traxman25

Cadman, I got your email but you need to white list me so I can reply. Thanks!

__________________

cadman

The ORS kit has a length of 1/4" fuel hose that you run along the firewall and back to the stock 3.0 hard line. I bent the hard line up the firewall, installed a rivet nut, and reused the clamp that held it on the apron.





For the fuel line, I removed the bolt and rotated the entire line so it was now facing the opposite direction. I replaced the bolt with new gaskets, positioned it, then carefully torqued the bolt. To help support the fuel line I bought a 3/16" thick x 12" long 1018 bar and cut, bent, drilled and tapped it and bolted it to an open M8 hole on the side of the head. I reused the clamp from the hard line to secure the fuel line to the support.





Finally, I hooked it up with the ORS adapter and clamped it to the skirt.

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

cadman

I bought the 1" body lift from 4Crawler. I was never a fan of body lifts, but before the 3.4 swap I was going to either drop in a reman 3.0 or rebuild the engine and I bought Downey headers for it in the meantime. After hearing stories about the tight fit to the passenger side floorbard and finally seeing pictures of how close the fuel lines get to the headers, I decided to get the lift. I also got the bumper and radiator brackets.

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

fillsrunner4

Hey Cadman I was wondering why you chose that name Cadman? The reason I ask is because thats was my great great grandfathers name and now my middle name.

__________________

94' toyota 4runner (Many a change!) purchased bone stock, NOW... SAS, 37x14" Iroks, Rear Leafs, 5.29's , Air locked front, Welded rear, 4.3L, Chevy V6 , 5spd swapped, dual T/C's MC10R10, flatbelly with custom skids, sliders, and so much more.

Might as well start reading this if ya want know more
Fillsrunner4 3.4crawler Build Thread
Fillsrunner4.3 crawler (Part Two) build thread

cadman

I'm jealous of all you guys that are already driving your vehicles. I wish I didn't waste so much time and money on the 3.0 and just went ahead with the 3.4 swap.

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

fillsrunner4

Dont be too jealous as it took me about 2 years to get mine to this point and a total of about 5 years or so in the making. Ive still got plenty of work to do and im sure ill have alot more time I wish mine was on the trail rather than being worked on.

It takes time but it will be worth it

Keep it up it looks clean as hell

__________________

94' toyota 4runner (Many a change!) purchased bone stock, NOW... SAS, 37x14" Iroks, Rear Leafs, 5.29's , Air locked front, Welded rear, 4.3L, Chevy V6 , 5spd swapped, dual T/C's MC10R10, flatbelly with custom skids, sliders, and so much more.

Might as well start reading this if ya want know more
Fillsrunner4 3.4crawler Build Thread
Fillsrunner4.3 crawler (Part Two) build thread

cadman

I'm a CAD designer and CAD/CAM programmer. This is the first and only user name I've ever had, going back to around '97/'98.

So it's also a real name? You and your great, great grandfather definitely have a unique name. Do you know any history about it?

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

fillsrunner4

Its Norwegian and thats about all I really know about it It definetly is not a highly used name although Im reminded of it after every time I see one of those cement trucks.

Its cool to have such a unique middle and last name (Stokke pronounced Sto-key) Not many people have either name.

Thats cool your a CAD designer I wish I was better with that stuff as it could come in real handy. I took a class on it in high shcool but those years sucked so I didnt really learn a whole lot from it.

Keep up the work on yours and cant wait to see it finished

__________________

94' toyota 4runner (Many a change!) purchased bone stock, NOW... SAS, 37x14" Iroks, Rear Leafs, 5.29's , Air locked front, Welded rear, 4.3L, Chevy V6 , 5spd swapped, dual T/C's MC10R10, flatbelly with custom skids, sliders, and so much more.

Might as well start reading this if ya want know more
Fillsrunner4 3.4crawler Build Thread
Fillsrunner4.3 crawler (Part Two) build thread

cadman

The bellows on the engine harness are now sealed and ready. At first I used a urethane adhesive, but it turned out it wasn't flexible enough and peeled from the rubber where I joined the two bellows. I removed the urethane and used black silicone sealer instead. I flexs with the rubber, not that there will ever be that much movement, but in the interest of longevity thats what you want. I thought I could do a better job of applying the sealer cosmetically, but it doesn't look all that bad.





The upper cable is the starter trigger wire and the lower goes to the transfer case switch. Besides sealing where the cover passes through the grommet, I stuck the sealer nozzle into the covers and filled them up where the wires also pass through the grommet. The transfer case cable will head downwards so water won't migrate along it towards the firewall. I'll loop the starter wire downwards before routing it up to the top of the firewall and towards the driver side. I'll also use the 3.4 harness retainer to keep the bellows from rubbing on the fender skirt.






The 3.4 & 3.0 alternator cables need to be spliced together. Instead of cutting and soldering or crimping them, I just bolted them together and wrapped them with self vulcanizing tape. This tape is amazing. I had to cut through a previous splice I made and I had about 4 wraps of this tape at the splice. After curing, it was a solid piece of rubber, no layers of tape. Neat stuff, but a little tricky to use because you have to stretch it about 50% of it's length while you use it.

Anyways, If I need to disconnect here for some reason all I have to do is cut off the rubber at the connection.

I need to splice the 3.0 alternator wires to the 3.4 alternator wires at the battery harness and splice the starter trigger wire from the ORS harness at this point too. I don't have any 4 pin male connectors that will work with the connector on the battery harness, or any other 4 pin matching male & female connectors, so I'll start looking through some industrial electrical catalogs and see what I can find. I don't want to just solder the wires together.

