So. I purchased a long travel suspension setup for my 1991 4runner, total chaos Gen II. It came with a whole pickup though.


At the train station parking lot in Modesto CA

6 hr drive South back to LA. Ugly fiberglass parts are on sale.

The suspension I bought


After the long drive home, I decided this car was Happy. So, now it shall be called Happy.

It has several flaws, but it works well and the AC blows cold and it was very fun to drive home.

I then decided that I will do some restoration and at least for now, I will keep it.

The initial plan was to swap front suspension with the 4Runner and sell the truck.

I will post some more pictures and details soon

 

Removed (and sold) the camper shell, the hood and fenders and the steel tube bumper.

Rear was saggy with just a tiny bit of weight (lol) . After much research for a 2 inch lift spring, I just got stock ones with the idea of future add-a-leaf for additional height and capacity.

Changing out the springs. First time ever I worked with leaf springs. Learning curve was steep.

Having a bit of a tough time shifting into 1st and a lot of play. No seat and this plastic piece was jacked. Replaced with parts from marlin crawler. Everything seems to be working great now.

Interior needed love. No carpet and lots of trim pieces missing. I purchased some good as new condition seats from a scion TC, fabricated mounts to make it work. Seat decision was ok. The back of these seats are much thicker and therefore can't go as far back as the stock seats. Doesn't bother me, I'm not too tall. Tall people will be unhappy.

Ordered some surprisingly affordable pre-formed and sized carpet from rockauto, with insulation. Not a fan of upholstery or carpet work, but it came out great.

I took the money i made from selling parts off of this and ordered the missing trim pieces, they shall be here soon.

Then I got a couple of my buddies to come over so we can do the suspension. Remember, this is why I bought this truck. We took the total chaos off, put it on my 4runner.

Installed all the 4runner stock pieces on the truck. Need to weld couple of rubber mounts back on still. Also, test fit the new fenders. The hood you see here is stock to this car, came with it in the bed.


So the challenges of reinstalling a stock IFS suspension on one with Total Chaos long travel installed.
1. The holes where tapered tie rod ends and upper balljoint goes into were drilled out to straight holes. I found an insert that takes the upper balljoint straight cut and creates a tapered insert. It was meant for some jeep to gm tie rod conversion, but the dimensioned of the taper are very close. I just got those in and will post about it when I do that job.
2. The drag link holes, less options. I tried to find similar solution but would have to machine the parts myself. Although I have asked my wife to get me a medium size lathe for my birthday, she has no idea what that is and hasn't gotten me one yet. Alas, no machining can be done. Insert very frowning face here!!! SO, I looked around for a used drag link to replace (if you are asking why I didn't swap it with the 4runner, good question. It was too late, lol, and I didn't want to remove the 4runners off of the pitman arm . Anyway, couldn't find a reasonably priced used option. Very limited quantity out there and people want to charge 300 bucks. uhhh wtf? So, I eventually found an aftermarket brand, Beck Arnly? and it was little over 100 bucks. ordered. should get in soon.

SO, as I may have mentioned, this truck turned from a 'i bought a suspension and it came with a truck' to ' I like this truck' to 'Im going to do a medium restore'

The goal is to make it my daily until my ordered vehicle gets to my house... which at this point is a year or more away Anyway, this things gets killer gas mileage with the 22RE engine and lightweight body.

I do have to smog it.. I expect no issues.

Upcoming work:
1. Clean all trim pieces, paint if necessary and install.
2. Install some felt liner on interior back wall
3. FInd some center console that works
4. Prep outside for raptoliner paintjob. The lighter raptoliner paint job looks excellent! The black is a bit dull. So I plan on color matching existing color.

Thanks for tuning in folks!

 

Here is a pic of the truck with the stock IFS parts. The last pic was a fender fitment with TC setup still.

 

Nice work!

 

I want to upgrade my ball joints and rocker arms as well as add lower gearing, ring and pinion....any suggestions on what would be best?