85 4Runner - Breathing some new life

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hman913

hman913

10 Year 15 Year
Joined
Jun 22, 2009
Threads
69
Messages
678
Location
High Point, NC
After selling my 40 this past July, I wanted to replace it with something that had a good start on what I ultimately wanted and that was proven reliable. I had always wanted a mini-truck or first gen 4Runner so I started my search there. Scouring the various classifieds I found @DTCsk8er here selling his moderately built 85. Started what would be many conversations and emails back and forth, and she eventually showed up at my doorstep.

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Some quick specs before I get too far…
Rebuilt 22RE within the last 20k
Dual cases w/ stock 2.28’s and twin sticks
No rust
4.88 diffs – locked rear/open front
TG birfs
OG Longfield hub gears
Davez Off Road leaf packs
Raptor lined exterior
OBA
Zero rust
35s
Warn 9000XD
Moldy carpet

Along with those installed parts were a set of unfinished sliders, disassembled e-locked 3rd for an air conversation, unfinished half doors and some other bits.

After fighting with rust on the 40 – replacing the tub completely, cutting off part of the frame and cutting out others – not having to deal with any this time around was well worth the price of admission.

I think I barely waited long enough for it to be loaded on the truck in Houston before I started ordering the first of the parts:
37” Maxxis competition Treps
17” Racelines
RCV’s
Front Range Off-Road keyed steering arms and 25mm bearings
FROR hub and knuckle studs
Aussie to lock up the front

Before I put it up on jack stands, it got a state inspection. Something my previous truck never had.
 
Shortly into the tear down of the front axle I found the axle seal on the passenger side starting to fail with gear oil mixed with grease, and rust on the driver’s side hub spring and wheel bearings from a failed hub gasket. An unplanned knuckle rebuild never hurt anyone. Rebuild kit from Sky and Marlin's Eco seals were soon on the way.

These arms are the balls
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Front end done
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Don't mind the dangling steering stabilizer... that has since been removed.

I'm almost positive the tires are going to use up the entire fender opening and be into the sheet metal at the back of the fender, so that will have to get trimmed. Whatever is necessary to keep the low stance is worth it.
 
In the time (much longer than necessary) that it was up on jack stands, the battery took a crap because of me neglecting to disconnect the negative battery cable. And by dead I mean wouldn't even charge dead. So again I used it as an opportunity to upgrade. Odyssey 34/78 with a Ruff Stuff box

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Come to find out the dead battery was due to the fuel pump constantly running when the battery was fully connected. Key didn't even have to be in the ignition. After some research, looking at fuses and relays I found a jumper wire had been inserted in the test plug for the pump. Yanked it out, reconnected the battery and Silence! To make sure everything was still happy with the FI, I started up the truck no problem.

All weather-stripping for the driver and passenger doors have also been replaced due to dry rot. Windows actually seal up properly now and should avoid future moldy carpet and stank.
 
As the proud owner of a 85 4Runner myself (and recovering from selling my built 40) I say Welcome!
 
Man, I LOVE seeing my old rig get the attention it deserved. That rig never failed me on my adventures, most of which were +1000 mile trips. I am glad to see it transform.
 
The current project is replacing and relocating the pneumatic switch for the rear locker. I will be using a Power Tank Campbell toggle switch with push-lock fittings located next to the e-brake handle.

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The only thing hanging me up right now is waiting on some in-line fittings to extend the lines from the firewall to the switch.

The front bumper will also be getting some cleanup and re-work, hopefully starting this week(end). Once that is done it will be treated to a new winch. The 9000XD that came on it was fine, but the solenoids were not protected from the elements whatsoever. The money necessary for the parts from Warn just wasn't worth it, so I was able to nearly recoup the cost of an M8000 by the sale of the other.
 
YES this weekend!!

Where did you get those push-lock fittings and those sweet switches again?
 
Last edited:
Looks to be the same, albeit different exterior style and a bit cheaper, than the Campbell switch. Mine is also plumbed via a Puma compressor.
 
Nor did I pay the current price for mine. When I ordered it they realized the website was incorrect and honored that price. Glad I only needed the one.
 
Locker switch has been installed and tested successfully.

In the garage Friday night with the sawzall and the damnedest thing happened...

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And not to be out-done, while removing the driver side shackle tab it ripped out part of the spring hanger

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Dug through my pile of scraps and found a small enough piece to shape and fit in there for a patch. Since the cross-member is 2.5"x0.25" square tube and the spring hanger is 1/8" wall tube, I will be plating both with a piece of 1/4"x4" plate for remounting the bumper and recovery points.
 
1/4" thick seems a bit excessive considering what you're weld it to. I'd use 3/16" and put a lot of rosette welds in it, especially have some centered on where any tubes might be welded on.
 
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