T4rchadly's '96 "RADRNR" build thread *pic heavy*

[T4Rchadly]

welcome to my build thread and see the start of my 1996 toyota 4runner build. im a mercedes benz technician in Anchorage, Alaska, and planning on moving to colorado this fall of 2019. i recently sold my 1989 pickup in search for a stupid clean 4runner, and just so happened to find a mint 1996 runner. manual trans with 222,000 miles.
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[T4Rchadly]

maintenance

222,000 MILES:
- Mobil1 synthetic: engine oil, rear/front differentials, transmission/transfer case
- mercedes DOT4 brake flush/ clutch cylinder flush
- OEM rear brake shoes,drums, e-brake bells, adjusted parking brake cable to factory spec
-OEM LBJ's
-coolant flush, swapped to toytoa red coolant than the green
-Maf sensor cleaned
-new powersteering pump w/ correct dex fluid
-new OEM alternator/ac/PS belts
-OEM idler pulley
-cleaned engine bay real good
-removed crappy cold air intake (i HATE cold air intake noises on stock engines)
-optima redtop battery
-dealership "CRYSTAL FUSION" water/rock chip repellent on ALL windows

224,000 MILES:
denso spark plugs
denso spark plug wires
OEM toyota steering rack
OEM toyota outer tie rods/all nuts
OEM toyota lower control arm assemblies
OEM cam bolts for LCA
denso A/C compressor
denso radiator
new toyota red coolant

227,000 MILES:
OEM denso fuel pump
OEM fuel sending unit assembly system

228,000 MILES:
new front/rear differential fluid & inspection

229,000 MILES:
front/rear toyota OEM u joints (not including cardans)

230,000 MILES:
OEM starter rebuild (denso parts)

232,000 MILES:
FL/FR OEM toyota wheel bearings, dust seals, c clips
OEM rear pinion seal

233,000 MILES:
LCE O-shape throttle body gasket
OEM toyota intake gaskets
OEM toyota fuel rail crush washers
LCE upgraded injectors
OEM filter + synth oil

237,000 MILES:
OEM filter + synth oil

238,000 MILES:
OEM TRD pro wheels
new milestar patagonia m/t 285/70/17 tires

239,000 MILES:
OEM radiator cap

241,724 MILES:
oil change
tire rotation

245,000 MILES:
oil change
tire rotation

------------------------------------------------------------------------------------------------------------------------------------------------------

Modifications…

Suspension:

- Front: OME struts/ 881 coils
- replaced OEM LCa's (stock bushing)
- toytec 1” diff drop
- Front sway bar removed
- Durobumps front bumpstops

- Rear: OME 891 Coil Springs
- OME shocks
- Emkeith PCK w/ gusseted upper panhard bracket
- Rear sway bar removed
- Durobumps rear 2.5" bumpstops

Wheels and Tires:

- TRD Pro 17x8 wheels
- Milestar Patagonia 285/70/17 M/T tires

Drivetrain:

- replaced OEM steering rack
- Wheeler’s Off-Road steering rack bushings
- New Toyota OEM inner/outer tie rod ends and lower ball joints
- Total Chaos spindle gussets
- Extended Breather with filter front/rear
- mobil 1 synth oil
- Lce heavyweight flywheel (38lbs)
- Marlin crawler 1200lbs clutch kit


Engine and Performance:

- Northstar 27F AGM battery
- New OEM toyota injectors
- Genuine Toyota Block heater
- ARB high output compressor
- LCE upgraded alternator
- "Big 3" wire upgrade (4gau)

Brakes:

- Wheeler's Off-Road stainless steel brake lines front/rear

Lighting:

- Clear headlight housings
- GTR Ultra 2 LED bulbs
- Burtman Clear corners w/ LED bulbs
- APC clear tail lights W/ all LED bulbs
- Vision X light cannon 6.7 spot lights (X2)
- Baja designs XL80 lights spot/flood combo (X2)
- CBI ditch light brackets
- VLED interior dome lights, License plate light
- VLED dash/cluster bulbs
- HIDkitpros rock lights (8 total)

