caligula455

After looking at all the taco and 4runner conversions and looking pretty carefully under my truck, i decided to start a 4wd conversion on my truck. I'm starting with a 2000 4.7 V8 2wd Limited Access Cab and i'll end up with a more or less factory IFS 4wd setup. I have seen some SASed tundras but I think I may be the first to do a stock type conversion (please correct me if I'm wrong on that). At the same time, i'll be putting in a diff drop, putting in new 5100 adjustables in the front and 5100s in the back, re-gearing for larger tires in the future, switching to TRD front springs, new ball joints and polyurethane steering bushings which should fix all the slop in the old suspension and steering. Yes, i could have sold the truck and bought a 4wd model, but I didn't want to. I like my truck, it was a graduation gift and i plan to keep it for a long time. I could have done a SAS instead but that is big money for a tundra, more downtime, lots of cutting and an IFS setup is capable enough for me. After doing A LOT of research, I've found that the procedure is very similar to a tacoma or 4runner swap with a couple of exceptions pretty much all of which are because of the torque from the v8. There is a lot more in common with these trucks than people realize. Things that are exactly the same as tacos and 4runners: spindles front diff rear gears transfercase (i think) Things that are different: front CVs (inner different, outer the same, shaft 3" longer) transmissions (externally the same but NOT internally the same) driveshafts transmission cross member (different from 2wd tundra) And finally, the status of the parts list: spindles - 2003 tacoma w/ ADD and ABS front diff - 2001 tacoma, 4.30 gears electric ADD control rear gears - 2001 tacoma, 4.30 to match front diff CVs - new 2000-2006 tundra transmission/transfercase/crossmember - 2003 tundra front drive shaft - 2003 Tundra TRD springs - 2001 tundra That only leaves the rear drive shaft to buy but I'll get on that soon. I'm still waiting for all the parts to come in, but I'll get pictures up asap and document the hell out of the whole process.

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2000 Tundra V8 - 4wd conversion thread - pictures

caligula455

dust shields on my CVs were damaged in shipping:



ADD Diff:


everything so far, the rear gears are back on that table:

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2000 Tundra V8 - 4wd conversion thread - pictures

zlathim

Cool thread caligula! I am interested to see how this works out for you.

I have a 2000 sr5 AC 4x4. If you need pics or anything, let me know and I will do my best to help you out.

caligula455

Thanks, i've stuck my head all the 4x4 tundras i've seen parked on the street to check out how different things were mounted while i was researching the swap, but that would be much easier.

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2000 Tundra V8 - 4wd conversion thread - pictures

thebusine$$

What is the "ball park" estimate of how much the conversion is going to cost you? Specifically parts?

zlathim

I'll try to snap a few photos tonight. I'll get them on here, but maybe not until tomorrow...

caligula455

$1500 in conversion parts

$800 in upgrades/maintenance that needed to happen anyway (shocks were shot, ball joints, rear seals, O2 sensor)

$0 Labor

hopefully i can get some $ out of the parts i pull. all in all not to expensive considering all the used parts have half the miles of the rest of my truck, the drivetrain only has 15k on it!

awsome, i'll be putting up more pictures as well.

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2000 Tundra V8 - 4wd conversion thread - pictures

zlathim

Sorry caligula, I had to attend a preschool function for my son last night. I did snap a few pics, but I am thinking that they are worthless because they don't show much. I think the best thing to do is jack it up and pull the wheels (and maybe the skid plate)in order to get better pics. I'll get some this weekend and post them up.

caligula455

thanks, i didnt mean for you to have to go to all that trouble, but it would be nice to have as reference.

I'm going to pick up the transmission, transfercase and driveshafts this afternoon so I'll have some pictures to put up here tonight as well.

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2000 Tundra V8 - 4wd conversion thread - pictures

zlathim

Not big deal, It is time for a thorough visial inspection anyway. Besides, this site has helped me out a bunch, I'm just trying to give a little back.

caligula455

picked up the transmission, transfercase and both drive shafts on the way home from work. all off a 2004 with only 15,532 miles!!

here is everything:


transmission:





this F on the bell housing really threw me cause i was expecting a U, thought they had mixed it up with a v6 some how pulling the part off the shelf, but they didn't.


transfercase:




torque converter and front drive shaft


rear drive shaft


ring and pinion:

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2000 Tundra V8 - 4wd conversion thread - pictures

Corey

Very cool.
I have not seen a conversion before of this kind.

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caligula455

moved the TRD coils on to the new Bilstein 5100 adjustable shocks today and got them on the truck. it wasnt all that hard and the spring compressor didn't give me any trouble at all, did it all with a ratchet. also looked like it had never been used before so that may be why.





on to the bilstein


ready to install







the drivers side didnt go as easily, the inner fender is different and made getting to the back nut impossible. quick cut with a dremmel helped.



before/after






now it sits nice and level, a little high in the front but it will come down with the differential and axles installed.

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2000 Tundra V8 - 4wd conversion thread - pictures

zlathim

Nice work caligula. At this rate you will have your truck fully converted before my slacker a$$ gets any pics for you.

I hope to get some today. If not, just consider me a flake...

crolison

looking good, good to know more toyota stuff is easily converted to 4x4

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97 4runner, 2.7 5speed 4wd, 5.29, 33 horns
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caligula455

i forgot that i needed the dust boots from the stock shocks on the new bilsteins so i took the stock ones apart this morning. the top nut was so rusted i could only get it off far enough to get a hack saw blade in. now to tear the front half of the truck down again to put the boots on . . .

