My '94 4Runner SAS

Blizzard · 11-19-2007, 08:00 AM

Hello,

Finally, after years of dreaming it, the SAS has become real!

This swap is almost unknown in Spain, I only know four trucks SASed and legal in Spain, and this is the 1st Toyota 4Runner.

My truck is a 1994 Toyota 4Runner 3.0 Turbo Diesel. The odometer reads now 199k miles and still running strong. I've the stock clutch too and it doesn't slips! I love this truck.

It's being more than a SAS, the setup is this:

'89 Toyota Hilux front axle
Stock 4.88 High Pinion diff from a Toyota LJ-70 (Waiting for the HP Aussie Locker)
Rear E-Locker coming from a Toyota KZJ-90, regeared to Yukon 4.88
Rear disc conversion. Toyota BJ-73 discs machined to fit and Toyota Supra calipers
Toyota 3rd Gen 4Runner rear driveshaft (CV) T-Case Flange drilled to accept it.
Custom T-Case disc brake with Sky Manufacturing caliper
Dual fuel reservoirs
Front driveshaft hybrid (CV+Trail-Gear Long slip yoke)
Trail-Gear 4'' SAS
Trail-Gear 5'' rear leaves
Trail-Gear Backplate eliminator kit
Trail-Gear Rock ring kit
Trail-Gear Creeper Gussets
Bilstein 5150 shocks
Rear airbags
Intercooler fitting
Injection pump rebuild
Injector rebuild
Turbo wastegate mod
New SS exhaust line, 70mm ID with constant-radious bends.
8x15 ET -24 Vaska alloy wheels
Copper Discoverer STT 35x12.5x15 tires with airsoft pellets for balancing

I think I've forget something...

First day we took off the truck all the IFS parts, the rear axle, fuel tank, exhaust and began cutting:

Tipical POS pile

Ready to regear the E-Locker. I bought it with a broken R&P for 300$

The front ready to grind

The rear axle stripped. Panhard braket was a PITA to cut

Welding the E-Locker beads and the armor

Altought the High Pinion diff had 4.88 gears from stock (Toyota LJ-70) we had to adjust the backslash. Also changed the seals

The E-Locker carrier with the new ring gear installed

Pressing the bearings with the "SST"

The rear cut

Front grinded and ready to weld

The E-Locker with the new R&P. Unlocked position

And locked:

The backslash became perfect

Tacking the front spring hanger

The shackle jig tacked in place

The metal eater hehehe

"Plasmaing" the holes

Hole finished

And the tube welded in place

This is me (The long haired guy) and my friend and welder JuanFran mounting the front leaves

The truck in it's weight

Greasing the shackle bolts

As the shackle angle was good JuanFran began welding it definetively

Front hanger welded and gusseted

Mounting the discs to the hubs. I had to buy new hubs because the old ones were rust-welded to the discs. We applied 16.5k tonnes in the press till the disc broke and still were welded.

Where to pound the hub bolts more confortable than over a wheel?

The rear axle plates cut to accept the discs

Front axle truss fully welded

Front diff armor welded

The E-Locker mod made to the rear axle housing

New seals all around

Testing the rear axle without discs

Fully welding the rear leave hangers

Presenting the axle to it's new friends the leaves

Ready to weld the perches in the 0? driveshaft position

The driveshaft angle. or better said, no-angle

Welding the perches to the axle

My friend welded them in the inside too

"Martacking" the front axle shafts

The new axle seals and the Rock Rings installed

The birfields fully litium-greased

Altought I had all well studied sometimes I need a bit of help hehe

The Creeper Gussets welded

Better view of the Rock Rings

And the backing plate eliminator

The Creeper Gussets are also the front shock brackets

Front axle ready to clean and paint

And the rear one

Axles primed

As you can see we left our creativity flow

Matt black painted

The rear discs machined in the inside and the axle shaft plate in the outside to fit

Testing the Supra calipers

Rear axle hung

Primed the grinded/welded areas

Front axle ready to go

Front axle ready except for the Aisin manual hubs

Hy-Steer installed

And finally, the truck on it's four!

