The SAS has begun Ladies and Gents….

The car, 1986 Toyota 4Runner 4x4 22r EFI, IFS w/ 38.5 Super Swapper TSL, ProComp IFS 4” lift (front & rear), 3” body lift by “??”, 5.29 gears (front & rear).

Just Install:

Python Alarm hidden unit, w/ 3 sirens hidden, 3 hidden backup battery, tilt sensor, shock sensor, glass sensor, power door locks, hood sensor, trunk sensor, and 2 kill switch. Looking for a removable quick release steering wheel with lock and key.

Up Coming installs:

Solid Axle Donor: 1985 Toyota PU rear end total damage, $300.00, local pick up.

Lift Kit: Trail Gear 5” Lift $1200.00

In Search of: Yukon Lockers, Aussie Lockers, 1x 5.29 Gears = USED or if NO luck, Brand Spanking New....

Well after a long consideration, I decided to go with solids. What wrong could that be? This is my weekend warrior. I don’t drive this daily and use mainly for hunting, fishing, camping, and wheeling part time. It’s one of the cleanest 4Runner I ever had. The project started 2 weeks ago but finally had some time to prep the axle. Doing this swap solo and would be very educational to learn how everything goes. So here it goes….

The Ride:

http://www.flickr.com/photos/16968889@N06/5573190880/http://www.flickr.com/photos/16968889@N06/5573190880/ by http://www.flickr.com/people/16968889@N06/, on Flickr

The Clean Clean Axle:

http://www.flickr.com/photos/16968889@N06/5573192126/http://www.flickr.com/photos/16968889@N06/5573192126/ by http://www.flickr.com/people/16968889@N06/, on Flickr

Check this ProComp Lift out, it was pretty usefull until the light turn on my head about SAS... Now its gotta go, perhaps a new home...BTW, it looked PIMPED with this lift...

http://www.flickr.com/photos/16968889@N06/5572601683/http://www.flickr.com/photos/16968889@N06/5572601683/ by http://www.flickr.com/people/16968889@N06/, on Flickr

Pulled everything I can off the axle to start the rebuild process. Lets say it was very greasy and messy. Heres a picture of it, with axles out, brakes, and all the other bolt on. I know should of taken the 3rd out too but, thought if i cant find some gears or lockers before my install this week i can always run open till then. And plus no rush for the Weekend Warrior....

http://www.flickr.com/photos/16968889@N06/5573192550/http://www.flickr.com/photos/16968889@N06/5573192550/ by http://www.flickr.com/people/16968889@N06/, on Flickr

Cutting these parts off the Solids where a pain the ass without the right tool, I end out settling with a grinder. It took me some time but hey it clean up pretty well...

http://www.flickr.com/photos/16968889@N06/5573193050/http://www.flickr.com/photos/16968889@N06/5573193050/ by http://www.flickr.com/people/16968889@N06/, on Flickr

Finally cut those pieces of crap off, and looked like it wasnt there. Grinder was "DADDY" with shaping it nicely with the axle...

http://www.flickr.com/photos/16968889@N06/5572604093/http://www.flickr.com/photos/16968889@N06/5572604093/ by http://www.flickr.com/people/16968889@N06/, on Flickr

Thought I try fitting the top gussett on and making some adjustments before welding it on. Damn this looks so sexy already, I can imagine it under my rig..

http://www.flickr.com/photos/16968889@N06/5573194766/http://www.flickr.com/photos/16968889@N06/5573194766/ by http://www.flickr.com/people/16968889@N06/, on Flickr

http://www.flickr.com/photos/16968889@N06/5573195430/http://www.flickr.com/photos/16968889@N06/5573195430/ by http://www.flickr.com/people/16968889@N06/, on Flickr

This is were a good welder comes in handy.. My popcorn welder happens to go out today at this moment. Im usually really good with these popcorn welder and decide to give another 30 mins before giving up. But just in 5 mins I threw in the towel. Picked up my boys Miller mig welder and did the job, it was so clean, I didnt even clean it with a grinder...

http://www.flickr.com/photos/16968889@N06/5572606045/http://www.flickr.com/photos/16968889@N06/5572606045/ by http://www.flickr.com/people/16968889@N06/, on Flickr

http://www.flickr.com/photos/16968889@N06/5573196314/http://www.flickr.com/photos/16968889@N06/5573196314/ by http://www.flickr.com/people/16968889@N06/, on Flickr

After finishing welding the gussett decide to take it for a bath. My boy who had a pressure washer was out of town on business. That bad boy is about 2000 PSI and basically clean my black algae pool to everything it comes in contact with... Too bad I had to do it the hard way... First started off with engine gunk spray, flat head screw driver, and a wire brush. After many attemps got some dish washing soap and washed it down. Did a little sanding on the gussett to make sure paint stays... SO FRESH AND SO CLEAN....

http://www.flickr.com/photos/16968889@N06/5573196728/http://www.flickr.com/photos/16968889@N06/5573196728/ by http://www.flickr.com/people/16968889@N06/, on Flickr