Interior/Electrical:

- Pioneer AVH-2550DEH headunit
- Spod Bantam system
- Extra plug in dual USB charging port/ cigarette lighters
- Cobra s75 CB with 3' firestik antenna
- CBI antenna bracket
- Garmin GPS Smartdrive 65
- Husky Floormats front/rear
- Ram mounts on driver A pillar for phones
- ARB compressor/rear/front locker switched on center console
- Blueridge molle seatback panel w/ multiple attachments (i keep my air-up equipment in)
- ARB 50 QT fridge
- Vinyl wrapped rear quarter panel windows matte black
- Mckinsey craft Co. rear drawer system/sleeping platform

Exterior / Accessories:

- 20% Tint
-5% ontop of 20% tint (hatch window)
- Yakima skybox 18
- Sherpa equipment "matterhorn" rack
- Custom traction board mounts
- Shovel w/ quickfist mounts

Armor / Recovery:

- ARB Front Bumper
- Smittybuilt X2O 10,000 winch w/ ORCISH w/8 synthetic line
- Custom built Rock sliders
- Lil’ Skip gas tank skid plate
- Budbuilt front and belly pan
- Recovery kit

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plans
TRD wheels/35s no body lift- TRD wheels owned, keeping 33s for a little for fuel economy
front/rear ARB
forced induction
spc UCA/king coilovers
tokico black shocks/ new 891s -plan on different route
12" rear shocks/ dobinson/861 coils
AGM battery - done

would like to do list
rear molle panels
apply black vinyl to inside of rear quarter windows - done
rear hatch window switch
rear hatch LED lights for cooking
tint very back window to 5%-done
17" wide drawer system -done w/ dual drawer and sleeping platform
road shower
awning setup
RGB rock lights (for ambiance camping) done

 

[T4Rchadly]

the first weekend i got it took a 600 mile trip to homer, alaska and went biking/exploring.
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i then took it on its first wheeling trip to a trail called kings river.
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[T4Rchadly]

on a side note, im looking for a set of clear tail lights for the truck. does anyone know SOMEONE or a link to clear tail lights? i know APC's are hard to get ahold of and i have money to buy a set. im not interested in 01-02 crystal clears, euro style, or LED style. im looking for specifiaclly a set of all clears. please let me know if anyone knows something. all the links on other threads are dead or lead me to a euro style.

this is the style i'm talking about
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[Lamer]

nice looking runner. do you have details on the last time the timing belt was changed? along with water pump?

jealous about the move to Colorado. and I have a college buddy who lives in Homer! small world.

 

[T4Rchadly]

the water pump and belt were changed at 180K. im going to order the kit here in a week or two so i dont get stranded, it has a oroblem with extended crank after being heat soaked, i think it could possibly something with timing belt as the previous owner had a reputable shop change a bunch of fuel system components. going to do and OEM kit mostlikely. homer is awesome! little to small for my taste as im in the big city of anchorage. a lot more to do here

 

[Mzs14]

on a side note, im looking for a set of clear tail lights for the truck. does anyone know SOMEONE or a link to clear tail lights? i know APC's are hard to get ahold of and i have money to buy a set. im not interested in 01-02 crystal clears, euro style, or LED style. im looking for specifiaclly a set of all clears. please let me know if anyone knows something. all the links on other threads are dead or lead me to a euro style.

this is the style i'm talking about
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Burtman Industries is the only place that I have seen that still offers these Burtman Industries

 

[T4Rchadly]

thank you!! ordered a set with clear corners, way too stoked. ive been digging for awhile now with nothing but dead links

 

[T4Rchadly]

well, big betsy finally came in after 2 months, ordered even before i had a 3rd gen lined up and bought.
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i will do a small how to but i was not into extreme detail with pictures. i will provide the links i had used to help install the bumper.

i started by taking off the bumper. there will be 2 12MM nuts to take of on both left and right fenderwells facing the front of vehicle. after taking those off, i unbolted the 4 17mm bolts connecting the tow hooks on the bottom side of the frame. after that i unbolted the 4 14mm that hold the OEM brushguard to the bumper and had help from another guy remove bumper at my shop i work at. you are left with this.

