Well, they may be cool and helpful and all, but it seems that they gave the bleeding job to the new guy who knows nothing as the pedal was only slightly improved. It still travels half way to the floor before grabbing. So I searched around and discovered the wonderful product called "Speed Bleeder", which replaces the bleed screw-valve thing. I want to order some for GG, does anyone know what sizes to get? Speed Bleeder Bleeding Brakes Bleeding Motorcycle Brakes Automotive Bleeder Screw Brake Bleeder

That same Friday I got a new windshield! The old one was cracked through in six places when I bought it, which helped with the purchase price, but was lousy for visibility and aesthetics. One day the week prior to last I was stuck in traffic and it was really irritating, so I figured while I was doing 2mph I'd call Safelite on my awesome new bluetooth handsfree Pioneer radio and make an appointment. And with that, she feels like a much nicer truck! It's sort of like when you have a nagging hang nail and finally chop it off, you just feel much better mentally to have it cleaned up. And for that reason it was a very satisfying "upgrade."

That same Friday afternoon... damn, it was a good day, I decided to change the oil when I got home. So I did. I already had a Wix filter and Rotel T6 on the shelf so it was quick and easy. The fact I have no front bumper or skid plate at the moment definitely helped that. Then I think I did something else, but I for the life of me can't remember what. Time passed and then I drove her to pick up some take out sushi. A a great end to a great Friday.

Saturday morning I was up at 6:30, damn dogs, so while my wife was working out, she can keep that to herself, I went to the garage to charge the AC since I wanted to show off GG to the Mrs when we ran errands later and she won't ride in a car without AC. I broke out the gauge/manifold set, hooked up a can, and charged away. It didn't take much and GG was blowing in the mid 40's F. It almost felt too easy. It was too easy. I went on a test drive and the AC cut out after about six blocks. I returned home, googled, and concluded that my expansion valve is probably sticking. I've done multiple unscientific tests since then that only reinforced that diagnosis. The part is less than $40, but the crap thing is the whole dash has to come out to replace it. Also, I can't tell from the FSM if the system needs to be discharged prior to replacement. So I'm throwing this one on the back burner and just wait until the weather is cooler to give my wife a ride.

Nothing truck related happened Sunday-Tuesday besides me getting groceries, running other errands, and testing the AC. Then this morning I got the garage itch again. Went out and decided to finish with the rear swaybar. Decided to remove the whole bar and then the end links so I could use the impact gun. Well, I never got to the links. I removed 1, 2, 3 bolts, then on the fourth popped the head right off leaving the damn shaft in the welded on hole. I sprayed some PB Blaster on it and threw the swaybar in the corner. I need to get a quality screw/bolt extractor that won't snap off with 10ft/lbs of torque.

Anyway, after the swaybar I was going to install the ToyTec rear bump extensions. But I was disgruntled and forgot. So I went straight to the ISR delete/Air Raid. I'm not trying to squeeze more power out of the 5VZ-FE, just wanted to clean up the engine bay to make room for the ARB compressor. So I pulled out the ISR and MAF, cleaned the MAF and the TB, and installed the Air Raid. Easy peasy. Then it was time for a shower and work.

Oh, and that other thing I did Friday that I couldn't remember? I replaced the stupid POS K&N air filter with a Wix filter.

Next up, rear bump extensions and ARB compressor!

Also, no pics. They'd have been boring anyway.
 
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So I've decided to buy rather build skids just because I really don't seem to have the time for fabrication. I'm looking at the new Front Range Off Road set, which seems really solid and to offer more protection than most of the other ones on the market right now. I'm also considering the 4x Innovations set mainly because I know it will have no problems bolting up with the front bumper I ordered from them, and also because they're cheaper by at least $100 even with shipping included.

That said, I read in another post that at least two other companies have just started offering 3rd gen skids, though I haven't personally seen them or know who they are as I've been spending more time in the garage than on the forums over the last few weeks.

So what are people's thoughts on skids? Anyone to look at besides FROR and 4xinnovations? Should I just suck it up and buy a big sheet of 3/16's?
 
Went with FROR skids. They are three pieces and cover the t-case where the 4xinnovations only cover the transmission. So actually a better deal. Thanks for the input.

In other news, I am still trying to wrap up the mount for the arb compressor, and have it, and a few other things done before Sunday when I have a shake down run planned. It's a tight fit but coming together nicely.

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Got some huge, life changing news today. The Mrs was offered and accepted a job in Vancouver, WA. So the move to the PNW is actually going to happen! Now I am excited, anxious, apprehensive, and probably a whole lot of other things I haven't realized yet.

