The 2nd Gen Redemption by _ExpeditionMan

[_ExpeditionMan]

The Beginning

I started getting interested in overlanding about 3 years ago while still in college. I stumbled upon Expedition Portal and starting reading through Stioc's excellent Nissan R50 build thread. This thread was especially inspiring to me as it showcased a man building a vehicle he loved regardless of aftermarket support or stock capabilities, which is something we can all respect and certainly applies to me now. After getting a job and finally having the cash to purchase a vehicle I started looking around. I had settled on a clean first gen trooper (rare), a maintained Series 1 Discovery with a 5spd (unicorn), or a clean reasonably priced 1st gen 4runner with a 22re and a 5spd (rainbow unicorn). So as I was scrolling through craigslist hoping to win the lottery I stumbled on an ad for a 1994 4runner SR5 3.0 5spd with 178k. I had dismissed the 2nd gen 4runners as the black sheep of the otherwise studly Toyota truck family, but there was something about the simple straight edge styling and 4 door practically that struck home. So after talking with the owner (who was incredibly upstanding and honest) and reviewing all of his service records I caught a red eye flight to Albuquerque, New Mexico to pick her up. My Mom even tagged along to keep me company on the drive back! The truck was in really good shape and had a ton of work done to it, including the head gaskets, and drove better than any other car I had owned. So I bought her and made the drive back to Southeast Texas with no issues and even averaged 20.1 mpg. As an added bonus on the way home I got a chance to explore a few dirt roads in the hill country which let me drop it into 4wd for the first time. Man it feels great to finally have a truck and to be able to contribute to this awesome community!

The Goal

This will be an occasional DD along with my overlanding vehicle so all modifications will have to be practical, sorry no SAS here! I hope you enjoy the journey as turn this 4Runner into a capable, reliable, and comfortable platform from which myself and others can escape the daily grind to spend time outdoors. More to follow..

Immediate Needs

1. Timing belt, water pump, and associated items (complete - 12/18/2015)
2. Pull rear bumper and deal with rust to ensure it does not spread to body
3. Replace both front CV's, the boots are cracked (complete - 12/27/2015)

Secondary Needs

1. Rear recovery point (complete - 12/19/2015)
2. Engine skid plate (complete - 12/19/2015)
3. Extended differential breather lines
4. Rear window up switch on center console is not functional
5. Rebuild and install Aisin Manual Locking Hubs (complete - 12/27/2015)
6. 33" tires (complete - 5/8/2016)
   [*]Disable ADD system and lock shift fork
   

Long Term Wants and Dreams

1. Transmission skid plate
2. ARB Front Bumper
3. Custom Rear Tire Carrier
4. 2" Suspension Lift
5. Onboard air compressor (complete - update incoming)
6. Snorkel
7. Replace blown front speakers

The day I drove her home:

 

[Chuckles89]

Sounds like some solid plans!

 

[_ExpeditionMan]

Sounds like some solid plans!

Thanks Chuckles89. I've been lurking around here long enough without a build thread of my own.

 

[2ndGenFlip]

Nice truck good plans

 

[Desertrunnersr5]

For the waterpump and timing, what kit did you use? Looks good that's the route I'm going with mine. And why are you going to disable the add system and lock it in place if you don't mind me asking.

 

[_ExpeditionMan]

For the waterpump and timing, what kit did you use? Looks good that's the route I'm going with mine. And why are you going to disable the add system and lock it in place if you don't mind me asking.

For the water pump and timing belt I took it to a local shop. I still don't have a place to do any serious work on my 4Runner and had just moved so that was the best, if not the cheapest, option at the time. I'm sure there's a thread on the forum with the information you're looking for.

The link I've included below explains the limits of the ADD system better than I can, however I'll give you a brief summary. Essentially the vacuum operatated ADD system can be unreliable. It can fall in the open state which would prevent you from getting four wheel drive. Locking the fork AND installing manual hubs creates a more simple system and reduces the points of failure while still allowing you to run in 2wd. As far as disabling the ADD check out the link to www.4x4wire.com which has all the information you need. It's also a resource I've used multiple times as the write ups are generally of high quality.

