PreRunner to 4WD conversion

[SAR_Squid79]

Converting my PreRunner to IFS 4WD

In one day of wrenching by myself I got all of the following done:

Removed stock UCA's
Removed stock PreRunner Spindles
Installed new Camburg UCA's
Installed 4WD Spindles w/ Aisin manual hubs
Installed Donahoe Racing Extended-Travel Coilovers
Installed front diff
Installed CV Shafts


I was so pressed for time (b/c I was doing all the work 100% on my own) that I didn't have time to stop and take any pictures. I couldn't even stop to eat lunch!

Here's a pic where - if you look close - you'll notice Manual Hubs, Camburg UCA's and Donahoes:
http://img250.imageshack.us/img250/2122/1002836dt7.jpg (http://imageshack.us)

The next day (once again wrenching alone) I got the following done:


Removed stock PreRunner drive shaft
Removed transmission tail housing
Installed new Inchworm tail housing/adapter plate
Installed Inchworm Transfer Case
BudBuilt Crossmember Installed
Installed rear drive shafts


Here are a few pics from that:

Tail Housing Removed from PreRunner Transmission:

http://img235.imageshack.us/img235/47/1002839ua2.jpg (http://imageshack.us)

Inchworm PreRunner Adapter Plate:

http://img63.imageshack.us/img63/4043/1002840db1.jpg (http://imageshack.us)

Inchworm PreRunner casting and coupler mounted:

http://img442.imageshack.us/img442/7667/1002841kp5.jpg (http://imageshack.us)

Inchworm "Lefty" Transfer Case Installed:

http://img442.imageshack.us/img442/3265/1002842qa8.jpg (http://imageshack.us)

I got the Crossmember mounted up, but I ran out of time at the shop so I didn't get a pic with the Crossmember mounted, and Rear D-shaft connected.

The calculations that I did in http://www.tacomaterritory.com/forum/showthread.php?t=63114&highlight=prerunner+math"]THIS (http://"[url) THREAD[/url] ended up being right on! I took a stock 4WD Tacoma rear driveshaft and had it shortened by 4", and it turned out to be dead on balls! My logic that since I'm shortening the rear D-shaft by 4", I should extend the front D-shaft by 4" . . . that turned out to be WRONG! My front driveshaft is about 1" too long. So I'm gonna have it shortened back down by about 2 1/2" and it should be perfect.

Everything went pretty smooth. No big drama, aside from not having a few bolts that I needed, and stuff like that. I will take and post more pics as I get the last few details buttoned up.

[SAR_Squid79]

IT'S ALIVE!!!!


Got her all finished up, and took her for her maiden voyage in 4WD!


Got the Front Driveshaft back from the shop, and got it installed:

http://img231.imageshack.us/img231/8057/1002853xz5.jpg (http://imageshack.us)

http://img442.imageshack.us/img442/6406/1002854hc6.jpg (http://imageshack.us)



Here's a few shots of the suspension / front end:

http://img231.imageshack.us/img231/6241/1002855ak3.jpg (http://imageshack.us)

http://img442.imageshack.us/img442/3649/1002857ae9.jpg (http://imageshack.us)


Got the shifter mounted.

It was overall a pretty simple job. Just a lot of measuring and re-measuring. I had to do a little cutting and a little trimming - nothing a few minutes with the Dremel couldn't handle. On the twin stick, though, I did have to take a torch to one of the handles. The shifter comes with one stick bent to the left, and one stick bent to the right. Well the one that was bent to the right would have been too far over, and would have been into the Auto Trans shifter. The fix was to just make it exactly straight up. With that, and the fore-mentioned dremel timming it fit like a glove!

It came out looking pretty good, too, and shifts great! ...but I had to sacrifice my cup holders.

Here's the finished product on the interior:

http://img246.imageshack.us/img246/692/1002850ul6.jpg (http://imageshack.us)

http://img301.imageshack.us/img301/3198/1002851wv0.jpg (http://imageshack.us)


And here's a couple of shots of her 1st 4WD trial run!

http://img57.imageshack.us/img57/9082/1002858zi0.jpg (http://imageshack.us)

http://img57.imageshack.us/img57/9295/1002859dw4.jpg (http://imageshack.us)

[SAR_Squid79]

For you inquiring minds that want to know how much this conversion cost - Here is how it breaks down:


4WD Conversion Parts & Price List:

Front Drivetrain:

1999 Tacoma Front Diff with 4.88's
1999 4WD Spindles
Aisin OEM Manual Hubs
CV Shafts
OEM 4.10 Gears
[$800]

1999 ExCab F & R Driveshafts
[$275]


Tranny / T-Case:

Inchworm "Lefty" Gear Driven T-Case w/ 5.0:1 Low Range
Inchworm PreRunner Transmission/T-Case Adapter Plate Kit
FROR Twin Sticks
Toyota T-Case Mount
Speed Sensor
[$2500]

BudBuilt Crossmember/Skid Plate
($218)


Front Suspension Upgrades:

Used Donahoe Racing Extended Travel Coilovers
($500)
Donahoe Racing Extended Travel Coilovers rebuilt by DR
($160)
Camburg Uniball Upper Control Arms
($475)
WabFab Off-Road Swaybar Quick-Disconnects
($75)
Replacement OEM Lower Ball Joint's
($35)


Misc:

Regearing front diff back to 4.10
($260)
Lengthening/shortening Front/Rear Driveshafts
($325)
Replacement Studs for Manual Hubs
($17)
Repalcement Gaskets for Manual Hubs
($12)
New Center Console (front Half for 4WD shifter)
($37)


TOTAL:
$5689 (Plus odds & ends like bolts, permatex, etc.)