This is me, tired but happy

My Toy and an Opel Frontera (Rodeo I think in the US) for comparing

Forklift time. We were testing the shock and bumpstop location

We stopped when the rear tire began rubbing the bumper

Presenting the front shaft and the lonk slip yoke

I've to say that the Trail-Gear long slip yoke was very bad machined. The outside was off-center to the rest of the yoke, so we had to machine the outside again to center it. I know they're not intended for highway use but we put it in the balancing machine and the shacking was horrible even at low speeds. It could have caused the T-Case or diff seals to leak in a few weeks!

The stance. Note there's no weight on the truck (No exhaust, fuel tank, front bumper, winch...)

Rear shock brackets

The front shock towers with the gussets

Front bumpstops

The rear axle shaft plates machined to fit the discs

Aligning the front

As we where welding we decide to add a dual shock support. We've to gusset it

The upper rear shock brackets

The dual shock (Testing)

The Aisins with SS bolts and washers

And the Sky Manufacturing caliper

I must go now, I'll add more pics later.

Cheers,

David

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Blizzard · 11-19-2007, 10:27 AM

This is the disc we made for the T-Case E-Brake. It has the V6 flange pattern and the 3rd Gen one.

This is the intercooler we're fitting in my Toy. It's from a Mitsubishi Montero/Pajero 2.8TD

The injection pump rebuilt

And the injectors

This is the SS piping we're using for the exhaust. It's 70mm (2.756'') inside diameter. We bought constant-radious bends too.

Those are the constant radius bends for the intercooler (2'' ID)

This is the Hilux tank we're using as 2nd one. A 4Runner tank would be easier to fit but this was cheap and the only one we found in that moment

David

4RocRunner92 · 11-19-2007, 10:47 AM

why not paint over that ugly looking red?

**Tofer** · 11-19-2007, 11:04 AM

wow!!! thats a nice swap!

Blizzard · 11-19-2007, 11:09 AM

Hahahaha because we're leaving the black paint for the last. As we have still to make the brake lines and so...

I'll add more pics in an hour or so.

David

AxleIke · 11-19-2007, 11:54 AM

Looks AWESOME! Great work.

Bet that will turn some heads on the roads in spain!!!

Congrats!

tc · 11-19-2007, 12:21 PM

Looks great david!

Since you are SAS'ing for reliability on your desert runs in the Sahara, I would have seriously looked into the full lfoater kit for the rear axle as part of your disc brake conversion:
http://frontrangeoffroadfab.com/nfos...100a13abc85e60

4RunnerKid · 11-19-2007, 10:22 PM

wow David... i'm blown away. that is how to do a SAS and rear susp. swap on a 4Runner. great work! glad you finally got it all done, i know how long you've wanted this.

Knuckles · 11-19-2007, 10:27 PM

wow... one of my new fav rigs.

Blizzard · 11-20-2007, 12:36 AM

I'm glad you like it.

Pics added to the 2nd post. Will update when my friend send me new ones. I was there for 2 weeks, now I'm at home again because I have to work...

David

fork · 11-20-2007, 05:04 AM

beautiful swap dude. if i could vote, this would get a 10.

jjrgr21 · 11-20-2007, 07:04 AM

great write up pics, you have one kick ass rig.

881stGenRunner · 11-20-2007, 07:21 AM

awesome job man, that thing looks great

time to update your signature!!

The Lovely Boyo · 11-20-2007, 10:28 AM

Hi David,

That is one sweeeeet rig.

Exactly what I want to do to mine. So how's about I get the kit off Trail Gear, and next Spring I get the ferry to Bilbao, pop over to Barcelona and we (OK, you) spend two weeks fitting it all onto my truck??

Sounds like a plan.

dlbrunner · 11-20-2007, 11:50 AM

muy bien!

Blizzard · 11-20-2007, 01:28 PM

Hahaha Andrew!

My truck is in Alicante, I've a friend there that is the person I trust more in the world to touch my Toy, if not I wouldn't drive 500km to reach him.

There's a lot of English people in Alicante hehe

David

The Lovely Boyo · 11-20-2007, 03:01 PM

Quote:

Originally Posted by Blizzard

Hahaha Andrew!

My truck is in Alicante,

There's a lot of English people in Alicante hehe

David

Closest I've been to Alicante is a holiday in Minorca a few years back.

I'll be visiting my twin brother in Tavira, Portugal in the spring - I'll have to detour......

