Builds 86 Xtra Cab Build (4Wheelunderground 3 link front, 4 link rear and 3.4 swap) (6 Viewers)

[aztoyman]

I've been working hard on this but I don't have much to show. I did get the tunnel cover cut for shifters and the heat shield installed. I had marked the bottom of the cover when I had the cab off for paint. I'm waiting for weather strip for the edges. I'll paint it blue eventually.

 

[aztoyman]

I put fuel in the tank for the first time. I replaced a 90 degree hose end in the engine bay with a 45 and replaced the return hose I had for mock-up with the proper type. I hooked up the pump to a battery to pressure test the system and had one leak. IDK why a brand new hose end and new bulkhead fitting leaked but it did. I couldn't see any defects or debris. I chucked the bulkhead fitting in the lathe and used crocus cloth on the sealing surface and no more leak.

New radiator hoses and spring clamps installed. No coolant yet. All other fluid compartments are full.

I got sent the wrong intake coupler so that's delaying other things.

I have the A/C lines figured out fortunately. I called one of the A/C custom shops about buying a 3 foot section of hard-line since mine no longer fits. I was told no one on the planet produces any in the size I need. It's Toyota only. So....I spent quite a while carefully straightening out the factory line without cracking it. And I actually managed to bend it to fit. It's not pretty but it should function. I'll cover it with a foam insulating sleeve and call it good.

One of the 3.4 swap hoses I had made years ago still fits. The other I just need to extend 3 inches.

Once I get my intake/filter sorted I can find a spot for my steering reservoir and work on sorting out the wiring and hoses. It's quite the cluster right now. A lot of "clutter" around that shock tower and I still have to install the wiper motor.

Gotta have pics since you had to read my rambling.

 

[Broski]

As always Nice work !

 

[aztoyman]

IT RUNS!!! Started it today for the first time. I started this build just a little over 3 years ago so this feels pretty good.

The steering reservoir and filter are temporarily rigged. I haven't run battery cables from the rear yet so I just used jumper cables to a battery on the floor.

No leaks, no CEL and it sounds good. It's not even close to being done but this is a huge milestone for me.

 

[aztoyman]

I have a couple questions about some emission hoses. The first one is this one that went from the evap cannister to the air box.

Is it mainly for fumes or do I need to plumb it to the intake tube for a slight vacuum source?

 

[aztoyman]

The second one I just don't remember. I need to find my stock intake tube to see if it attached to it somewhere. It's a big vacuum leak if I pull the red plug.

 

[aztoyman]

I was originally going to mount the fuel gauge calibrator back near the fuel tank but decided to put it in the dash. I used the same colored wire I salvaged from one of the other trucks to extend the fuel gauge wiring to the unit. I can quickly access it whenever I need to with it tucked behind this cubby.

It's pretty slick. I only have about a gallon of gas in the tank so I was able to set the low point of the gauge. I'll set the other points as I get more fuel in it.

 

[gnob]

my evap routing. lmk. I can get better pics.

Post in thread 'out with the old, in with the, well, old...' out with the old, in with the, well, old... - https://forum.ih8mud.com/threads/out-with-the-old-in-with-the-well-old.355254/post-5713406

 

[aztoyman]

Thanks gnob. I "assumed" it went to the intake tube but I don't know where I put it.

 

[aztoyman]

I found my reference pics. Just for the record, I'll post them here.

 

[aztoyman]

Since I found my original intake parts I installed the boot that has the hose connection for now. I still haven't worked out my intake system yet. I can at least run it as is for now.

I got my low side A/C hose made yesterday and installed. It's so tight around the shock tower I had to get the fittings oriented perfectly or I wouldn't be able to get my gauges on. I also wrapped the liquid line with insulation.

 

[aztoyman]

I had ordered a steering reservoir component from Radial Dynamics that someone suggested in a prior post. I'd have to go back and find who it was. It's a vent but more importantly it keeps 10 PSI in the system as the oil heats up. Helps to prevent cavitation.

Anyway, here's a pic. The resi is still just sitting there. I haven't permanently mounted it yet.

 

[aztoyman]

I was excited to get my A/C charged and see how the new parallel flow condenser worked out. The system holds vacuum and I started to charge the system but my clutch isn't getting power. The hard parts of my system are 1988 but electrically it's 99 4Runner so I need to find my manual and do some troubleshooting. It was working fine prior. Hopefully I just missed a connector or something else simple.