 

[_ExpeditionMan]

Hidden Falls - Group Trip

Hi All,

It is has been a while since I have updated this thread so I wanted to throw in a few photos of the trip I organized with two guys over on the Expedition Portal forum members to the Hidden Falls Offroad Park. This is a massive tract of trails throughout the Hill Country of Texas near Marble Falls. The land is covered in scrub and the trails are rocky and full of packed dirt.

We met and headed down a park road where we eventually found a small rocky stream. After consulting the map we decided to be adventurous and head up the stream.



This was a bit of a challenge for me as this was my first time ever off-roading, especially since the small rocks made modulating the clutch very touchy.



Eventually we encountered a huge rock which prevented us from proceeding up the river. Thus we had to escape from the river bed. I had a hard time with this one. It's difficult to tell from the angle of the video but I could not see what was to the right of the front right fender. Once I backed up far enough to see that I was clear I finally gave it the juice it needed to make it up the climb.



2nd Gen 4Runner - River Bed (video)

Eventually, we ended up at the end of the park along a huge hill. It was quite imposing, but we decided to do our best to climb it. Several ridges separated us from this end goal. Below is the picture of us starting our climb.


[MENTION=107308]jgilbreath[/MENTION] hit the first obstacle. As you all know things look way easier on video, but this was a huge dip. He had an e-locker on the truck but it was not working so this is all open diffs.

3rd Gen 4Runner - Hidden Falls (video)

I caught a quick video of the tacoma making it look easy here. Capable truck and good lines makes this look much easier than it should have been.

2nd Gen Tacoma - Hill Trek (video)

Finally, it is me bringing up the rear in the stock 4runner with worn tires. Here is me getting some guidance from a more experienced driver as I get guided up the ledge.



We found these awesome views at the top of the hill.





We hit a few more obstacles as we proceeded down the hilltop and I even got a chance to flex out the rear suspension. As you can tell I am pretty excited about this haha

2nd Gen 4Runner - Hill Descent (video)

Continued below...

 

[_ExpeditionMan]

Hidden Falls - Group Trip Part 2

We stopped to take a group picture when we noticed some oil leaking from the tacoma of the group. Queue the group diagnosis.



Luckily it did not seem like trail damage and later on the owner discovered it was a very slow leak from his front seal. Here's the awesome group shot.



Lastly, I snagged a cool photo of the tacoma on the way out of the park.



I had a blast doing this and while not the typical overlanders outing this was a great opportunity to practice and showed my just how capable my 4Runner was out of the box.

 

[RonJR]

If you really want to enhance offroad performance, install a locker. The 2nd gen front suspension has pretty limited travel, so lifting a wheel is a common occurrence. With open diffs that can stop you in your tracks. With a locker on either axle you'll never even notice it happened.

Depending on your budget, you can go to a lunchbox locker or a full switchable like an ARB. I'd recommend the Aussie lunchbox in the front, which is what I have. Since you already have manual hubs, it won't affect street driving at all, and will revolutionize your offroad performance. It doesn't behave great on snow and ice, but in Texas you may not have much of that.

 

[_ExpeditionMan]

If you really want to enhance offroad performance, install a locker. The 2nd gen front suspension has pretty limited travel, so lifting a wheel is a common occurrence. With open diffs that can stop you in your tracks. With a locker on either axle you'll never even notice it happened.

Depending on your budget, you can go to a lunchbox locker or a full switchable like an ARB. I'd recommend the Aussie lunchbox in the front, which is what I have. Since you already have manual hubs, it won't affect street driving at all, and will revolutionize your offroad performance. It doesn't behave great on snow and ice, but in Texas you may not have much of that.

Thanks for the advice Ron! I've done my homework on lockers and limited slips and I still haven't decided which I want to go for. Honestly, I haven't needed one yet due to picking good lines and not doing anything too wild. I have a few more updates to post about, one of which is much better tires and that has made a world of difference. Luckily the 5spd combined with 4low makes this thing crawl up everything despite the open diffs.