We've already started looking at neighborhoods and houses and will figure out more of that over the next few days. Then my wife fell asleep, and the first thing I did was look up the WA lift laws. :wow: I probably should have looked these up when she applied for the job there. There are a few in particular that I am concerned about and would greatly appreciate any input people are willing to provide on the following:

MAXIMUM BUMPER HEIGHTS (§204-10-022)
4,500 lb GVWR or less 24 in. front, 26 rear
4,501-7,500 lb GVWR 27 in. front, 29 rear
7,501 lb GVWR and more 28 in. front, 30 rear
"A blocker beam or additional bumper may not be used to meet the above requirements."

I have a 3" suspension lift, 1" body lift, 35" tires, and 4xinnovations front and rear bumpers on order (currently no front bumper at all). First, it's not clear if 24"/26" is to the top or bottom of the bumper, but I'm guessing the bottom. Second, and I haven't searched the forums yet to get an idea, but I have no idea what the height of the 4xinnovations bumpers are. This could be a really expensive problem.

Bumpers (§204-10-022): Vehicles originally equipped with bumpers shall "maintain that system in good operational condition." removing or disconnecting bumpers/"energy-absorption or attenuation systems" except to repair them is illegal. Replacement bumpers must be from a "recognized manufacturer" or must meet "the bumper standards set under [Insurance Institute for Highway Safety] 49 CFR 581," SAE Bumper Standards, "or equivalent standards." Bumpers must be at least 4 1/2 inches tall.

There are no energy absorption systems on the 3rd gen I can identify, and if there is it'll be the same no matter what bumper is on there. It's the "recognized manufacturer" and SAE standards bits that worry me. I think the argument can be made that 4xinnovations is a recognized manufacturer, but I just don't know for sure yet. Also, clearly I need to have a front bumper, derp.

Swaybars (§204-10-036): "Anti-sway devices to control lateral movement" are required in rear-coil-spring suspension systems.

I do not currently have a rear "anti-sway" bar installed, but I still have one and will go ahead and put it back on. So no problem here.

Fenders (§204-10-022, 46.37.505): These must cover the entire tread width and extend down to at least the center of the axle. "Coverage of the tire tread circumference must be from at least fifteen degrees in front and to at least seventy-five degrees to the rear of the vertical centerline at each wheel measured from the center of the wheel rotation. At no time can the tire come in contact with the body, fender, chassis, or suspension of the vehicle."

Ahhhhh Helllll. I stick out a good 3-4" past the fenders. Also, who wrote this nonsense about center lines and degrees? This is clearly going to require fabrication, duct tape and animal sacrifice (just kidding, I draw the line at animal sacrifice, humans and Chevys only). Any guidance here would be extremely helpful and appreciated. Like, is this a real thing? Or can I just get away with mud flaps? If it's really real, is there a decent inexpensive source for fender flares people use in WA? Should I sacrifice a Camaro or an S10?

We will be moving some time in September, exact date TBD, so there's time but I don't think it's too early to start figuring these things out and taking measures. Additionally, I will be driving GG there with the dogs on board and a trailer with four motorcycles in tow. Crap, guess I should look at trailer laws too. But anyway, that only gives me 60 days give or take to get everything sorted before the 30 day window to register is up, and that includes emissions inspection required by Clark county. Oy, so much to do, time to go make lists.
 
So, some random updates because I can't focus on work right now.

I finished iteration one of my ARB compressor mount, painted it with black primer and mounted it up in the engine bay.

IMG_20160730_080043 by seank13, on Flickr

IMG_20160730_080325 by seank13, on Flickr

IMG_20160730_103856 by seank13, on Flickr

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IMG_20160730_103903 by seank13, on Flickr

I had to extend the power wires by two feet in order to reach the battery. I did this... poorly, with Home Depot thick stranded 8 gauge wire, a blow torch and too much solder. I have not connected it to power yet and I'm thinking I'm going to cut it out and redo it. It was a rush job as I was trying to go wheeling the next day, which didn't happen anyway. I also ran the switch harness through the firewall and to the center console but didn't hook up the acc or illumination wires yet.

About this time, 7/28, I ordered the new three piece skid set from Front Range Off Road. there's four weeks lead time so they should arrive by the end of August, about the same time as the bumpers. These and the bumpers will all go to powder because I my work schedule is going to involve a lot of travel over the next few months, and The Big Move.

While I was under the day I removed the old alarm harness in preparation for the new alarm I'll be installing myself, probably within the next week. With the bumpers, tires, winch, and everything else I decided it was time and got the motion and glass break sensors in addition to the shock sensor. I need to rtfm, but I may add a tilt sensor too if I can.

My VW died a couple weeks ago so I had it towed home and put it in the garage where the runner usually goes. That meant I had to part the runner on the street, which is another thing that lead to the new alarm. So I took the subwoofer and amp out and neglected to disconnect the rca's when do so and ripped the ends off the super cheap cables. I ordered a new three set but have yet to install it, and probably won't bother until after The Big Move.

Since I haven't been wheeling since I swapped out the front diff I randomly decided to test 4h in a parking lot last week. In doing so I discovered that the ADD isn't actually engaging. *sigh* so I need to trace the vacc lines and replace as necessary. Again, probably not happening until after the move.