Swissdrums · 11-21-2007, 03:16 PM

Congrats David!
Your 4Runner is perfect. Keep up the good work!

Blizzard · 11-26-2007, 02:32 PM

Hi!

My friend has sent me new pictures, so here they are.

Those are the rear brake caliper brackets. They're made from 10mm laser cut steel. We could have made a simplier design but we prefered to use 3 bolts to hold the bracket to the axle.

This is how it goes in the axle

The rear axle shaft plate, painted and ready

The brackets with its spacers and gussets. The caliper isn't going anywhere!

Painting them

To hold the bracket longer bolts must be installed

And this is how the bracket and brake discs are together

And with the Supra caliper in place

Front axle is ready, with rebuilt calipers, new brake pads and front driveshaft

The Trail-Gear long slip yoke. You can see how we had to machine all the outside because it was off-center.

Angle seems a bit excessive but this is with the front axle hanging. Once it rest in the ground the angle will be less.

Hub, spacer, free wheeling hub and brake caliper

Front axle. I think it will last a little...

We sacrificed the upper crossmember. We need that space for the exhaust to go over the transmission. We fabbed another crossmember that will go below the driveshaft, made to hold the two fuel tanks and also the tanks skidplates.

Have fun,

David

**UKMyers** · 11-26-2007, 03:56 PM

Awesome build up! What part of Spain are you in? I spend a lot of time on the Southern Coast in Rota.

Blizzard · 11-26-2007, 10:30 PM

I'm from Barcelona, this is the north-east of Spain. Just the opposite side hehe

You've Morocco near then.

David

AxleIke · 11-27-2007, 07:41 AM

David, you gotta get er done, and go out and get some wheeling pictures!!!!

isaac338 · 11-27-2007, 08:33 AM

dude.. simply stunning work.

Blizzard · 11-27-2007, 09:21 AM

Don't worry AxelIke, noone is more anxious to test it than me...

But I cannot drive it untill it's legalized...

David

NC-B17A · 11-27-2007, 10:05 PM

Very detailed post makes me want to sas my 92 4runner

11-19-2007, 10:27 AM	#2 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 912	This is the disc we made for the T-Case E-Brake. It has the V6 flange pattern and the 3rd Gen one. This is the intercooler we're fitting in my Toy. It's from a Mitsubishi Montero/Pajero 2.8TD The injection pump rebuilt And the injectors This is the SS piping we're using for the exhaust. It's 70mm (2.756'') inside diameter. We bought constant-radious bends too. Those are the constant radius bends for the intercooler (2'' ID) This is the Hilux tank we're using as 2nd one. A 4Runner tank would be easier to fit but this was cheap and the only one we found in that moment David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler Auto – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35's, FR&RR E-Lockers and too many things more to write... Last edited by Blizzard; 11-20-2007 at 12:47 AM.

11-19-2007, 10:47 AM	#3 (permalink)
4RocRunner92 Registered User Join Date: Apr 2005 Location: Boone, NC Posts: 1,519	why not paint over that ugly looking red? __________________ Jason A friend of the devil is a friend of mine. 1992 SR5 4RocNC Videos

11-19-2007, 11:04 AM	#4 (permalink)
Tofer Super Moderator Staff Join Date: Jul 2004 Location: Tacoma WA. Posts: 6,902	wow!!! thats a nice swap! __________________ 94 4runenr: all the good stuff....... 89 4runner: 3.0, Auto, 5.29 lockright f/r. 31x10.5 wildcountry ATs. 81 2wd pickup: 22R \| 5-sp \| long bed \|Civic SI seats \| LockRight \| Hella 500s pacific-crawlers.com For all your Trail-gear and HID lighting Solutions Needs check out yotaworks.com Online store coming soon :)

11-19-2007, 11:09 AM	#5 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 912	Hahahaha because we're leaving the black paint for the last. As we have still to make the brake lines and so... I'll add more pics in an hour or so. David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler Auto – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35's, FR&RR E-Lockers and too many things more to write...

