Ripcord's 2002 Sport Ed. Version 2.0

[MillerPKA]

Killin it!

Do you know what happened to your first one? Maybe I'm a bit biased but I love these phoenix rebuild threads. Gets me all nostalgic and teary eyed. Just need [MENTION=7025]neliconcept[/MENTION] to rejoin the dark side.

 

[4-Ripcord]

Killin it!

Do you know what happened to your first one? Maybe I'm a bit biased but I love these phoenix rebuild threads. Gets me all nostalgic and teary eyed. Just need [MENTION=7025]neliconcept[/MENTION] to rejoin the dark side.

No idea where it is, don't really care either. The person I sold it to didn't seem like much of an enthusiast.

Speaking of the now, I FINALLY got the new rear shock mounts cut from BAMF. Should have the rear done this weekend.

 

[4-Ripcord]

Filler Post #1
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[4-Ripcord]

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[4-Ripcord]

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[4-Ripcord]

Suspension Lift

|December 13, 2015|

The suspension is finally done!!!
This is practically a brand new truck with all the parts on it now.

Parts/Cost: Not including wheels/Tires
Aftermarket parts: $2,958.08
$1,290.00 - ICON 2.5 Extended travel coilovers w 600# spring [58716] (normally $1575)
$520.00 - ALL PRO Uniball Front Upper control arms (normally $650)
$330.00 - ICON 2.0 Land Cruiser 10" Rear Shocks [56510]
$169.00 - OME 861 Springs
$130.00 - Toytec Lifts 1" Body lift
$75.00 - Toytec Lifts SS Extended Rear Brakes lines
$64.00 - Toytec Lifts SS Front Brake lines
$50.00 - Toytec Lifts Panhard drop Bracket
$68.18 - Dorman extended wheel studs [RNB-610-407]
$42.00 - ENERGY Suspension Poly Front control arm bushings [8.3115G]
$25.00 - ENERGY Suspension Poly Front Stabi bushings & Bump stops
$21.50 - ENERGY Suspension Poly Steering rack bushings [8.10101G]
OEM Parts: $521.84
$340.00 - Front Lower Ball Joints [43330-39585 & 43340-39465]
$98.02 - Outer Tie Rods [45046-39335 & 45047-39215]
$132.06 - Front Wheel Bearing x2 [90369-54002]
$71.22 - Outer Bearing seal x2 [90316-69001]
$29.92 - Inner Bearing seal x2 [90312-95001]
$10.32 - Bearing snap ring x2 [90521-99114]
OEM Fasteners: $179.64
$7.44 - Lower Ball Joint bolts x8 [90080-10066]
$4.08 - Damper Bolt washer x2 [94622-41400]
$2.58 - Damper Nut x2 [90170-14026]
$10.86 - Damper Bolt x2 [90105-14104]
$84.72 - Lower arm Cam plate x4 [48452-35020]
$22.88 - Lower Control arm bolt x4 [90080-11283]
$6.20 - Upper control arm Nut x2 [90080-17208]
$18.24 - Lower control arm bolt x4 [90209-14010]
$22.64 - Upper control arm bolt x2[90105-14105]

Tools:
-Assorted sockets
-Assorted wrenches
-Torque wrench
-floor jack
-jack stands
-mallet & Hammer
-blowtorch
-drill
-press
-etc...

Time:
A LOT. I could have done it in a weekend if everything had gone as planned..

Procedure:
http://www.toyota-4runner.org/3rd-gen-t4rs/149467-official-lower-ball-joint-write-up-thread.html
http://www.toyota-4runner.org/3rd-gen-t4rs/200181-torque-specs-service-information-revisited.html

Here is all the parts:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372871562/in/album-72157682681808563/" title="20151024-IMG_1210"><img src="https://c1.staticflickr.com/5/4211/35372871562_2f4614f1f5_b.jpg" width="683" height="1024" alt="20151024-IMG_1210"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

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================================================

First up is the body lift. Body lifts are so much easier than I thought they would be. Seriously takes less than an hour to do.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34699038424/in/album-72157682681808563/" title="20151022-IMG_1196"><img src="https://c1.staticflickr.com/5/4234/34699038424_66428a461c_b.jpg" width="1024" height="683" alt="20151022-IMG_1196"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>



The part that takes the longest is getting access to the tops of the bolts through the interior.

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Once the bolts are removed, just jack up the body by the pinch weld, throw the spacers in, and put the new bolts in.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35501265356/in/album-72157682681808563/" title="20151023-IMG_1199"><img src="https://c1.staticflickr.com/5/4240/35501265356_f9f25c933a_b.jpg" width="1024" height="683" alt="20151023-IMG_1199"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

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==========================================

Up next is the front suspension. As you can see from the parts list, I am pretty much replacing all of it..