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

mt_goat

Now that you mention it one of my isolators looked like that too. Wonder if I should worry about that.

Great work! The shifter came out perfect.

My tranny dip stick was hitting there too, but I bent it out of the way. My kick down cable still hits the steering shaft some though. Not too bad.

__________________
Dale

"America is in a hole and it's getting deeper every day. We import 70% of our oil at a cost of $700 billion a year - four times the annual cost of the Iraq war." T. Boone Pickens
Check out the plan: http://www.pickensplan.com/index.php and http://www.cngnow.com/EN-US/Pages/default.aspx

cadman

Both of the isolators on my wife's 4Runner look like that too. There haven't been any issues with them but the 4Runner sees little offroad use and is pretty much just a DD. The isolators on my 3.0 however, were right on center. I'm going to put some mileage on the spacer I make before I have my cross member built to make sure the engine and tranny are straight and there are no drive line issues.

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

RobG

Great Thread! Really Clean install.

Curious about where you got the doner 3.4. price, mileage, extra parts...

__________________
'93 4runner 4WD/V6/5spd

yotasavg

inspiring thread! thanks for sharing

__________________
-Andrew

cadman

This is the engine I bought:

http://www.yotatech.com/f107/96-4run...engine-100260/

I picked it up WITH the tranny, torque converter and transfer case for $1200 and everything was in pretty good shape as advertised. I did rebuild the engine and critcal dimensions (cam, crank, bore) were all in print with no weird wear patterns. Additional parts were sourced from my local mini truck yard (Ferman's, Santa Ana), Toyota of Dallas, and a guy from Desert Island, Maine, doing a diesel conversion. I also have the full auto kit from ORS.

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

fillsrunner4

Thats an expensive oil cap Very clean!

__________________

94' toyota 4runner (Many a change!) purchased bone stock, NOW... SAS, 37x14" Iroks, Rear Leafs, 5.29's , Air locked front, Welded rear, 4.3L, Chevy V6 , 5spd swapped, dual T/C's MC10R10, flatbelly with custom skids, sliders, and so much more.

Might as well start reading this if ya want know more
Fillsrunner4 3.4crawler Build Thread
Fillsrunner4.3 crawler (Part Two) build thread

cadman

I picked one up at Ferman's in Santa Ana. A little on the dirty and greasy side, the castings appeared to be in one piece with no visible cracks or any thing broken. Still had the mount attached to it. It came off a 1985 4Runner and is a top shifting version.





The first step was to clean the cases then tear it down and rebuild it. I bought the Major Rebuild Kit from Trail Gear because it was a little cheaper than the kit from Marlin. Looking back, I should have bought it from Marlin instead. When I started to reassemble the tc, I came across problem #1:

one of the gaskets is cut incorrectly.










Taking an Exacto knife, I elongated some of the holes and with the gasket mounted on the two dowel pins, there was just enough room, and I mean barely, to get all of the screws through without distorting the gasket. There was a small hump at one area that I could feel as I assembled the case, but I used the orange Toyota FIPG that came with the ORS kit and it should be leak proof.

Problem #2 was Trail Gear left out the flange nuts. I sent them an e-mail and the nuts came two days later. Very good service, but this should not happen.

Problem#3 - one of the large bearings is missing it's retainer ring.

Problem #4 was the absence of one bearing. Looking at the picture of the kit on their website, I don't see it, but they say the kit contains all bearings. By this time I'm not happy with them and I need to go to the Toyota dealer to order shims (which do not come with the kit) so I'll just get the bearing & ring there. At least I know I'll get them. A few of the bearings have no ID on them at all, no sizes or manufacture names. Will these hold up? I guess I'll find out as I put on off-road miles. My previous experience with Trail Gear has been good, but I give them a thumbs down on this project.


From Marlin I get the 23 spline input gear, which comes complete with bearing and covered with cosmoline, or something like it, and two new flanges. The bolt pattern on the U-joints is slightly different than whats one the existing flanges, so this is an excuse to get new ones. Thumbs up for Marlin.


Problem. No way to get the M8 screw in. The 4WD indicator switch blocks the hole in the adapter plate, so I drill, tap, and install a thread insert for a M6 screw. I have to use a shcs to bolt from the opposite side, a hex head won't fit here. I did not drill out the threads from the case, it was not needed.








Finished. I bought the new flanges after this picture was taken. You can see them in the tranny install pics. I also needed a 4WD indicator switch with 2 leads. The one that was on the tc only had one. I got a 2 wire switch from Marlin.



The next time I have the transmission out, I'm going to drill a hole for a breather tube and connect to the breather tube on the extension housing. As I understand it, these gear driven transfer cases breath out of the shifter opening.

__________________
"If it's worth doing, it's worth doing right" my father-in-law

1989 4wd Xtra Cab
3.4L V6
A340F auto, '85 4Runner gear driven transfer case
Alpine CDA 9857
3" Downey rear leafs, 1.5" BJ spacers
Doetsch Tech shocks front & rear

Next projects (in no particular order):
TRD SC
trail armor, bumpers
LT suspension

RobG

Thanks for the engine info, I'm starting to keep an eye out for a good 3.4 deal just trying to get some info so I know a good if I come across one.

Your work is really clean, and great pics and description. Thanks.

Is that 8mm to 6mm change common or is that something you came up with?

Where are you located in OC?

__________________
'93 4runner 4WD/V6/5spd