11-19-2007, 11:54 AM	#6 (permalink)
AxleIke Contributing Member Join Date: Apr 2004 Location: Boulder, Colorado Posts: 4,887	Looks AWESOME! Great work. Bet that will turn some heads on the roads in spain!!! Congrats! __________________ 1987 Mutant 4runner\|Slightly Modified\|Lacking general build direction -Lifts and Tires look cool at the Mall, Lockers and Gears look cool on the trail. -Internet Nice Guy

11-19-2007, 12:21 PM	#7 (permalink)
tc Contributing Member Join Date: Nov 2005 Location: Longmont, CO Posts: 8,372	Looks great david! Since you are SAS'ing for reliability on your desert runs in the Sahara, I would have seriously looked into the full lfoater kit for the rear axle as part of your disc brake conversion: http://frontrangeoffroadfab.com/nfos...100a13abc85e60 __________________ Check out www.coTTORA.org to hook up with great Toyota 'wheelin' folks! Current - 93 4Runner: 3VZ 33"x10.50" no lift ARB F/R 96 Impala SS: My own personal cop car Previous - 89 2WD Pickup 22R, Fabtech "Ivan Dan" lift, 31x10.50, IASCA World Finals 4th Place Stop with the mods and get on the trail! Pix at www.4wheelingoh.shutterfly.com/action

11-19-2007, 10:22 PM	#8 (permalink)
4RunnerKid Registered User Join Date: Aug 2004 Location: Sac + SLO, CA Posts: 1,033	wow David... i'm blown away. that is how to do a SAS and rear susp. swap on a 4Runner. great work! glad you finally got it all done, i know how long you've wanted this. __________________ -Mikey- 1993 4Runner ~ TG HD/RUF front \| All Pro rear \| 37" Krawlers \| Marlin UM06s \| 12" King 2.5s \| 2" air bumps \| 12" Fox 2.0s \| Aussie front \| Lock-Right rear \| 5-speed swap \| TG 4.7s \| 5.29s \| 4xInnovations cage \| bumpers \| sliders \| t-case skid \| K&N intake \| Flowmaster 40 \| Optima red top \| clear lenses \| PIAA 1400s \| LED rock lights \| PIAA superwhites \| stereo Polygoats 4-Wheel Drive Club Poly Performance

11-19-2007, 10:27 PM	#9 (permalink)
Knuckles Registered User Join Date: Jul 2006 Location: Tulsa,OK Posts: 698	wow... one of my new fav rigs. __________________ 97 Limited 4Runner

11-20-2007, 12:36 AM	#10 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 912	I'm glad you like it. Pics added to the 2nd post. Will update when my friend send me new ones. I was there for 2 weeks, now I'm at home again because I have to work... David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler Auto – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35's, FR&RR E-Lockers and too many things more to write... Last edited by Blizzard; 11-20-2007 at 12:48 AM.

11-20-2007, 05:04 AM	#11 (permalink)
fork Registered User Join Date: Sep 2006 Location: out in the pacific Posts: 648	beautiful swap dude. if i could vote, this would get a 10.

11-20-2007, 07:04 AM	#12 (permalink)
jjrgr21 Registered User Join Date: Aug 2006 Location: Maryland Posts: 1,520	great write up pics, you have one kick ass rig. __________________ 2003 4WD TRD Tacoma 1986 4Runner

11-20-2007, 07:21 AM	#13 (permalink)
881stGenRunner Registered User Join Date: Mar 2006 Location: Newnan, GA Posts: 2,343	awesome job man, that thing looks great time to update your signature!! __________________ -Brandon 1988 4Runner SR5 4x4 V6 5 Speed Swap (R150F)~SDORI 1.5" BJ Spacers~Downey 26MM TBs~Downey 3" Springs~Downey Shackles~PC ES3000s~PC ES2000 SS~Motive Gear 5.29s~Rear Detroit~Front Lock-Rite~Yakima Load Warrior~33x12.5 Pro Comp M/Ts~Cragar 15x8 Streetlocks~Cobra 18 WXSTII~Marlin Crawler Rear~Addicted Offroad Front Bumper~4X Innovations Sliders~WabFab Bikini Kit~Optima Yellow Top~SS IFS Truss. My 4Runner and Other Stuff

11-20-2007, 10:28 AM	#14 (permalink)
The Lovely Boyo Registered User Join Date: Nov 2006 Location: South Wales, UK Posts: 39	Hi David, That is one sweeeeet rig. Exactly what I want to do to mine. So how's about I get the kit off Trail Gear, and next Spring I get the ferry to Bilbao, pop over to Barcelona and we (OK, you) spend two weeks fitting it all onto my truck?? Sounds like a plan. __________________ 1992 2nd Gen 2.4turbo diesel Hilux Surf, 2'' sus lift Procomp ES9000'S, 1.5'' body lift, 33x12.5 mud terrains Last edited by The Lovely Boyo; 11-20-2007 at 10:33 AM.

