YotaTech Forums

Go Back   YotaTech Forums > Toyota Forums Available > Off Road Tech, Fab Shop, Solid Axle Swaps, Tool Time, & Engine Swaps > Solid Axle Swaps, All Years
Home Photo Gallery Register Search Today's Posts Mark Forums Read Tread Lightly Wiki

Reply
 
Thread Tools Search this Thread Display Modes
Old 11-19-2007, 08:00 AM   #1 (permalink)
Registered User
 
Blizzard's Avatar
 
Join Date: Jul 2004
Location: Barcelona (Spain)
Posts: 871
Send a message via MSN to Blizzard
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
__________________
'94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

Last edited by Blizzard : 05-09-2008 at 02:34 PM.
Blizzard is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Sponsored Links
To remove this ad, register today!

Old 11-19-2007, 10:27 AM   #2 (permalink)
Registered User
 
Blizzard's Avatar
 
Join Date: Jul 2004
Location: Barcelona (Spain)
Posts: 871
Send a message via MSN to Blizzard
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 – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

Last edited by Blizzard : 11-20-2007 at 12:47 AM.
Blizzard is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-19-2007, 10:47 AM   #3 (permalink)
Registered User
 
4RocRunner92's Avatar
 
Join Date: Apr 2005
Location: Boone, NC
Posts: 1,542
Send a message via AIM to 4RocRunner92 Send a message via MSN to 4RocRunner92 Send a message via Skype™ to 4RocRunner92
why not paint over that ugly looking red?
__________________
Jason
A friend of the devil is a friend of mine.
1992 SR5
4RocNC

Videos
4RocRunner92 is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-19-2007, 11:04 AM   #4 (permalink)
Contributing Member
 
Tofer's Avatar
 
Join Date: Jul 2004
Location: Tacoma WA.
Posts: 5,713
Send a message via ICQ to Tofer Send a message via AIM to Tofer Send a message via MSN to Tofer Send a message via Yahoo to Tofer
wow!!! thats a nice swap!
__________________
3genRunner: including parts from 3 generations of 4runners, '92 pickup, '80something Land Cruiser, Chevy truck, Ford sedan
89 4runner: Project DD. 3.0, needs a new tranny
81 2wd pickup: 22R | 5-sp | long bed | quad hauler, leaks oil but gets 26mpg

91 Honda Prelude: the Daily Driver


WA, OR or CA wheeler?? Check out pacific-crawlers.com and check out yotaworks.com
Tofer is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-19-2007, 11:09 AM   #5 (permalink)
Registered User
 
Blizzard's Avatar
 
Join Date: Jul 2004
Location: Barcelona (Spain)
Posts: 871
Send a message via MSN to Blizzard
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 – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...
Blizzard is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-19-2007, 11:54 AM   #6 (permalink)
Contributing Member
 
AxleIke's Avatar
 
Join Date: Apr 2004
Location: Boulder, Colorado
Posts: 4,536
Looks AWESOME! Great work.

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

Congrats!
__________________
IFS SAS

My mods aren't bling enough for the signature line.

-All Terrains are for when you know how to drive.
AxleIke is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-19-2007, 12:21 PM   #7 (permalink)
tc
Contributing Member
 
tc's Avatar
 
Join Date: Nov 2005
Location: Longmont, CO
Posts: 6,813
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
tc is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-19-2007, 10:22 PM   #8 (permalink)
Registered User
 
4RunnerKid's Avatar
 
Join Date: Aug 2004
Location: Sac + SLO, CA
Posts: 1,002
Send a message via AIM to 4RunnerKid Send a message via MSN to 4RunnerKid Send a message via Yahoo to 4RunnerKid
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 5" HD/RUF front | All Pro ~4" rear | 37" Krawlers | bomb-proof front housing | Marlin UM06s | 12" Fox 2.0s | Aussie front | Lock-Right rear | 5-speed swap | TG 4.7s | 5.29s | bumpers | sliders | t-case skid | K&N intake | Flowmaster 40 | Optima red top | clear lenses | PIAA 1400s | KCs | LED rock lights | Midland CB | Firestik 4' antenna | PIAA superwhites | stereo


Polygoats 4-Wheel Drive Club -> check it yo
4RunnerKid is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-19-2007, 10:27 PM   #9 (permalink)
Registered User
 
Knuckles's Avatar
 
Join Date: Jul 2006
Location: Tulsa,OK
Posts: 698
Send a message via AIM to Knuckles Send a message via Yahoo to Knuckles
wow... one of my new fav rigs.
__________________
97 Limited 4Runner
Knuckles is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 12:36 AM   #10 (permalink)
Registered User
 
Blizzard's Avatar
 
Join Date: Jul 2004
Location: Barcelona (Spain)
Posts: 871
Send a message via MSN to Blizzard
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 – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

Last edited by Blizzard : 11-20-2007 at 12:48 AM.
Blizzard is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 05:04 AM   #11 (permalink)
Registered User
 
fork's Avatar
 
Join Date: Sep 2006
Location: out in the pacific
Posts: 597
Send a message via AIM to fork
beautiful swap dude. if i could vote, this would get a 10.
fork is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 07:04 AM   #12 (permalink)
Registered User
 
jjrgr21's Avatar
 
Join Date: Aug 2006
Location: Maryland
Posts: 1,414
great write up pics, you have one kick ass rig.
__________________
2003 4WD TRD Tacoma
1986 4Runner
jjrgr21 is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 07:21 AM   #13 (permalink)
Registered User
 
881stGenRunner's Avatar
 
Join Date: Mar 2006
Location: Newnan, GA
Posts: 2,084
awesome job man, that thing looks great

time to update your signature!!
__________________
-Brandon
1988 4Runner SR5 4x4 V6 5 Speed Swap 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~33x12.5R15 Yoko Geolander M/Ts~Cragar 15x8 Streetlocks~Cobra 18 WXSTII~3' Firestik II~Marlin Crawler rear~Custom Front~4X Innovations Sliders~WabFab Bikini Kit~Optima Yellow Top~SS IFS Truss.
My 4Runner and Other Stuff
881stGenRunner is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 10:28 AM   #14 (permalink)
Registered User
 
The Lovely Boyo's Avatar
 
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.
The Lovely Boyo is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 11:50 AM   #15 (permalink)
Contributing Member
 
dlbrunner's Avatar
 
Join Date: Nov 2004
Location: phoenix
Posts: 1,118
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"
dlbrunner is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 01:28 PM   #16 (permalink)
Registered User
 
Blizzard's Avatar
 
Join Date: Jul 2004
Location: Barcelona (Spain)
Posts: 871
Send a message via MSN to Blizzard
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 – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...
Blizzard is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 11-20-2007, 03:01 PM   #17 (permalink)
Registered User
 
The Lovely Boyo's Avatar
 
Join Date: Nov 2006
Location: South Wales, UK
Posts: 39
Quote:
Originally Posted by Blizzard