 

[ntsqd]

I built a slick PS reservoir that didn't work because it was carefully vented. My early research hadn't revealed the need for the reservoir to pressurize in use. I've since found a 10-20 psi check-vent valve on mcmaster with 1/8NPT threads that I've modified the reservoir to accept. Itching to test it again, but not looking forward to the inevitable mess that a PS system can make.

 

[aztoyman]

FIXED! I found my 99 4Runner electrical manual and started checking. Everything checked ok???
Must have been just a dirty contact?? I used contact cleaner and Deoxit on everything so??? It's working and cold.

To add, I was able to check everything electrically by accessing the A/C amplifier. Everything goes to it so I just unplugged it to check for power and continuity. Got lucky. It would have SUCKED to have to pull the entire A/C unit.

 

[aztoyman]

My instrument cluster had half the lights out so I replaced bulbs and hopefully I put the dash back for the last time for a while anyway. Getting tired of redoing everything. Same for the glove box. A/C is fixed and is freeze your face off cold.

Got the tunnel cover on too. When I was running the engine to charge the A/C I noticed that the driver side floor still gets hot but only directly above the exhaust. Even with the wrapped pipe, heat shields and the entire cab floor heat shielding. The tunnel and the rest of the floor is good to go.

I don't want to put sticky floor stuff on. Maybe insulation pad under carpet? I have to bend up a cage first so I have time to decide.

I want to drive it out of the garage and around the hood before I go down for surgery. I'll have to stick a seat in, and charge the shocks and bumps. And not get caught.

 

[aztoyman]

The hot floor bugged me and I had some good sized scrap pieces of heat shield left. So I added more heat shield between the exhaust and floor right at my feet.

I also pulled the small tin heat shield that was originally for the 22RE back out and stuck heat shield on it. It's really close to the top of the cat so it was just getting hot and radiating heat into the floor. The floor is insulated but now at least it has a second layer with an air gap. I don't know how long it will last being so close to the cat. Supposed to tolerate 400 degrees of direct contact , 700 degrees @ 2" but it's almost touching in certain areas. 1200 intermittent. Time will tell I guess.

I swapped the plastic wire loom that was on the O2 sensor pigtail for woven heat shield.

 

[aztoyman]

You know I THOUGHT I was done with the dash so I organized the wiring under the hood. I installed the Koito H4 headlight kit and shortened up the harness to eliminate bunching it up.
I tested the lights and they come on. High and low beams work. The flash function works and I noticed that the high beam indicator didn't work. Dang it! Gotta pull the cluster...... AGAIN. I just put new bulbs in.

Bulb is good. I get my 88 manual out and start looking at the schematic and checking wires. Continuity is good.

Long story short, it works as it should without the H4 conversion. You unplug both headlights, plug the new harness to both headlights and use one of the original headlight connectors to operate the H4 kit and the indicator does not work.

I don't want to put high current back through the original wiring and switches so I bypassed the switches and ran a wire direct from the high beam lead at the relay to the indicator bulb. I cut the original wire that went to the switch. Maybe I didn't need to cut it, but it works as it should now.

I tried other things but the high beam indicator lit up with both low and high beams on or not at all, depending on how I hooked thing up. Unhook the H4 kit, go back stock and it all works normally. Weird. I think I'll be ok with what I did. Nothing gets hot, no fuses blow, no high current through the switches and everything works as it should.

 

[aztoyman]

I keep getting pulled off this project lately but I keep trying. I did my wire harness mod and buttoned up the dash. Most of the stuff under the hood is good to go. I need to find a coolant bottle. Mine is shot.

I hooked up tail lights and tested. Brake lights work but the brake switch needs adjustment.

I removed the wiper motor and linkage from the 88. I'll need to clean and lube it before I install it in this truck.

If I can stay on this without any distractions this weekend, My plan is to droop the shocks out and charge them, stick a seat or seats and belts in, one more brake bleed and DRIVE IT out of the garage for the first time.

 

[aztoyman]

Had some chores and a honeydew I had to get done first but I got to the truck today. It's friggin hot and humid but I'm not stoppin.

I had pieced together a nitrogen charging kit a while ago. I jacked up the truck, disconnected the limit straps and drooped out the shocks. Got the shocks and bumps charged.