Stoopid question of the Day Award: Upgrading a '99 2WD to 4x4

[88toy4x4]

EDIT: 88toy4x4 posted this exact thing while I was typing mine.

Perhaps I missed it (likely) but has anyone mentioned the ADD system yet? And that you should, if you can help it, go with the J shift transfer case from an SR5 or Tacoma vs the limited pushbutton one?

ADD = automatic disconnecting differential. There's a vacuum reservoir on 4x4s (unsure if it's on 4x2s) mounted to the back side of the core support on the driver's side front.

There is also a vacuum manifold with electrical connectors on it that helps manage this.

But I'll stop here. I'm not as well versed in the ADD system as many others. Those are the two parts I know of, but there are a bunch more.

Yes, I would use a SR5 J-shift transfer case versus a Limited push button. Less electrical to worry about. The Limited push button transfer case has the electric 4wd actuator on the back. It also has a 4wd computer which means more wires.

For my swap with a J-shift case, I believe I had to connect 5 wires to make it work. Pretty simple.

 

[octanejunkie]

Yes, I would use a SR5 J-shift transfer case versus a Limited push button. Less electrical to worry about. The Limited push button transfer case has the electric 4wd actuator on the back. It also has a 4wd computer which means more wires.

For my swap with a J-shift case, I believe I had to connect 5 wires to make it work. Pretty simple.

This is the plan [emoji115] [emoji115] [emoji115]

Real 4WDs don't have pushbuttons [emoji51] [emoji56]

Sent from my Nexus 5X using Tapatalk

 

[AntleredRuin]

I'm liking this thread because while I've not done the swap, I'm considering it in the near(ish) future. I've done a lot of homework, but here most of it is all nice and laid out for me!

You may also need the rear diff if the your current gearing is different from the donor front diff. I see you have 4.10s, but make sure the donor front diff has 4.10s also.

I've never done a diff or gear swap (so that'll be a learning process) but i hear that it's easier to install an entire diff than swap the gears.

 

[octanejunkie]

I'm liking this thread because while I've not done the swap, I'm considering it in the near(ish) future. I've done a lot of homework, but here most of it is all nice and laid out for me!

Your contributions are appreciated. Looking forward to your build thread :boink:

I've never done a diff or gear swap (so that'll be a learning process) but i hear that it's easier to install an entire diff than swap the gears.

I'd rather not pattern gears :doh:
My plan is to find the right ratio/donor vehicle and hold out till I do.

 

[ajordan1975]

Find a Tacoma w/ manual hubs and you won't need to worry about all the vacuum lines and actuators.

 

[kolelt]

Find a Tacoma w/ manual hubs and you won't need to worry about all the vacuum lines and actuators.

Didn't some 4Runner came with that to?
I've seen people do the manual hub conversion.

 

[88toy4x4]

Find a Tacoma w/ manual hubs and you won't need to worry about all the vacuum lines and actuators.

You can convert to manual hubs but you will have to do some press work to keep your 2wd spindles to retain the ABS. If you don't keep the ABS, no speedometer.

I have read that you can disable the ABS completely and convert back to a gear drive speed sensor off of the transfer case. Then, wire the sensor back in to the system and the speedo should work again. Somebody who did a SAS did that and I can't remember who.

I remember, it was Mossyrocks.
Speedo fix for 3rd gen 4Runners

So it is either wire up the ADD with a few wires or convert to manual hubs and rewire your speedometer.:noidea:

I think I will stick with the ADD. After having a manual hub Tacoma for 10 years, shift on the fly ADD is pretty nice.

Didn't some 4Runner came with that to?
I've seen people do the manual hub conversion.

Manual hubs on 4runners stopped in 1995 on the 2nd gen 4Runner.
All 3rd gens are ADD. Vacuum ADD from 96-00 and Electronic ADD in 01-02.

 

[octanejunkie]

I think I will stick with the ADD. After having a manual hub Tacoma for 10 years, shift on the fly ADD is pretty nice.

Ditto

Sent from my Nexus 5X using Tapatalk

 

[diverscale]

Lot of knowledgeable people in here, hope you keep us posted with your ''build'' with some pictures

 

[gamefreakgc]

Manual hubs on 4runners stopped in 1995 on the 2nd gen 4Runner.
All 3rd gens are ADD. Vacuum ADD from 96-00 and Electronic ADD in 01-02.

