94 4runner solid axle project

[PurpleFJ62]

Hey all, been working on my 4runner when i am not busy with school. I am putting in a 84-85 solid axle and i thought it would be nice to share some pictures of the progress.
before.

IFS

Cut out

no engine

Frame rails

Sand Blasted parts


bare painted axle test fit.


The cross memeber under the radiator rused out so i weled in this 1/4 wall 2x2 square stock. Should do the job.
The goal for this project is to basically have a solid truck with a shit body so i can hit things and blend in here in flint. I am driving my rust free 91 runner and i am a little nervous sometimes. I would really love to swap in a 5vz if i can swing a deal with a junk yard.

Enjoy the pictures.

[theside00]

holy rust batman that is a lot of it there.

Looks good that will be a nice rig when you get it all done nice job

What engine are you going to run in it?

[PurpleFJ62]

yes this thing has alot of rust. to bad, it was my DD until last january when i was out drifting in the snow and slid into the ditch infront of one of those rich suburban mcmansions. I hit a huge rock, there was a little bumper damage, nothing to bad, nicked a wheel and knocked out the alignment. But strange enough a brake line broke. rusted right in half. So it got retired from DD uasage, then i had to drive my TJ, i really hate that thing!!!! Stupid heep.

I would like to cut out the rust and weld in new sheet metal, dosent have to look good, just keep out the wind/water/snow.

As for an engine i would love a 5vzfe, still looking for a good donar. I dont have time or parience to try to figure out the wiring so i will buy a ORS conversion kit. Then i can bolt it in and be done. I have been reading alot on yotatech about 3.4L swaps. After its in, if it goes in i will defintally find a used trd supercharger for it.

I grew up in the front seat of this 4runner, since i was 4 or 5 years old. I am not parting with it anytime soon. Its got about 194k on the clock and i am shooting for 300k.

I go to school in flint michigan, a pretty ruff city. Me and a friend go urban offroading alot. probally 3-4 times perweek. Basically we drive over the shit you would find in the ghetto, we drive thru vacant neighborhoods and climb a couple of really steep hills. I will have to take some pictures.
We have alot of fun up here!! My friend has a fzj80 and FJ cruiser and we both take alot of shit for having toyotas, this is chevy world here.

later

[the truck doctor]

keep up the good work! what lift 3,4,5 are you going with and tire size?

[PurpleFJ62]

its the 3 inch kit. i think some 33x10.5 will do alright. what do most people run you think?

[EVILSPOTTER]

It looks like a Trail Gear kit that you have in your photos, so you can plan on 3" of spring & about 2.5" of shackle & hanger. I'd say you could fit 35" tires with out much trouble.

[PurpleFJ62]

with that big of an increase a regear might be necessary.....I am hoping the 5vz will compensate for a slight increase in tire diameter. will have to get on the gearing calculator.

yes it is a trail gear kit....5 inches of lift, thats quite a bit!!

[KLF]

I hate to tell you this, but those control arms for your rear axle are gonna snap like twigs with those stiff poly bushings in them, especially if you add a bunch of lift. I've seen it happen more than once. A friend of mine installed them in the back of his 4Runner, then snapped an arm backing out of his driveway. I recommend you pop them back out and put new OEM rubber bushings in.

Dayum that's a lot of rust on that poor truck.

[DanS HJ-45]

Looks like good stuff.

Is the TG 3" the smallest lift available in the SAS kits?

I ask because I'd like to go solid axle, but I don't want much lift (2" would be ideal), and I don't know if it'd be easier to buy a kit from someone, or try to transplant the solid axle stuff to my IFS frame to keep the factory spring locations.

Don't worry about driving the Toyota. My best friend went to Kettering, and he's a subaru guy to the core (he owns nothing but Suby's, and he works for Nissan now!), they'll get over it.

Is what we see there the result of one weekend?

Dan

[PurpleFJ62]

I dident want alot of lift eaither, 3 inch was the lowest advertised so i went with that. Last school term i broke both my rear bump stops, i have to figure out a way to reconstruct those, but make them much stronger than stock. I am thinking about putting the rubber absorbers on the axle instead. Havent had much time to look into it.


