2004 Tacoma PreRunner 4x4 Conversion & Build Thread (1 Viewer)

yotadude520

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A while ago I bought a 2000 Tacoma PreRunner with a 2.7l to get me by while my 1987 was getting painted. Ended up really liking the comfort & drivability of the 1st gen Tacos and decided to sell that one and get a newer one with a V6. A few months ago I ended up finding a 2004 Tacoma PreRunner with a 3.4L and 124k miles on the side of the road with a for sale sign in it. Got it for a great price and absolutely love the thing. I'm dead set on building this one up as it is an excellent platform and the truck is in great shape.

Here's a pic from our first trip up to the White Mountains:

FSgCX9.jpg


Plans:

-4X4 conversion with manual locking hubs & j-shift transfer case
-OME 883's & Dakar Rear leafs
-ARB Bumper w/ Warn Winch, IPF lights
-ARE Camper shell
-265/75/16 tires on stock rims (for now)

I've already started stockpiling parts for the 4X4 swap and am almost done. I'm replacing every part I can while I'm in there so I don't have to mess with anything for a long time.

Here's a list of everything I've bought for the 4x4 swap so far:

Front Manual Hub & Bearing x2
Aisin Locking Manual Hubs x2
CV Axles x2
Front Wheel Seal x2
Front ABS Rings x2
Wheel Bearing Seals x2
8mm Hub Hardware Kit
OEM Tools Hub Locknut Socket
Shifter
Front Diff
Front Diff Brackets
Front Diff Drop
Front Diff Manual Hub Tube (w/o ADD)
Transmission Output Shaft Swap
New OEM Ball Joints (Upper & Lower)
Donor Tranny (taken apart for output shaft & tail housing)
Front Driveshaft
Rear DriveShaft

Still looking for a J-Shift transfer case, but think I have a line on one. I'm going the route of converting my A340E transmission to an A340F as all the used 2003-2004 A340F's I have found either can't have verified mileage or have shavings in the pan and they still want $800+. I know for a fact that my transmission is good so I'm more than happy to reuse it.

I've already gone ahead and ordered the ARB Bumper & my OME lift from Wheelers. I'm going to be installing the lift first as it'll give me some more room to work with when I'm dropping the trans & installing the front diff. I'm also going to go ahead and re-seal the oil pan while there's no diff in the way since I'll be there.

Anyway - super excited to get going on this build!
 
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Have you compared the costs of a straight axle swap to the costs of an OEM IFS? Just curious how close they would be. Love to see people still willing to major wrench on these.
 

yotadude520

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Have you compared the costs of a straight axle swap to the costs of an OEM IFS? Just curious how close they would be. Love to see people still willing to major wrench on these.

I honestly really had no interest in doing a SAS since this is still my daily driver. I don't do any serious rock crawling anymore and just want something that'll get me where I need to go, through almost anything.

The cost for a SAS is roughly anywhere from $3,500-$4,500 and that's being pretty conservative. I'd probably have to buy a kit since I'm not much of a fab guy! The total cost of my 4x4 conversion will be right at $2k, BUT I'm replacing a ton of parts while I'm in there including my ball joints, wheel bearings, hubs, having the transmission converted, new CV axles, seals etc.

One of the main reasons I wanted to buy a PreRunner over a 4x4 is A) they're much cheaper and easier to find in good shape with low mileage and B) all the work you do to convert it to a 4x4 probably already needs to be done on an old 4x4.
 

yotadude520

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As I've been piling up the parts needed to do my 4x4 conversion, I ordered my ARB bumper and an OME lift kit with the 883 coils & rear leafs. I figured that I would lift the truck first as it would give me more room to work underneath it to get the tranny out, as well as being able to have the truck on all 4 wheels while I do it. Ordered the stuff through Wheelers Off Road and less than a week later I had this giant box show up!

gNVoT8.jpg


I got the bumper and crush cans off, and started the task of putting the ARB together. I've heard the instructions are extremely terrible, and they are. Took me about a few hours but I was able to get it on and I have to say it looks great.

7CTdFz.jpg


I haven't bought a winch yet - that will be down the road with the lights. First mod - complete!

A common problem on these trucks that I've seen is the passenger air vent either being broken or completely falling apart. When I bought my truck, the vent had broken and the previous owner Mcgyvered a spatula into a vent...needless to say that had to go.

You can buy the vent new from Toyota, the part # is 55660-04030-B1. There's not much online about replacing it, but it's really not that hard to do. The only post I found on the subject said that the airbag had to be removed. Well, I'm glad to say you don't have to. It is a bit of a PITA, but you basically have to remove the glovebox & the top of the glovebox, then remove the air duct behind it and that connects to the vent.

Then there are three phillips head screws that you can remove to get the vent out. One is on the far passenger side of the dash and it is a PITA to get out, but can be done with a stubby screwdriver and some serious contorting of your arm. I did not put that screw back in because well, I couldn't even get close to getting it started. Plus I figured if I ever have to replace the vent again it'll be a much easier job.

Here's the old spatula vent and you can see how it mounts.

wRQXLa.jpg


And the new one in place:

m0OsH8.jpg


I just got the OME lift kit last weekend, and am going to be throwing it on this weekend since I have Monday off. More pics to come!
 

yotadude520

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When I bought the truck I always wanted to put a bedliner in it because the bed has seen some better days - it has lots of dings and dents inside of it. I was extremely surprised that I was still able to buy them brand new from the dealership!

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