My '94 4Runner SAS
11-19-2007, 07:00 AM
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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:
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
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
Last edited by Blizzard; 05-09-2008 at 01:34 PM.
11-19-2007, 09:27 AM
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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
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
Last edited by Blizzard; 11-19-2007 at 11:47 PM.
11-19-2007, 10:09 AM
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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
I'll add more pics in an hour or so.
David
11-19-2007, 11:21 AM
#7
Contributing Member
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
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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11-19-2007, 09:22 PM
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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. 
11-19-2007, 11:36 PM
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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
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
Last edited by Blizzard; 11-19-2007 at 11:48 PM.
11-20-2007, 09:28 AM
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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.
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.
Last edited by The Lovely Boyo; 11-20-2007 at 09:33 AM.
11-20-2007, 12:28 PM
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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
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
11-20-2007, 02:01 PM
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11-26-2007, 01:32 PM
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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
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