If I had to choose I'd probably go limited slip in the front and a selectable in the rear, but that's assuming I had the cash to drop for that at any moment. And sadly I just don't drive the truck off road enough (yet) to justify the investment. Besides that money needs to go towards all the little maintenance items that keep popping up. Haha. How do you like the truetrac limited slip in the rear of your 2nd gen?

 

[jgilbreath]

Great trip report and pics/videos. That was a lot of fun and a good introduction to going offroad.

 

[RonJR]

How do you like the truetrac limited slip in the rear of your 2nd gen?

The Truetrac is nowhere near as effective as a locker in really difficult terrain. If one wheel is in the air, it can't control spin on that axle unless you do some skillful braking. However, it does control spin on loose gravel and snow pretty well - I really notice it when ascending steep dirt hills, especially if I haven't yet bothered to lock in the front hubs. It does a good job of keeping one wheel from breaking loose and digging a hole. The other thing I like about it is that, on the street, you simply don't know it's there. No clunking, chirping, binding, nothing.

I made a trip into the Maze district of Canyonlands this past spring, and was able to do about 90% of the roads there without ever locking the front hubs. I don't think I could have done that without the Truetrac.

The combination of the Aussie and the Truetrac makes the 4runner pretty unstoppable, short of deep mud or getting hung up on a rock. It's amazing what it will go through seemingly without breaking a sweat.

 

[_ExpeditionMan]

Great trip report and pics/videos. That was a lot of fun and a good introduction to going offroad.

Hey jgilbreath!

I did not know you were on here! Glad I tried tagging you regardless. Any updates to your 3rd gen? Ever get that E-locker working?

The Truetrac is nowhere near as effective as a locker in really difficult terrain. If one wheel is in the air, it can't control spin on that axle unless you do some skillful braking. However, it does control spin on loose gravel and snow pretty well - I really notice it when ascending steep dirt hills, especially if I haven't yet bothered to lock in the front hubs. It does a good job of keeping one wheel from breaking loose and digging a hole. The other thing I like about it is that, on the street, you simply don't know it's there. No clunking, chirping, binding, nothing.

I made a trip into the Maze district of Canyonlands this past spring, and was able to do about 90% of the roads there without ever locking the front hubs. I don't think I could have done that without the Truetrac.

The combination of the Aussie and the Truetrac makes the 4runner pretty unstoppable, short of deep mud or getting hung up on a rock. It's amazing what it will go through seemingly without breaking a sweat.

I have read and heard similar stories about limited slips. It just seems like I will probably go selectable at some point if I have feel the need to get further and deeper into trouble while wheeling.

 

[CentCalKid]

Thanks for the inspiration. Good for you and your off-road buddies.
Even stock...these Classic 4Runners are reasonably good off-road vehicles.

 

[_ExpeditionMan]

Tires update!

Hey guys,

It has been a long while since I have updated this thread, but now that I have sometime the backlogged updates should be flowing in. After the last trip to Hidden Falls Adventure Park it was clear that the 4Runner needed new tires. The 31x10.50 Michelin LTX A/T tires on there were worn down badly, and were starting to show signs of spider cracks on the sidewall. I have had a tire blow on me on the highway previously in an older Acura and there was no way I was going to take a chance of that happening in a SUV. Therefore.. meet the new tires, I got a really good price match at Discount Tire for a set of 33x10.50 BFG K02 tires. I did a lot of research before purchasing these and it was really between these and one of the Cooper tires. I have always been a sucker for the white lettering. I purchased five and went with the warranty provided by Discount Tire since I read of a few issues some owners have had with these wearing strangely due to bad molds. Here are a few pictures! Keep in mind I have zero lift on the truck and that it is completely stock.

Interesting story on the picture of the truck at Autozone. I was just taking the truck home with the new tires when I took a turn a little faster than usual and I hear a bunch of noise come from the engine bay. I pull over and look for something wrong and spot some liquid dripping to the ground. Some genius had removed the battery tie down and never reinstalled it and I hadn't caught it until now. The whole battery and tray had slid from its position over into the power steering pulley which had cut a hole in the side of the battery... GAH! A new battery and a bunch of bungee cords held me over until I got a new clamp from Toyota. Learn from my mistake and make sure your battery is completely secure.

Before:



After: