Now that my 4Runner seems to finally be working properly, I want to start improving it for off-roading. For reference, it's a 1994 SR5 V6 4x4 5MT with P225/75R15 tires.

I've got a few questions:

1. Is it true that 33x10.5" tires will fit without rubbing, but 33x12.5" ones won't? In what off-road conditions would the difference between 10.5" wide tires and 12.5" ones be important?

2. This thing kinda struggles to keep up with freeway traffic or drive up steep hills as-is. Even if 33s do fit, will I hate them without re-gearing?

3. Looking at the owner's manual, the fuel tank and spare tire lowering mechanism are different between models equipped with P225/75R15 and 31x10.5R15LT tires. Will I have to swap the spare tire carrier from one that came with 31's to have a 31x10.5" spare? What's the largest-size spare that will fit (either as-is or with swapping to other factory parts, but without modification beyond that)?

4. I'm going to be adding some extra lights now, and maybe other stuff (winch etc.) eventually. Are there any OEM-looking switches available that would fit in the existing blank spots in the dash/center console (such as the one next to the clutch start cancel button or the squares that currently have coin holder inserts)? Otherwise, is there an aftermarket switch panel that integrates nicely (i.e., without cutting the dash)?

 

You can use this to compare tire sizes - https://tiresize.com/comparison/

 

As far as wheel size goes, my 31x10.5s rubbed on my 93 pickup at stock height if I really crossed it up. I now have a 6" lift with 33x12.5s and they get CLOSE when I'm fully "flexed". I have the 3.4 in my truck, and the 33's make it feel like a 3.0, so if your rig is already struggling on the highway I would bet you are going to hate it with 33's on it.
But hey, it'll look cool.

 

I will second moto on the hatred I have a 22re, when I got the truck it had the stock tire size, put 31s on it and pulling out of the tire shop parking lot I instantly hated my face, re geared a week later. You will 100% hate it without re gearing

This switch fits the square blanks from Toyota:




I’m not familiar with the spare as I have a pickup and I’m sure the spare configuration is not the same, but a 31 fits fine but barely clears my hitch.

 

Hmm... I think I'll probably go for the 31s then.

Did the 4Runners that came with 31s stock also have a different diff ratio than mine does?

Some more unrelated questions:

1. I'm thinking of adding a roof rack. My 4Runner didn't come with factory rails and therefore has zero roof penetrations except for the high mount rear tail light, and I'd kinda like to keep it that way to avoid future leaks. I'd like decent capacity for mounting a light bar and carrying stuff like bikes, spare tires or misc. gear, but not anything crazy like for a rooftop tent. Are there feasible clamp-on rack crossbars, or should I bite the bullet and drill holes? And if I should do the latter, should I install OEM side rails or do something aftermarket/custom?

2. My 4Runner is missing the rear spoiler/wind deflector. Would it be worthwhile to get one for the purpose of minimizing exhaust gasses back-flowing into the passenger compartment with the rear window down?

 

According to this link, 31s with a M/T used 4:56s while 31s with an A/T used 4:88s . With 28" tires, it was 4:10s/4:30s.

https://www.4crawler.com/4x4/4R_TechInfo.shtml

 

I have 33x10.5 tires on my '94 and I like them. No rubbing. Mine has the 4.56 gearing. I would not go to 33x12.5's - I think that's too much tire for a '94 if you're doing much highway driving. The 12.5's will only be of help in very soft mud, sand, or snow conditions. For rocks and packed snow, the 10.5's will be as good or better. For sure you'll want to regear if you currently have 4.10's and want to upsize your tires.

As far as power goes, make sure you keep the rpm's well above 3000 when going uphill or accelerating. This power band on this engine is between 3000 and 4500 rpm, and you'll never hurt it by running it there.