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2000 Tundra V8 - 4wd conversion thread - pictures

zlathim

caligula- I sent you a pm.

caligula455

boots went on in about 2 hours.

i'm stuck waiting on spindles, ball joints and CV dust boots then i'll be ready to finish off the front end. next is re-gearing the rear diff. i have some electrics to sort out before the tranny is ready to go in and i'd like to test the drive train controls on the bench before installing. the next big hurdle is finding a 4wd ecu and pigtail.

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2000 Tundra V8 - 4wd conversion thread - pictures

caligula455

I recieved the spindles last night so except for a front diff drain plug i'm all set to put the front end on this weekend. The dust shields needed a bit of unbending, but i'm going to swap on the tundra shields to match the tundra calipers anyway so not a big deal.

The bearings and hub are in great shape and a test fit confirmed the tundra CVs fit like they should. i'll get some pics of the prep work on the spindles up tonight.

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2000 Tundra V8 - 4wd conversion thread - pictures

zlathim

I'm looking forward to the update.

caligula455

a little bit of progress to post, but not much. the long weekend was not as productive as i was hoping for.

I can't get the ball joints pressed in with the Autozone press. it wont line up even because the screw threads hit the upright part of the spindle and the ball joint starts going in crooked. i tried it upside down, but am having trouble clearing the threaded end of the joint. i have another idea to try, but it will have to wait for tonight.

next weekend is my girlfriend's birthday, so not going to make a lot of progress then either. if i can't get the ball joints in myself i'm going to take it to a shop to press in for me some time this week

other progress:

• bought drain plug for front diff
• swaped transmission with junkyard
• installed new dust shields on CV shafts

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2000 Tundra V8 - 4wd conversion thread - pictures

caligula455

Finally some progress!

I found a pipe fitting about the right size and cut it down to length with a hack saw.

This let me get the ball joints started as the tubes that came with the press were too short on their own and two deep stacked together to fit. The ball joints started going in a little crooked, but with a little pressure they both popped in straight.




Once they were pressed in a bit, I switched to the tubes from the press stacked on each other. The adapter in the middle was for the non-turning side of the press. I did this to make sure it seated level.



Then all you have to do is put in the retaining clip




and put on the boot and spring. The castle nut and cotter pin are on there just so I don't lose them.



Next up, swapping the spindles and installing the front end, hopefully this weekend.

Anyone know if the 4xinnovations transfercase mount will bolt up to the chain drive t-case? I know its not designed for tacomas and it's too short but the bolt spacing/angle on top looks right.

I have an idea for using the 2wd cross member and a clocking adapter but i need a really short mount like that one.

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2000 Tundra V8 - 4wd conversion thread - pictures

bigtrucknwheels

very nice work man, I am glad to see someone do a swap like this. you're a brave soul, this is uncharted territory to my knowledge. haha.

excellent though, and I am subscribed!

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'97 4Runner SR5 V6. 4wd/V6/5spd. Factory rear locker, 2" OME suspension lift, 265/75-R16 BF Goodrich A/T KO's, Gray (in my case Blue/Red) wire mod.

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caligula455

no real progress over the weekend, but i did manage to spend some more money. I also dug into the wiring diagrams from several years of tacoma and tundra and figured out exaclty what type of connections i have on the transfercase and ADD actuator (there are several different control styles, all using the same connector.

From amsoil:

• SEVERE GEAR 75W-140 Synthetic EP Lubricant
• Synthetic Manual Transmission and Transaxle Gear Lube (75W-90) API GL-4
• Synthetic Universal Automatic Transmission Fluid

From Toyota:

• 4wd transmission crossmember
• electrical connectors
• "4wd" badge for the tailgate

From Inchworm:

• used tacoma VSS - 30 tooth

Still need to buy:

• 4wd transmission mount
• transfercase controller
• misc electrical wiring, heat shrink, split loom, etc.
• good shop vise to hold the carrier during the re-gear

I found a transfercase controller from a junkyard with the pigtail attatched that they said was for a 2004 tundra for $75 but it was for a manually shifted transfer case, not the electrically shifted that i have, at least as far as i could tell from the FSM. It had one connector, and the one i'm looking for has two.

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2000 Tundra V8 - 4wd conversion thread - pictures

caligula455

all the parts to install today



the front diff mounts in the stock 2wd #1 crossmember



diff being jacked up - big thanks to my girlfriend for working the jack while i kept the diff balanced. went right in to place like it belonged there.



diff all mounted with drop spacers - view from the back



Calipers removed and hung out of the way and ABS sensor and brackets removed



I for the life of me could not get the upper ball joint and tie rod end off. hit them with a deadblow hammer for an hour and got nowhere. finally went to autozone and got both sizes of tie rod pullers. the small one worked for the tie rods



still cant get the upper ball joints loose. I tried hitting the ball joint, the UCA, the spindle, nothing worked. i literally cut the end off my deadblow hammer trying to get them loose.



off to autozone again tomorrow to get a gear puller to work on the upper ball joint. I have to get the new spindles on so i can install the drive shafts and get oil in the front diff.

i'll post more progress tomorrow.

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2000 Tundra V8 - 4wd conversion thread - pictures