Before:

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Took the knuckle off and removed the old studs.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372900372/in/album-72157682681808563/" title="20151024-IMG_1206"><img src="https://c1.staticflickr.com/5/4212/35372900372_a13bffa1e0_b.jpg" width="1024" height="683" alt="20151024-IMG_1206"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Dorman RNB-610-407 extended wheels studs compared to OEM wheel studs:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372892662/in/album-72157682681808563/" title="20151024-IMG_1207"><img src="https://c1.staticflickr.com/5/4258/35372892662_4255b0f5a4_b.jpg" width="1024" height="683" alt="20151024-IMG_1207"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

New stabi bushings and bump stops.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372865322/in/album-72157682681808563/" title="20151025-IMG_1211"><img src="https://c1.staticflickr.com/5/4213/35372865322_925e14a440_b.jpg" width="1024" height="683" alt="20151025-IMG_1211"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Toytec brake lines in.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35540312135/in/album-72157682681808563/" title="20151025-IMG_1221"><img src="https://c1.staticflickr.com/5/4257/35540312135_fc9fd789a7_b.jpg" width="1024" height="683" alt="20151025-IMG_1221"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>]

Old bearings out:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35153356610/in/album-72157682681808563/" title="20151101-IMG_1237"><img src="https://c1.staticflickr.com/5/4212/35153356610_7a7dc637a1_b.jpg" width="1024" height="683" alt="20151101-IMG_1237"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

New OEM bearing:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35153353400/in/album-72157682681808563/" title="20151101-IMG_1238"><img src="https://c1.staticflickr.com/5/4277/35153353400_eb9378a6fa_b.jpg" width="1024" height="683" alt="20151101-IMG_1238"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Pressed in:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35153348540/in/album-72157682681808563/" title="20151101-IMG_1239"><img src="https://c1.staticflickr.com/5/4234/35153348540_107d516d56_b.jpg" width="1024" height="683" alt="20151101-IMG_1239"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Oil seals on:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35540275255/in/album-72157682681808563/" title="20151101-IMG_1249"><img src="https://c1.staticflickr.com/5/4255/35540275255_8f9dd021b6_b.jpg" width="1024" height="683" alt="20151101-IMG_1249"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

 

[4-Ripcord]

For the front lower control arm bushings.. There are very different procedure for installing poly bushings vs OEM style bushings. See here:
https://www.tacomaworld.com/threads/how-to-replace-upper-lower-control-arm-bushings.280375/

The procedure basically leaves the outer collar in the arm, removes the inner collar, and just replaces the rubber. First up is to remove the inner collar. To do so, you need to first remove the washer that is pressed onto the inner collar.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35501202666/in/album-72157682681808563/" title="20151108-IMG_1259"><img src="https://c1.staticflickr.com/5/4279/35501202666_866da2a463_b.jpg" width="1024" height="683" alt="20151108-IMG_1259"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35409924841/in/album-72157682681808563/" title="20151108-IMG_1260"><img src="https://c1.staticflickr.com/5/4258/35409924841_bbfc0475a9_b.jpg" width="1024" height="683" alt="20151108-IMG_1260"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

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Then press out the inner collar, just tear your way through the rubber.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35153319750/in/album-72157682681808563/" title="20151108-IMG_1262"><img src="https://c1.staticflickr.com/5/4212/35153319750_f86a1c29ac_b.jpg" width="1024" height="683" alt="20151108-IMG_1262"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34730894383/in/album-72157682681808563/" title="20151108-IMG_1263"><img src="https://c1.staticflickr.com/5/4279/34730894383_9aa423a0a7_b.jpg" width="1024" height="683" alt="20151108-IMG_1263"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Now is the fun parts.. just kidding! Well it's kind of fun. Best way to remove the rubber is to burn it out then scrape the burnt rubber.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372790122/in/album-72157682681808563/" title="20151108-IMG_1272"><img src="https://c1.staticflickr.com/5/4213/35372790122_2dc9388929_b.jpg" width="1024" height="683" alt="20151108-IMG_1272"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35501174596/in/album-72157682681808563/" title="20151108-IMG_1267"><img src="https://c1.staticflickr.com/5/4280/35501174596_c6c3c1ce55_b.jpg" width="1024" height="683" alt="20151108-IMG_1267"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35540252145/in/album-72157682681808563/" title="20151108-IMG_1266"><img src="https://c1.staticflickr.com/5/4257/35540252145_665bb665ed_b.jpg" width="1024" height="683" alt="20151108-IMG_1266"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372792162/in/album-72157682681808563/" title="20151108-IMG_1268"><img src="https://c1.staticflickr.com/5/4257/35372792162_ea197f9204_b.jpg" width="1024" height="683" alt="20151108-IMG_1268"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35501160686/in/album-72157682681808563/" title="20151108-IMG_1273"><img src="https://c1.staticflickr.com/5/4282/35501160686_a8f46d6a26_b.jpg" width="1024" height="683" alt="20151108-IMG_1273"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Now press in the new Poly Rubber.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35501157126/in/album-72157682681808563/" title="20151108-IMG_1274"><img src="https://c1.staticflickr.com/5/4287/35501157126_5b82505d05_b.jpg" width="1024" height="683" alt="20151108-IMG_1274"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Last thing to do for the lower arm bushings is to bend the washer back into shape then press it back onto the inner collar.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35501181926/in/album-72157682681808563/" title="20151108-IMG_1264"><img src="https://c1.staticflickr.com/5/4254/35501181926_2fbccf478b_b.jpg" width="1024" height="683" alt="20151108-IMG_1264"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