I know some people who would take manual hubs over ADD any day. I've never owned a vehicle with a locking differential, whether electronic or manual (no need for it) on my 91 or my 98 but some people would do anything to swap them in. I've even seen manual hubs on Tacomas around here, which means they took the time to put them in.

 

[octanejunkie]

I know some people who would take manual hubs over ADD any day. I've never owned a vehicle with a locking differential, whether electronic or manual (no need for it) on my 91 or my 98 but some people would do anything to swap them in. I've even seen manual hubs on Tacomas around here, which means they took the time to put them in.

I had a '93 Pathfinder 4x4 with ADD that worked like a charm. I can't imagine Toyota's not being as good, if not better.

Plus who wants to get out of their truck in crap weather to lock their hubs?

:girl: gratuitous boob bounce

 

[IBallEngineer]

Unless you were doing a SAS, forget hubs. Don't forget you can always lean on the local members for help on just about any part of this project. I've been known to help a little myself.

:keyboard:

 

[octanejunkie]

Parts and Steps, Draft Two

Here's the second draft of the basic outline for this swap. My mission, should I choose to accept it, will be to document and detail the swap as I do it - it's good to be single/divorced sometimes.

Special thanks go out to 88toy4x4 for the vacuum system parts and tips section at the bottom :bravo:

PARTS FROM DONOR
Spindles
Front Diff
CV joints/shafts
Front Drive Shaft
Rear Drive Shaft
Transfer Case
Output shaft
Pan
Filter
Shifter linkage
Shifter arm(s)
Shifter Boots and Trim
Vacuum solenoids on the drivers wheel well (under hood)
Vacuum canister from under drivers wheel well (right in front of the tire)
Vacuum line with check valve & tee from intake to solenoids
Vacuum lines to the front diff metal lines
4WD relay and plug from passenger kick panel (interior)
Harness plugs for front diff and trans


GENERAL STEPS and NOTES IN ORDER
Drive up on ramps
Remove rear driveshaft and trans
Install front diff while trans is out
Swap tail piece, 4WD output shaft, filter and pan from donor trans on mine Reference Post
Move Trans x-member (buy or fab) or temp extension mount
- Trail Gear Tacoma single transfer case cross member kit???
Cut trans tunnel, install cage nuts or similar
Install shifter group
Install trans and drive shafts
Modify Stock Exhaust bracket on trans x-member
Fab up and install Front Diff harness:

• 2 wires from the front diff that go to the 4wd indicator light
• 2 wires from the 4wd switch on the transfer case to 4wd relay(mounted behind the passenger kick panel)
• 2 wires from the 4wd relay to the vacuum solenoids that are mounted on

the drivers wheel well
Roll off ramps, jack up front end
Replace upper and lower ball joints on donor spindles
Install cv joints, axles and spindles
Replace wheels, drop front end
Check/replace 4x bulb in gauge cluster
Test drive
Shower beer

88toy4x4's TIPS

1. Getting the wire diagrams for your model year will help with the wire colors and locations of all the different items that you need locate and connect to.
2. Instead of drilling a hole in the firewall to get to the interior, I unwrapped my main engine harness at the firewall and routed my 3 wires through it. It made the install much cleaner.
3. Try to get as many extra plugs from the donor vehicle that way you can take out the terminals and use them to connect your wires to the factory plugs. This goes back to where I said many of the wires are there but they will terminate at certain harness plugs. You can salvage terminals from other plugs to make your install cleaner by not having to cut your factory wires.
4. Don't use butt connectors to join wires...well you can if you want. I chose to solder & heat shrink any wire connections that I made. This goes along with using existing terminals. Instead of trying to re-crimp the factory terminals, I would leave 3-4" of the factory wire attached to the terminal and solder my wire to it for a good connection.

 

[phattyduck]

Keep in mind you'll want to do a bunch of maintenance while you are at it... So, fluids, seals, ball joints, etc. should be on the list. Expect the unexpected too (bad CV boots, broken parts from an accident, etc.).

I was lucky enough to find a $300 rolled 4WD with no engine, but all the 4WD parts intact. My 4Runner has been in the family since new, passed down from dad to sister to me...