I removed the engine and trans during my last work term. I was really close to scraping that runner. but i really am attached to it. I love them so much i bought a rust free one that is currently my daily driver. I love it. Its a 91, so its a little older than the one pictured. It took me and a friend one weekend to cut off the ifs shit and prepare the chassis for the solid axle. We hung the springs on a sunday before we came back to school. It was a blast.

I am enjoying myself at kettering, its a hard school however, but urban offroading makes it alot of fun. I really look forward to beating the hell out of this thing.
I found another toyota head up here, he lives with me over work term. He has an mr2 and i have 3 4runners and 1 LC at my house. I defintally will never go back to my jeep.

snap control arms??? damn, i really liked the way those bushings looked.........

[OffRoadSolutions]

Originally Posted by PurpleFJ62

As for an engine i would love a 5vzfe, still looking for a good donar. I dont have time or parience to try to figure out the wiring so i will buy a ORS conversion kit. Then i can bolt it in and be done. I have been reading alot on yotatech about 3.4L swaps. After its in, if it goes in i will defintally find a used trd supercharger for it.

Thought I'd throw some advice your way to hopefully help save some issues in the future! If you plan on running a supercharger the 99-02 model 5VZ-FE are best, their fuel systems can handle the supercharger the best without issues.

Good luck with your swap!

[PurpleFJ62]

thanks for the great info. i have been emailing back and fourth with someone at offroad solutions about this swap. I want to make sure i get the right engine from the start. I wont be able to pick one up until the middle-end of june, when i get out of school. Then i will have to get the ors conversion kit also. Should be a fun toy when its done.
I do have a few progress pictures.
I put these mounting brackets on before i painted it up. So when i get the chance to make a bumper I can just bolt it to these. From the looks of things i might have to weld studs in the holes because i was in a hurry and forgot that my gusset and weld bead would get close to the bolt. I dont think the head of a bolt will go in there.

Painted up with por 15.

[fortysixandtwo]

Not sure if you already have it mind but you should definitely plate the frame in the front.

[PurpleFJ62]

what is the reson for plating the frame in the front. aside from the gain in weight and strength, is it absoulty necessary for a solid axle swap?

[2ndGenToyotaFan]

The frame needs to be reinforced when you do a cross over steering if you're going to wheel it hard.... You don't need to plate the whole thing, but it's good to do it where the spring hanger attaches....

[PurpleFJ62]

Would some braces that go across the chassis do the job? After the drivetrain in is I will be better able to see where i could do some bracing. I am not going to be doing anything to extreme in this rig. But you never know......it will get the shit beat out of it for sure.

[fortysixandtwo]

Originally Posted by PurpleFJ62

what is the reson for plating the frame in the front. aside from the gain in weight and strength, is it absoulty necessary for a solid axle swap?

It doesnt add very much weight. It does however add a lot of strength. While toyota frames are pretty stout, when you add flexy suspensions, long travel shocks, cross over steering and big rubber, the strain on the front frame begins to add up. Tearing a shock mount off the frame on the trail isnt such a big deal, but try getting home after tearing your steering box off the frame. No fun.

I recommend plating your frame the entire length of the outside frame rails on both driver and passenger sides. you can beef up the inside of the frame but that isnt necessary except for where your steering box is located, well worth it to plate both sides of the frame and sleeve it as well. Marlin Crawler sells a cheap kit for the steering box alone and you can either fab the rest up on your own up or have a shop make the rest of the plates. I cut mine out of half inch steel and used a piece of cardboard to trace the frame. Dont forget to leave a hole for your Vin number on the passenger side.

The braces are mandatory IMO. At the very bear minimum, plate the steering box. I also recommend moving the steering box as far forward as you can to save yourself relocation down the road (in case you decide to stretch the wheelbase). I dont have any pictures of my frame plates but this should give you a good idea of what needs to be plated (Sorry for the poor paint skills :P)

[beatdown83fj60]

Originally Posted by PurpleFJ62

its the 3 inch kit. i think some 33x10.5 will do alright. what do most people run you think?

