Over build thread-1996 LX450

[chuckc32]

Been going at it for a while, figured it’s time to put something down and hopefully help someone like everyone else here has helped me along the way with your post/info etc.

I got this 1996 LX locally last summer, 256k with not a ton of maintenance history, but rust free, and no glaring immediate issues I’d have to fix.

I sold my 100 series to get into an 80, hoping to build something I can take the kids on local trails and maybe do some bigger trips to windrock once my schedule gets more normal in the future.

Here she was as I picked up.

 

[chuckc32]

PO had installed a system with a couple subs in the back, which I had no need for, so I haggled the price a bit and took it without, radio, speakers all that.

First couple orders of business were, radio (obviously) and a cooling system overhaul. Radiator was old and browning, and hoses were rough, so ran through everything to include water pump to keep things cool for the end of summer and fall.

Speaking of cool, the AC system was pretty weak, so we went through all of that and got everything ICE COLD.

Mods started with that process, as. I figured while I was working on that, it couldn’t hurt to add a max flate aux condenser fan. So on it went. Honestly, a great add, keeps everything running cool regardless of outside temp, speed etc.

Once we got all that sorted it was time to start working on some random things previous owners, mechanics, someone had done…..

 

[chuckc32]

Up next was the fuel system, specifically the filter. Ended up doing a whole lot with this that I probably didn’t need to trying to find an issue, but oh well. Pretty much everything from the tank to engine has been improved.

Factory fuel filter had been deleted, and replaced with an inline canister type with rubber line clamps to lines from the original hard lines. After replacing the necessary hard lines with new Toyota stuff, as well as the filter, I ran myself into some issues. I started having losing fuel pressure when shutting down. And slow to build on startup. It always started, but boy would it try for a while to get there. Fuel pressure gauge showed instant drop of pressure on shutdown and the inverse on startup.

Enter the parts canon. Went through regulator, lines, pump, injectors, charcoal canister (AC Delco mod) and found a better tank (did discover quite a bit of rust in mine when doing the fuel pump). Hell, even through a starter on it. Redid all of the battery and ground wires to heavier gauge. NO IMPROVEMENT.

Sad to say my issues were likely caused by a torqued below spec fuel filter banjo bolt. Little tightening and issue was completely resolved. Don’t be like me, unless you just want a new fuel system then go nuts.

Running great at this point so we started working on some other things….

At some point I did the front wheel bearings as well. Helped the wander quite a bit

 

[chuckc32]

Next it was time to do some creature comforts.

Had a very shakey driver mirror. Enter the first, certainly not the last, of @Outsane parts.

Found an interesting attempted fix in there-wadding up grocery bag. Lee’s parts worked way better. Also a bonus wasp nest in there to get the heart rate up.

Decided to go ahead and upgrade the battery to an odyssey AGM around then too. Been great so far, but more on that later.

With the mirror wobble gone, I could see the factory running boards were cramping my style and took them off.

Next up was a trail-gear front bumper to protect from…. Nothing really yet, just liked it more than the factory setup.

With a little additional weight and Black Friday around the corner, it was time to start looking at some replacements for the TIRED factory shocks and springs. I went with the dobinsons nitro shocks and variable 1.75-2.5 lift springs since I don’t plan on doing more than 35s and already had my heart set on bumper kit for the rear.

What a difference the kit made. Ride wasn’t terrible by any stretch, but the dobinsons stuff is very smooth. Bonus pic if you made it this far

 

[chuckc32]

With the lift and spring in, it was time to put some weight on the back end. I picked up the 4x4 labs bumper kit. I’m not a welder by any stretch, but the kit wasn’t bad at all to get together. A LOT fewer steps than the coastal kits I had on the hundo.

Then it was back to comforts. The original seats were rough, and gears were natural gone as well. I decided to take a shot at some corbeau seats. Not the best but better than what we had in there.

Also decided to replace the factory steps with some rocky road sliders.

Somewhere around here, factory cats gave up to the ghost. Found the magnaflow kit on sale and slapped them on to clear out the CEL (which was now working again after a fusible link failure).

 

[chuckc32]

Once the weight started adding up, the brakes really started to glare at me. Tried all I could to get the abs bled, but alas, 30 years got the better of it. I deleted all the abs and got some improvement, and even got the new booster, but I was just not impressed with the stopping performance still.

I decided to redo it all and replace the vacuum boosted factory system for a powertrain solutions hydro boost adapter. Wow. Not the easiest thing to get retroed, but, what a difference. I decided to try a couple different reservoirs, and settled on a Lee power steering with @Outsane s mount.

 

[chuckc32]

Once the brakes were braking, I decided to celebrate with some bigger tires. Went with wrangler territory 315/70/17s. The toyos found their way to my excursion after camping out for a bit. The territory’s ride much better. In Toyos defense, a E load rating is a little overkill. And they ride much better on the “king of suvs”.

Then I found a good deal on a “broken” warn vr10. New contact pack and synthetic line on and in the bumper with relative ease.

After that I finally decided I needed to see at night and got the quads setup. I’m using some Auxbeam leds and could not be happier with the upgrade.

Electrical and some more interior were next.

 

[chuckc32]

Totally forgot. Threw some delta radius arms up front and found a local guy with some extended front sway bar mounts before the second battery and future fun went in.

 

[chuckc32]

I had an arb twin compressor that I had planned on throwing in the 100, so I figured I could find a purpose for it in the 80.

Slee’s dual kit seemed like a good option to get more volts on board and put everything in a good spot under the hood. Between the compressor, manifold and all the other vents, solenoids etc, things aren’t too cluttered, but definitely a lot going on under the hood.

I opted for a blue sea 7622 acr to have select-ability on batteries if I manage to kill either with the winch or compressor and other bits. I really like that slee’s kit gives everything a home. Keeps the brain from wandering.

 

[chuckc32]

I decided to add some more comfort and functionality in the cab and got the delta shift console and NYX fab center console. The consoles are pretty good and the delta panel makes setting up all the switches pretty easy.

I also have an Auxbeam controller to switch on compressor and winch and others on a thrills on wheels ashtray mount. Ignore the car seat base, we just went to front facing on the youngest

 

[chuckc32]

This brings us to about March, my birthday month, and also, about the time I received both of my diffs. I got my complete front from marlin crawler. I went with a zip locker and 4.88s. The rear was assembled by front range off-road. Unfortunately, shipping crushed the copper line on the arb in the rear third. Front range CS was fantastic. Had a replacement to me in a couple days.

And here we are today, about a week in with 4.88s…. By far the best thing I’ve done. That rear differential was an absolute PITA to install on my back in the driveway, but holy cow, I can actually keep up with traffic and cruise in overdrive at interstate speeds without hunting gears.

Lockers are working, but haven’t beat on them yet. I’m working through my break in on them for now, I can’t wait to do some wheeling once I get a few miles and a fluid change done. I’m seriously blown away with the drivability with the gears. Just woke the rig up. I hope to take it out for a light cruise in a week or so if I can find some off time. 3 kids has kept me very busy lately. Here’s some more pics.

 

[chuckc32]

only thing on the horizon at the moment now is miles.
And probably a lutz auto speedo calibrator. I hoped the gears would get me back to normalcy with the 34s. Unfortunately they over corrected and now I’m reading fast. No worries. Easy fix.

Definitely some stuff not in here. Did the cabin filter earlier today, but happy to help or chat with anyone about things on here! Hope to see you all outside!