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Old 11-19-2007, 08:00 AM   #1 (permalink)
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My '94 4Runner build-up (SAS, E-Locker, Intercooler, rear discs, dual tanks & more)

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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'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...

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Old 11-19-2007, 10:27 AM   #2 (permalink)
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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
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'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.
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Old 11-19-2007, 10:47 AM   #3 (permalink)
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why not paint over that ugly looking red?
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Old 11-19-2007, 11:04 AM   #4 (permalink)
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wow!!! thats a nice swap!
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Old 11-19-2007, 11:09 AM   #5 (permalink)
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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
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Old 11-19-2007, 11:54 AM   #6 (permalink)
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Looks AWESOME! Great work.

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

Congrats!
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Old 11-19-2007, 12:21 PM   #7 (permalink)
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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
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Stop with the mods and get on the trail!

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Old 11-19-2007, 10:22 PM   #8 (permalink)
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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.
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Old 11-19-2007, 10:27 PM   #9 (permalink)
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wow... one of my new fav rigs.
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Old 11-20-2007, 12:36 AM   #10 (permalink)
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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
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Old 11-20-2007, 05:04 AM   #11 (permalink)
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beautiful swap dude. if i could vote, this would get a 10.
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Old 11-20-2007, 07:04 AM   #12 (permalink)
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great write up pics, you have one kick ass rig.
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Old 11-20-2007, 07:21 AM   #13 (permalink)
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awesome job man, that thing looks great

time to update your signature!!
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Old 11-20-2007, 10:28 AM   #14 (permalink)
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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.
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Old 11-20-2007, 11:50 AM   #15 (permalink)
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muy bien!
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Old 11-20-2007, 01:28 PM   #16 (permalink)
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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
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Old 11-20-2007, 03:01 PM   #17 (permalink)
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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......
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Old 11-21-2007, 03:16 PM   #18 (permalink)
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Congrats David!
Your 4Runner is perfect. Keep up the good work!
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Old 11-26-2007, 02:32 PM   #19 (permalink)
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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
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Old 11-26-2007, 03:56 PM   #20 (permalink)
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Awesome build up! What part of Spain are you in? I spend a lot of time on the Southern Coast in Rota.
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Old 11-26-2007, 10:30 PM   #21 (permalink)
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I'm from Barcelona, this is the north-east of Spain. Just the opposite side hehe

You've Morocco near then.

David
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Old 11-27-2007, 07:41 AM   #22 (permalink)
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David, you gotta get er done, and go out and get some wheeling pictures!!!!
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Old 11-27-2007, 08:33 AM   #23 (permalink)
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dude.. simply stunning work.
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Old 11-27-2007, 09:21 AM   #24 (permalink)
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Don't worry AxelIke, noone is more anxious to test it than me...

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

David
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Old 11-27-2007, 10:05 PM   #25 (permalink)
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Very detailed post makes me want to sas my 92 4runner
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