Went to install the 1" lift yesterday and snapped off my rusted solid A-pillar body mounts. Looking to get some poly mounts from another t4r.org member to fix that early next week.

Talked to Alex at 4x Innovations this morning and he said that the bumpers and sliders are on track to ship 8/23. I found a highly reviewed powder coater 10 minutes from house so the bumpers will go straight there. I'll weld up the sliders myself and rattle can them to save time.

Also this morning I ordered OME 861's to account for the bumper with tire carrier, and to hold the weight of the trailer hauling the motorcycles for The Big Move.

And lastly, there's the actual prep for the road trip. I'm looking at about 1,200 miles hauling 4,000 lbs plus the wife, two dogs, firearms and stuff for two weeks. I will be changing out the front diff break in fluid soon, about to hit the 500 mile mark. I will also drain/fill the manual trans and t-case. I have a new steering rack, OTREs and LBJs sitting in the garage I will install. Then of course I'll get it aligned again. The one thing I'm not sure about is the radiator; it's damaged from the PO, dented but not leaking. The problem is the AC condenser is bent too and will have to be replaced. I wasn't going to touch any of this until the spring because I have to replace AC expansion valve and drier at the same time. If I do it myself, and that's my desire, I'd have to have the system evac'd first then vacc'd and filled after. And of course the time to do it. I do not want to pay someone to do as the book hours will insane because it says to remove the dash for the expansion valve, even though I don't think it's actually necessary from my research. I certainly don't want to pay someone to fix it all with the moving expenses. So gotta decide if I'm OK with a bent radiator on a 1200 mile trip hauling 4,000+ lbs. Ugh. Maybe I should have motorcycles freighted...
 
So my wife helped me make the decision about the radiator tonight, though she didn't mean to. She reminded me about the trip we took 9 years ago from DC to Corolla, NC in my 1998 Ford Explorer to get married and honeymoon. The story went like this: It's late May, the AC in the Explorer doesn't work, but we're trying to save money, we should be fine. Then the temperatures shot up to the 90's and we got stuck in stop and go traffic on I95 South for six hours. I swear if weren't pot committed at that point we would have turned around and called off the wedding. After that she said she would "Never Again" ride in a car without AC. And you know what, she hasn't since then now that I think about it. She told me I could fix the AC or she'd fly by her damn self and see me after a few days. It was a tempting offer, but ultimately I opted dropped a bunch of coin on Amazon for:


Denso 221-0508 Radiator
OES Genuine Radiator Hose for select Toyota 4Runner/Tacoma models
Gates 21534 Radiator Coolant Hose
Genuine Toyota 90916-03075 Thermostat
Fel-Pro 35445 Thermostat Gasket
3 of Zerex 675130 Asian Vehicle Anitfreeze
Denso 477-0518 Condenser
Denso 476-0019 A/C Evaporator Core
Denso 475-0505 Expansion Valve
Denso 478-0500 Receiver Drier
Four Seasons 26749 O-Ring & Gasket Air Conditioning System Seal Kit


I know I probably don't need the O-Rings, but I like to have extras of tiny rubber things.

Huge thanks to [MENTION=25434]BamaDrewski[/MENTION] for his great thread here: http://www.toyota-4runner.org/3rd-g...-replacement-2000-toyota-4runner-limited.html

Now I just have to figure out when the hell I'm going to do all this.
 
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So I got a call from FedEx about 1 PM today. They said my new 4xInnovations bumpers were too heavy to put on the delivery truck and that I would have to come pick them up. The lady on the phone actually started out by saying "I am really, really sorry I have to tell you this..." and I was/am in a good mood anyway, so I got in the truck for a little drive. There was a cool guy and gal there who gladly helped me get these massive things loaded. Just a really pleasant experience overall. And on top of that, I got to pull into the FedEx depot with my rig. So of course I took a few pictures.

I give you...

PHOTO DUMP from FEDEX DEPOT

IMG_20160826_141542 by seank13, on Flickr

IMG_20160826_141602 by seank13, on Flickr

IMG_20160826_141610 by seank13, on Flickr

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IMG_20160826_141757 by seank13, on Flickr

IMG_20160826_154108 by seank13, on Flickr
 
Yesterday and today, maybe a little Friday too (can't quite remember, it's been a long weekend) I cleaned, primed, painted and mounted the new 4x Innovations front and rear bumpers. It was a little challenging as I didn't have anyone lined up to help. However, they on and I only need a bottle or two aspirin.

IMG_20160910_162803 by seank13, on Flickr

IMG_20160910_164431 by seank13, on Flickr

IMG_20160910_213033 by seank13, on Flickr

IMG_20160911_163009 by seank13, on Flickr

IMG_20160911_163527 by seank13, on Flickr

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IMG_20160911_184308 by seank13, on Flickr

IMG_20160911_184323 by seank13, on Flickr
 

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