Some of the guys that have done it are making it sound easier than it is, assuming you want a factory quality install. If you want a hack job and have all the right tools, you could probably do it in a weekend.

I have a couple days of disassembly (complete harness to hack up, frame horns for moving the crossmember, rear end, front end, trans, etc.) and 1 day of reassembly so far done (rear 4.10 third member and rear axle seals). I figure 1 day for the front-end parts and two for the trans, crossmember and body cutting.

In the end, not counting modifications, I'll be about $1000 into a complete 4WD '99 4Runner... I count the manual labor time as fun/entertainment, so that's not part of the equation.

-Charlie

 

[octanejunkie]

All good points phattyduck

IF I do the swap it will be well planned with all donor parts prepped in advance and ready to go.

Sent from my Nexus 5X using Tapatalk

 

[88toy4x4]

I know some people who would take manual hubs over ADD any day. I've never owned a vehicle with a locking differential, whether electronic or manual (no need for it) on my 91 or my 98 but some people would do anything to swap them in. I've even seen manual hubs on Tacomas around here, which means they took the time to put them in.

Manual hubs have their place, I won't argue that. I was just speaking from my experience. As far as manual hubs on Tacomas, they were a factory option from 95-00 but a lot of people do still swap them on in place of the ADD. The Tacoma swap is easier since most all Tacomas don't have ABS.

Keep in mind you'll want to do a bunch of maintenance while you are at it... So, fluids, seals, ball joints, etc. should be on the list. Expect the unexpected too (bad CV boots, broken parts from an accident, etc.).

This is a must. Check out all your used parts well to see what needs attention. It is much easier to replace parts before it is all put back together.

Some of the guys that have done it are making it sound easier than it is, assuming you want a factory quality install. If you want a hack job and have all the right tools, you could probably do it in a weekend.

I read that as well. There were several that said it is a weekend job. The only way that it is a 1 weekend job is if you have at least 4-6 extra people to help that have experience doing the swap in the first place. Plus, I think a lot of them were Tacoma swaps which also didn't require the transmission crossmember mods or the body cuts for the shifter. Basically, remove 2wd stuff and reinstall 4wd stuff.

I did most of the work myself with some help from my dad when I needed more hands than I had. Doing the swap along with all the added maintenance parts took 2 weeks and that is hitting it hard on the weekends and a few hours most weeknights. Plus, I wasn't in a hurry since I have an extra vehicle to drive.

Take your time a do it right. I will be worth it in the long run.:nod:

 

[behitert]

Very possible, but probably cheaper to go find a 4x4 and buy it, unless of course you are just into diy.

 

[phattyduck]

I did most of the work myself with some help from my dad when I needed more hands than I had. Doing the swap along with all the added maintenance parts took 2 weeks and that is hitting it hard on the weekends and a few hours most weeknights. Plus, I wasn't in a hurry since I have an extra vehicle to drive.

Take your time a do it right. I will be worth it in the long run.:nod:

I'm doing the work at a friend's house, with his lift, welder, and his extra set of hands.

Beer is cheap compared to shop rate. :lol:

Oh, and I have done multiple Toyota engine swaps, etc. New to trucks, not new to serious custom work on Toyotas...

-Charlie

 

[octanejunkie]

I'm doing the work at a friend's house, with his lift, welder, and his extra set of hands.

Beer is cheap compared to shop rate. :lol:

Oh, and I have done multiple Toyota engine swaps, etc. New to trucks, not new to serious custom work on Toyotas...

-Charlie

Good to have friends with resources and experience!

I too would be doing this with a few buddies and we work on cars/trucks all the time, though not 4runners, we've done everything from engine rebuilds and installs to chassis modifications and suspension work.

With all our combined experience and tools, I'm still not willing to charge in blindly rife with bravado and beer; hence this thread.

:lookout: As usual, if you or your team are captured or killed, the Secretary will disavow all knowledge of your actions.

 

[phattyduck]

Had another thought: Make sure you get a normal transfer case 4Runner, not a limited with the multi-mode. The multi-mode transfer case is awesome, but would be a huge hassle to wire-in.

As for my project, I got another long half day of work in on the 4WD swap.

Front end apart, upper ball joints replaced...

Next work day will be putting the front end parts in.

And trying to get to 15 posts so I can start a build thread. :thumb3:

-Charlie