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you then need to cut the framehorns at the weld, and then grind smooth the weld splatter and weld itself. ive seen people remove this using a cutoff disk and grinder, a plasma cutter, and i chose to use my milwauke corded bandsaw and went right down the frame with perside accuracy. this took me maybe 3 minutes for both sides. I had used a file to smoothen everything out ensuring it would not be easy to cut my hands.

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i had fitment issues with the two front body mounts hitting the bumper support and had to cut a section off the bumper rather than grind more of the frame for better strength. I unfortunately did not capture that but it seems as if sometimes they have clearance issues and sometimes they dont, and i had to.

after making necessary fitment modifications, i bolted the frame support using the 4 17mm bolts you use to take off the bumper and tightened snugly. you then have to look on the bottom side of frame . facing up and see that there is a hole you have to drill. this hole needs to be drilled to 1/2" on each side to fit the long bolts with the sleeve. after that this is what i ended up with.

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on the last picture i show the gap between the support and frame. from all the videso and threads i have seen people have to fit with a hammer but mine slid in with eas and i have an 1/8th inch gap? i was thinking thats the jigs used to weld the frame could vary and so on so i rolled with it and proceeded. if anyone could shed light i would appreciate it.

you then need to put buffer kit on the bumper and in this case i have a brand new smittybuilt x20 10,000 synthetic winch and installed it to the bumper. i assembled the winch and fairlead, bolting it in via the bolts given in the winch kit and fits with ease; i have seen people with other smittybuilts have clearence issues but i had no issues for whatever reason. due to the control box wires being so short i did not want to but the box in a goofy spot, therefore i had made a custom mound by drilling holes and taking measurements to make it all even. i secured the control box wires onto the winch and tested the winch and verified proper working order. you then install the bumper via 6 medium length bolts. this is how it ended up

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unfortuneatly i had to cut the grill in order to fit the custom box mount oh well it looks very clean IMO. i will get pictures later i might go wheeling tomorrow. but anyways let me know what you guys think of the writeup even though it wasnt in crazy step by step detail. these are links i had used to help installation

YouTube
YouTube

 

[T4Rchadly]

yes i know the buffer kits are installed incorrectly and already changed them
:lol:

 

[T4Rchadly]

tested out both the winch and bumper today.
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[Avalanche666]

I still like the look with the factory wheels!!! dope rig

 

[T4Rchadly]

I still like the look with the factory wheels!!! dope rig

thanks man! i plan on ordering these TRD PRO wheels soon so i can put my tundra brakes on, and regear with bigger tires when i come down to lower 48.

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i think i want to run 34s for now so im overgeared a little? im going to be pulling a trailer and theres some pretty fat climbs on the way down. i made the trip in a different vehicle last summer from arizona

 

[T4Rchadly]

after doing the last trip there was a rock garden i couldnt get passed because i dont have sliders and i was bound to destroy my rockers/body panels. so i stole dirtcos sliders and made a near exact replica with 2/2 3/16" tubing ive already had. im not on a body lift and dont plan on doing one so i had to mound my sliders to the bottom of the frame plate and im going to weld a top gusset for added strength. this is where i'm at with them:
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i'm also really tired of not having an air compressor anymore since i sold my pickup, so i finally found a spot where i think i wouldn't compromise space with:naughty:
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i made a custom bracket but totally spaced the tank and made a use hold for weight savings in CAD. this is useless now and using just for mockup until i make the final bracket. the only thing im worried about is i think the air line going to tank will be interfering with the panel. i have to remove the cubby pocket unfortunately but im willing to take a loss in order for a gain on a clean install and using good space. let me know what you guys think.