35's without question. The smallest tire I would run would be a 34x10.5 r15 LTB.


P.S. in regards to bracing the driver's side for the steering box, read this all the way through Crossover Steering

[Marc P]

Looks like a nice...rusty project. I ran 33x10.5's on my 4Runner when I first did my axle swap. They seemed a liitle narrow, and I was taller so it was very tippy.

Now I am running 33x12.5's and I am much happier....

33x10.5


33x12.5

[PurpleFJ62]

well its time for an update. Progress is moving along pretty good. Except for the hubs the front is just about wrapped up.
Here is a picture as she sits currently.

I had a blast putting in the shock hoops.

I used a tubing notcher to make the additional supports. I think these hoops will last a good while.

Finished and painted

Knuckles going together



A good time for reflection, man we have come a long way.


Next up will be the rear suspension. That should be lots of run, I have lots of rust to get rid of.

enjoy the pictures.
For the complete album you can visit
NateFrame69/94 4runner rebirth - Photobucket - Video and Image Hosting

[jtaco1]

Looks good, only things I see that may be an issue is that your steering box will most likely need to be moved forward, it looks like your drag link is already behind the tie rod, it will only get worse on compression. Move it forward into the core support.

Also the studs on the lower kncukle bearing cap look really long and may get wacked and marred up to the poin that the threads get bogered beyond service.

Looking good though.

[Hilux]

Originally Posted by DanS HJ-45

Looks like good stuff.

Is the TG 3" the smallest lift available in the SAS kits?

I ask because I'd like to go solid axle, but I don't want much lift (2" would be ideal), and I don't know if it'd be easier to buy a kit from someone, or try to transplant the solid axle stuff to my IFS frame to keep the factory spring locations.

Don't worry about driving the Toyota. My best friend went to Kettering, and he's a subaru guy to the core (he owns nothing but Suby's, and he works for Nissan now!), they'll get over it.

Is what we see there the result of one weekend?

Dan

Look at this and see what you think. I didn't even know this was out there...till about a week after I had the idea of a bolt on SA kit..

Toyotas at Off-Road.com - The Ultimate Resource of Information for your Toyota Trucks and Land Cruisers - - Toyota at Off-Road.com

Take a look at the fwd spring mounts they look low profile enough.

I'm with you, there's enough spring choices out there and I don't want all my lift in the kit. I like a moderate, "sleeper" lift.

[DanS HJ-45]

Originally Posted by Hilux

Look at this and see what you think. I didn't even know this was out there...till about a week after I had the idea of a bolt on SA kit..

Toyotas at Off-Road.com - The Ultimate Resource of Information for your Toyota Trucks and Land Cruisers - - Toyota at Off-Road.com

Take a look at the fwd spring mounts they look low profile enough.

I'm with you, there's enough spring choices out there and I don't want all my lift in the kit. I like a moderate, "sleeper" lift.

Whoah! That's the ticket I think! Much appreciated link.

Purple FJ62: looking good! The solid axle is much more becoming for a truck IMHO.

Dan

[kd4runner]

your going to like your kit. I just did the exact same kit in the front. Here's what mine ended up like.

[PurpleFJ62]

i think i will like it very much. The biggest bitch job left in the project is going to be fixing brake lines. Something i have never done before. That was the reason this runner got pulled from the road in the first place. A brake line broke when i hit a big rock, it still drove and ran just fine. typical toyota...the only way you can kill one is to let the rust eat it.

I really tore up one of my rims on that rock i hit, anyone out there know where to get some affordable steelies and new rubber?

I am going for the dark look, since its going to be a urban offroader here in flint. So flat black is a must.

Here is my 91 runner, all stock. with about 138K on it, drives really nice.
This one i am keeping for a long time, it only gets light offroading, like the mounts 4x4 park here by flint.

I take pretty good care of it.