With Bilateral Carpal Tunnel, got this heavy bad boy in the garage all by myself to tape the outter housing and the 3rd.

http://www.flickr.com/photos/16968889@N06/5572607223/http://www.flickr.com/photos/16968889@N06/5572607223/ by http://www.flickr.com/people/16968889@N06/, on Flickr

Was really debating about that 3rd being painted, but couldnt help it, i started paint... Also debating about primer paint, but i guess the surface is ruff enough and paint would hold pretty darn good.......2 coats of paint is what she got....

http://www.flickr.com/photos/16968889@N06/5572608889/http://www.flickr.com/photos/16968889@N06/5572608889/ by http://www.flickr.com/people/16968889@N06/, on Flickr



Well as of today 03/29/2011 7:48pm Cali Time Zone, this is how it sits... More to come tomorrow or the next with another 2 coats of paint total 4 coats and knuckle clean and painted... Will keep you folks updated...

 

You going to box in the steering stops?

 

Nice!!

 

Not sure what you mean....Like I said this will educational so please do explain...

 

DAYUMMMMMMMMM! That is one SICK RIG, TYES! Can't wait to see you flex'n up the trails..... or just locally on some logs for now, whatever, lol! VERY NICE!

 

the > that are on the front and back of the axle. it it limits the steering. they are open from the factory but people box them in to keep them from getting crushed and deforming with larger tires hitting rocks.

 

Thank you for encouraging.... my IFS cant flex for *bananas*...one of the many reasons why im on this journey. Flexing is on my 1st thing to do...heheheh

 

OH, those little suckers huh... They kind of have their reasons on staying on the axle.. I personally dont think it would make any major effects, since its the knuckle that will be tapping into that.. I'll try it out with these BIG OL Tires and if worst case, I'll snipp them off...

 

You need them there.. Of course..
They are notorious for caving in and crushing with any hard wheeling. When I said box them in, I mean reinforcing them on the top and bottom with plate steel. IE. Box them in.
If they crush in you will over extend the steering which could lead to a broken birfield.

 

Shiny!

:wabbit2:

 

Now that you mention it, just took a look last night and did saw the passenger side a little cave in.. It the direct me to look closely to the birfield housing and notice markings on the inner side... Luckly Marlin Crawler and Trail Gear is 6 miles away, I'm pretty sure they have a fix... Thanks dude you just saved me a birfield... =)

 

subscribed....good lookin rig

 

Ok my axle seals wont come out... Any ideas????

 

BTW, is this seal all rubber or is it a combo of a metal ring and rubber, cause i was only able to remove the rubber...

 

Hit them with your purse.

Or use a seal puller.

Press fit metal ring OD rubber ID seal.

Should be some in your knuckle service kit.

:wabbit2:

 

Glad I could help. Good luck with it.
Can't wait to cut my IFS off either.

 

aint that how it is for all of us haha

 

Heres another update on the progress. Did a lot of work today and got a lot done. Could of did more but hell, that axle seal was just big pain…

Went to Trail Gear this morning and picked some steering stops made from billet… Looks pretty darn cool but needs some work to make it fit. Seems to be a little too long and won’t fit… This where that grinder comes in play… Didn’t get the chance to work on that since priority was to get the axle completely install and ready for install…



Also stop by at Marlin Crawler and picked up a HD axle seals for $14 bucks.. Orginal price tag was $15, but no one had change for $100 bill.. Saving a little is what I need now… So it helped. Man this bad boy is built very well. Compared to the one included in the kit, it was DADDY of all sealers. Should have taken a picture of the inside too sorry…



Borrow my buddy’s pressure washer and did some dirt. Definitely had to change cloths afterwards. I had oil and gunk all over. I was so in the hurry and forgot to wear pant and only shorts. Man, was that a big mistake.. BTW this is a 2350 PSI Craftsman…



Got the knuckle and disc covers sprayed and clean with some engine gunk… (engine gunk works magic)





Also had the chance to sprayed it to clean finalize it. The knuckle was with high temp paint so it looks a little dull. The cover was with original black paint. 2 coats of each… Thinking of repainting the knuckles again… but we’ll see.



Well here we are again at the axle seals…. Again it was a pain… I looked through a few forums and saw a guy banging it with a hammer and flat head screw driver… so I thought I do the same, No time to stop and shop around.. just so anxious to put it together.. 1.5 hours later this is the result…. Left is Craftsman R wheel axle seal, Right is "No Name" L wheel axle seal..



At this very moment 03/30/2011 9:30pm this is how she sits….





Till next time…..

 

for steering stops you can also weld a nut inside the stock ones to give it from crushing...I think it it is a 3/4"/19mm that drops right in..cheap and easy

 

Looks great so far!

Before you go any farther, and since Marlin is right down the street from ya, you might want to consider these:

http://www.marlincrawler.com/axle/fr...ate-eliminator