 

[4-Ripcord]

Now that the Bearings and Bushings are done, its time to put it all back together!

Upper ball joint collar pressed into knuckle:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34730811503/in/album-72157682681808563/" title="20151114-IMG_1304"><img src="https://c1.staticflickr.com/5/4212/34730811503_91e5e16ffc_b.jpg" width="1024" height="683" alt="20151114-IMG_1304"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

New lower ball joints on:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35501104476/in/album-72157682681808563/" title="20151114-IMG_1303"><img src="https://c1.staticflickr.com/5/4210/35501104476_fd8376ceee_b.jpg" width="1024" height="683" alt="20151114-IMG_1303"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Reservoir mounts

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34730856363/in/album-72157682681808563/" title="20151114-IMG_1289"><img src="https://c1.staticflickr.com/5/4281/34730856363_647116d695_b.jpg" width="1024" height="683" alt="20151114-IMG_1289"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Starting to come together.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35153280470/in/album-72157682681808563/" title="20151114-IMG_1290"><img src="https://c1.staticflickr.com/5/4257/35153280470_463eeb778f_b.jpg" width="1024" height="683" alt="20151114-IMG_1290"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34698850184/in/album-72157682681808563/" title="20151114-IMG_1301"><img src="https://c1.staticflickr.com/5/4240/34698850184_de38c68f83_b.jpg" width="683" height="1024" alt="20151114-IMG_1301"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>



Now its time for the rear...

 

[4-Ripcord]

Rear suspension

The reason this suspension install took over a month was because of these parts right here..

As you can see, I went through a few different plans for rear upper shock mounts! (and a couple of shocks too)

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34698787954/in/album-72157682681808563/" title="20151212-IMG_1349"><img src="https://c1.staticflickr.com/5/4279/34698787954_855cb5cd84_b.jpg" width="1024" height="683" alt="20151212-IMG_1349"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


This was the final plan. These are shocks for the Rear of 80 series land cruisers. A lot of 3rd gen owners use OEM rear land cruiser shocks for a 3" 4Runner lift. Well These are for lifted land cruisers! They have more travel than the OEM shocks, they just need to be mounted higher.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35540142385/in/album-72157682681808563/" title="20151212-IMG_1348"><img src="https://c1.staticflickr.com/5/4212/35540142385_4e8f3ea631_b.jpg" width="1024" height="683" alt="20151212-IMG_1348"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


The only modification to this design would be to make the hole 5/8" instead of 1/2".

EDIT: After using these shock mount at this position, I found they were about an inch higher than they should have been. This led to not having as much downtravel as I could have had. I have since fixed this by making new mounts for 12" travel shocks instead.

Also, you will want wheel spacers with outboard shocks.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372478392/in/album-72157682681808563/" title="Shock mounts"><img src="https://c1.staticflickr.com/5/4217/35372478392_2f9b19b69a_b.jpg" width="957" height="662" alt="Shock mounts"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Ground down the frame.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34698777664/in/album-72157682681808563/" title="20151212-IMG_1352"><img src="https://c1.staticflickr.com/5/4231/34698777664_fe5a9695fe_b.jpg" width="1024" height="683" alt="20151212-IMG_1352"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


My friend Steven came to help weld, but the breaker in my garage could only handle a few seconds of welding before popping so the weld came out kind of ugly..