11-20-2007, 11:50 AM	#15 (permalink)
dlbrunner Contributing Member Join Date: Nov 2004 Location: phoenix Posts: 1,141	muy bien! __________________ Duncan -------------------------------------------------- Current: 95 4X4 SR5 V6, Yakima tracks/rack installed. Aisin hubs. Sonoran Steel IFS Truss. Cobra CB(finally!) Desired: 66 FJ45 shorty EX's: 89 4X4 V6 Downey'd 72 FJ40 W 350/SM465 powertrax, "Billy"

11-20-2007, 01:28 PM	#16 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 912	Hahaha Andrew! My truck is in Alicante, I've a friend there that is the person I trust more in the world to touch my Toy, if not I wouldn't drive 500km to reach him. There's a lot of English people in Alicante hehe David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler Auto – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35's, FR&RR E-Lockers and too many things more to write...

11-21-2007, 03:16 PM	#18 (permalink)
Swissdrums Registered User Join Date: Aug 2005 Location: No.Va. Posts: 361	Congrats David! Your 4Runner is perfect. Keep up the good work! __________________ 1994 Toyota 4Runner V6 Auto 4WD

11-26-2007, 02:32 PM	#19 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 912	Hi! My friend has sent me new pictures, so here they are. Those are the rear brake caliper brackets. They're made from 10mm laser cut steel. We could have made a simplier design but we prefered to use 3 bolts to hold the bracket to the axle. This is how it goes in the axle The rear axle shaft plate, painted and ready The brackets with its spacers and gussets. The caliper isn't going anywhere! Painting them To hold the bracket longer bolts must be installed And this is how the bracket and brake discs are together And with the Supra caliper in place Front axle is ready, with rebuilt calipers, new brake pads and front driveshaft The Trail-Gear long slip yoke. You can see how we had to machine all the outside because it was off-center. Angle seems a bit excessive but this is with the front axle hanging. Once it rest in the ground the angle will be less. Hub, spacer, free wheeling hub and brake caliper Front axle. I think it will last a little... We sacrificed the upper crossmember. We need that space for the exhaust to go over the transmission. We fabbed another crossmember that will go below the driveshaft, made to hold the two fuel tanks and also the tanks skidplates. Have fun, David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler Auto – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35's, FR&RR E-Lockers and too many things more to write...

11-26-2007, 10:30 PM	#21 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 912	I'm from Barcelona, this is the north-east of Spain. Just the opposite side hehe You've Morocco near then. David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler Auto – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35's, FR&RR E-Lockers and too many things more to write...

11-27-2007, 07:41 AM	#22 (permalink)
AxleIke Contributing Member Join Date: Apr 2004 Location: Boulder, Colorado Posts: 4,887	David, you gotta get er done, and go out and get some wheeling pictures!!!! __________________ 1987 Mutant 4runner\|Slightly Modified\|Lacking general build direction -Lifts and Tires look cool at the Mall, Lockers and Gears look cool on the trail. -Internet Nice Guy

11-27-2007, 08:33 AM	#23 (permalink)
isaac338 Registered User Join Date: Jul 2006 Location: Halifax, NS, Canada Posts: 849	dude.. simply stunning work. __________________ 1994 Xtracab pickup, 180,000km 1987 4Runner, 510,000km

11-27-2007, 09:21 AM	#24 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 912	Don't worry AxelIke, noone is more anxious to test it than me... But I cannot drive it untill it's legalized... David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler Auto – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35's, FR&RR E-Lockers and too many things more to write...

11-27-2007, 10:05 PM	#25 (permalink)
NC-B17A Registered User Join Date: Jan 2006 Location: Alabama Posts: 271	Very detailed post makes me want to sas my 92 4runner __________________ 90 4runner-3.0-5spd For sale lifted 2nd gen 4runner

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