 

[T4Rchadly]

well i finished up my rock sliders using the ideas of Dirtco's using 2x2" 3/16. this is how they turned out and im in love.
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went wheeling to test out how they work. got to test out the new winch on a steeper section i couldnt get up that had a few gnarly ruts.

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finally made it to Eska Falls, Alaska.
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"WIDE fU***** OPEN TOYOTA"

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on the way up was fairly difficult with no lockers a bunch of bogs. on the way down was steady up until i hit 2 swamps using a different trail down, and got my world rocked with hidden boulders under the mud/water. didnt get pictures as i was too busy getting winched out from my buddy with the new can-am mavrick.

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but eventually made it to the bottom of the parking lot. i hate mud....... this will be fun cleaning.
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[T4Rchadly]

i was tired of doing this rear main seal on a G wagon at work so i decided to pull in my truck for a bit to install my wheelers offroad brake lines from when i had ordered my poly bushings for my brand new Toyota OEM steering rack. my idiot self didn't realize there was a clip for the rear brake line and now i have to go to a store and find one. got the two front ones installed and moved on to the next task; fixing a power steering pump squeal. it squeals only on full lock so it was obvious the belt became a little loose when i last changed all the belts. I've been having this issue where i let go of the clutch and i hear a metallic loose sound and never really bothered to look into it. turned out the top bolt for the clutch bracket had came out and was sitting on the clutch pedal spring. bolted it where it needed to go and no more flex on the plate or noise. i ordered a SRQ CB antenna mount and routed all the coax and unit for my cobra 75. im tired of this a/c compressor whine so i ordered up a denso one and going to be installing with a couple other parts this Saturday. on the bright side my RMRACK/sherpa rack comes in friday!

 

[T4Rchadly]

well monday morning i heard a knock on the door and ended up being my sherpa equipment co rack! put it together and went camping this last friday. this is headed towards from anchorage alaska, to cooper lake alaska.
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check out all the smoke coming from a wild fire nearby! made for an unreal sunset..
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camped infront of the lake and drove 20 minutes out to go fishing at a popular river for red salmon. love my CVT setup!:biggrin2:
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came back to town and found another surprise at my door step.. ill get pictures tomorrow and show everyone! definitely the first person in alaska with these on a 3rd gen 4runner. finally finished up the CB radio setup and have yet to test it out; appearently our truckers down here dont use channel 19. trying to get rid of my complete SAS kit with a bunch of upgraded goodies all unused to i can get my front ARB and install them before i head down to the states and endure my girlfriend and i's long vacation of driving around the west coast-to colorado.

 

[sleepydad]

well monday...

How are the fish running this year?

I like to try and make it up to the kenai river, Russian river every couple of years. Fishing the smaller tributaries around coper landing as well because I don't like to stand arm to arm when I fish.

I always find it funny if you just take a 20 min walk you can usually fish all by yourself. I was surprised in 2017 how few fish returned compared to past years I have fished AK.

 

[T4Rchadly]

How are the fish running this year?

I like to try and make it up to the kenai river, Russian river every couple of years. Fishing the smaller tributaries around coper landing as well because I don't like to stand arm to arm when I fish.

I always find it funny if you just take a 20 min walk you can usually fish all by yourself. I was surprised in 2017 how few fish returned compared to past years I have fished AK.

im honestly not quote sure why they upped the limit to 9/day down there from 6. they had a 50,000 fish run this year but by the time i got there they were all gone and pure combat fishing.. i caught 4 with my fly rod setup and that was it.

 

[T4Rchadly]

also forgot i had a horrendous bearing noise coming from the a/c compressor clutch. ordered a denso one(OEM) and changed it out, filled with refrigerant. all is good. also noticed i was dripping coolant and took a better look at my skid plate to realize it was canned from when i last went wheeling. took it off and the coolant REALLY starting pouring and saw that the bottom plastic had cracked. put in a denso radiator the same day and called it good. now i need a skid plate before i go wheeling. also changed my LCA,s and steering rack finally with toyota OEM. aligned it and called it good. driving a lot better and didnt realize how loose my steering was until i put in the new rack and tie rods.