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34730773163/in/album-72157682681808563/" title="20151212-IMG_1355"><img src="https://c1.staticflickr.com/5/4213/34730773163_1ba878b081_b.jpg" width="1024" height="683" alt="20151212-IMG_1355"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34730767793/in/album-72157682681808563/" title="20151213-IMG_1361"><img src="https://c1.staticflickr.com/5/4208/34730767793_03032955a6_b.jpg" width="1024" height="683" alt="20151213-IMG_1361"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Primed.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35372690682/in/album-72157682681808563/" title="20151213-IMG_1362"><img src="https://c1.staticflickr.com/5/4260/35372690682_af0c3d4f3d_b.jpg" width="1024" height="683" alt="20151213-IMG_1362"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Welded on the Toytec Panhard drop bracket:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34730778793/in/album-72157682681808563/" title="20151212-IMG_1350"><img src="https://c1.staticflickr.com/5/4286/34730778793_68093bb1b0_b.jpg" width="1024" height="683" alt="20151212-IMG_1350"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>]

All together!!

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/34698748424/in/album-72157682681808563/" title="20151213-IMG_1369"><img src="https://c1.staticflickr.com/5/4282/34698748424_932e0943da_b.jpg" width="1024" height="683" alt="20151213-IMG_1369"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>






EDIT: After using these shock mount at this position, I found they were about an inch higher than they should have been. This led to not having as much downtravel as I could have had. I have since fixed this by making new mounts for 12" travel shocks instead.

Also, you will want wheel spacers with outboard shocks.






================================================



Before we finish, there were a few other small things to take care of. Extended bump stops, Diff breather and low profile wheel well bolts.

You can get 3" Extended bump stops for less than $10. Go to a junkyard and find a 1995-2005 Chevy blazer/S10/Oldsmobile Bravada and take the rear bump stops.
http://www.toyota-4runner.org/3rd-gen-t4rs/134139-junkyard-rear-bump-stops.html

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[4-Ripcord]

Final Product!

[MENTION=85422]FNWheels[/MENTION] 17x8.5 5-Star in Bronze
315/70/17 Goodyear Duratracs

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[Grey-Thunder]

Love your build man! The bronze wheels look great! :bravo: :trophy:

 

[the great him]

Now you just need to swap in a 1UZ...

 

[THatfield]

Glad to see it's finally done man!

 

[robb1887]

Suspension looks great!

If you find my master thread list in the body lift section there is a thread that is the DIY for doing it and has a way that modifies the bumper brackets to get rid of the droopy bumper with the 1" lift. But I'm sure you already have a plan for it

P.s. those 315s make the 17 FNs look like 16s :rofl:

 

[4-Ripcord]

Love your build man! The bronze wheels look great! :bravo: :trophy:

Thanks! Yours is off to a nice start too. :rockon:

Now you just need to swap in a 1UZ...

I have been looking into it actually.. Probably do that instead of supercharger if I did either.

Glad to see it's finally done man!

Thanks for the assistance! I still have your mud flap too.

Suspension looks great!

If you find my master thread list in the body lift section there is a thread that is the DIY for doing it and has a way that modifies the bumper brackets to get rid of the droopy bumper with the 1" lift. But I'm sure you already have a plan for it

P.s. those 315s make the 17 FNs look like 16s :rofl

Thanks!

I will have an aftermarket bumper in the near-ish future, so for now I don't really care. I may do that if it starts to bug me though.

 

[TCMach]

Loving the look of the truck man. What do those shocks measure out to? I know you were looking at some 12" stroke shocks for a while. Also those wheels are killer.

 

[the great him]

That's the motor I'm gonna swap with. Just need to find the donor car first...

 

[derpiful]

Nice work, it's looking amazing! I'm super jealous of your suspension setup. Can't wait to see it in action.

 

[4Running Daily]

I believe there is a minor typo,

$132.06 - Front Wheel Bearing x2 [90369-54002]
$71.22 - Outer Bearing seal x2 [90369-54002]

You have the same part number twice. I believe the correct part number for the Outer Bearing seal is 90316-69001


Otherwise great info! Looks sweet!

 

[4-Ripcord]

Loving the look of the truck man. What do those shocks measure out to? I know you were looking at some 12" stroke shocks for a while. Also those wheels are killer.

Thanks! These are 10" travel, dialed back the goals a bit.

That's the motor I'm gonna swap with. Just need to find the donor car first...

The new rig must really be getting to you..

Nice work, it's looking amazing! I'm super jealous of your suspension setup. Can't wait to see it in action.

Thanks! Me too, should be a blast offroad.

I believe there is a minor typo,

Otherwise great info! Looks sweet!

Fixed
Thanks for the heads up.