[EWAYota]

Looks good. Why didn't you just throw a solid axle under there?

[garrett]

nice work. what do the 4WD guys do for cupholders? could you not get some from a 4WD tacoma?

[waskillywabbit]

Holy Cow Batman! :D

Only thing I DON'T like about all the twin sticks I've found (except Marlin's) is that they don't take Toyota thread shifter knobs.

:guitar:

[SAR_Squid79]

Looks good. Why didn't you just throw a solid axle under there?


After all the time & money I've put into performance mods on my truck, I don't want to put all that SAC weight under it.

...Also as I've stated before - at TTORA TakeOver last year, I saw SAC rigs breaking down all over the place, and I did not see one single IFS guy break. That kind of made my decision for me. Plus I've seen what guys like Hytenor have conquered with IFS, and I don't forsee doing anything that extreme with THIS truck.

different strokes for different folks. My decision was VERY well thought out, and I am very happy with the decision I made to go this route, and not SAC. I like the fact that my truck can do a little of everything. Kick butt on the trail, and on the street. I can do mild rock crawling, trail riding, and overland expedition type stuff, and still smoke the tires no problem!

I think there will be an FJ-40 in my future, so I'll take my Solid Axle on that, and go nuts, and build a bad-A$$ crawler out of it.

[slosurfer]

Very nice! :thumbup:

[Cheese]

Good looking project and right up.

"Just throw a solid axle up there?" That doesn't happen.

The reason lots of swapped trucks break is because they are hacked. You did a great job here and have a clean IFS truck that will be reliable. Well done.

[bigwapitijohnny]

Sar,

I did my poor man's black pearl emblems in 1 day, and I thought I was doing good... :rofl:

Great job,

BWJ

[all_terrain17]

Very clean and well written. :thumbup:

On your transfer case, the fill plug is at a lower point. Do you just run with less fluid?

[Jerm]

Looks good, alot of good info there.

[Lee]

wow, good work. you used very good components for your setup too :thumbup:

[BruceTS]

Very nice job, I'm surprised neliconcept hasn't commented yet, he's gettin all the parts together to do the exact same thing......

[SAR_Squid79]

Very clean and well written. :thumbup:

On your transfer case, the fill plug is at a lower point. Do you just run with less fluid?


You're probably talking about the drain plug:

http://img104.imageshack.us/img104/5608/tcaseks4.jpg (http://imageshack.us)




Very nice job, I'm surprised neliconcept hasn't commented yet, he's gettin all the parts together to do the exact same thing......


Neicconcept has messaged me on TTORA numerous times since I did my conversion, and asked me a bunch of questions. I did this conversion back in early April.

[neliconcept]

i was wondering where the hell that fill plug was lol

oh yeah another question Jamie, Did the lower mount for the xmember come with the case? I didnt seem to get a mount so i can bolt it up to the budbuilt crossmember when it arrives.

[SAR_Squid79]

The T-Case mount, is the "old Style" '82 - '95 Toyota Transfer Case mount. I got mine from Inchworm, but it cost extra. They are like $75 bucks if I remember correctly.


...Nope - $110
http://www.inchwormgear.com/store/product_info.php?cPath=21_48&products_id=961

[neliconcept]

Scheiss!!

ill check with my dealer to see how much it costs (i get 25% off with Land Cruiser association)

oh btw, another question (ill take it to pms if i have anymore after this post)

with the shifter assembly, going from prerunner plate to 4wd plate, did you have to move the shifting linkage to the right? from the look of the casting adapter where the shift railes go in, it looks like it goes behind the auto shifter, which Id like to just surrender my front cupholder and keep my 2wd fat handle shift knob (so nice to rest a hand on)

thanks Jamie once again

[SAR_Squid79]

No worries, man - I happy to answer any questions, and help any way I can.

I wish I had taken more pics of that part, when I was mounting the shifter.

No - I didn't have to relocate any of the shifter linkage. Everything fit and clears perfectly. The AT shifter sits over to the right, but the linkage kind of bends over to the left under the truck. The Twin Sticks sit dead center, ans everything clears nicely.

**I just went and took a pic under the truck**
http://img502.imageshack.us/img502/1271/1003207nz1.jpg (http://imageshack.us)

[neliconcept]

nice!!! that makes everything a bit more clear now

Appreciate it Jamie, soon ill have the crossmember and able to bolt everything up except for the front end.

[xcmountain80]

Blake I thought this thing was supposed to be done already, what in the world is taking so long? I know it will be bad-ass once you get it done.

Aaron

[neliconcept]

umm parts? crossmember isnt built yet. i still dont have a front diff and front ds. i cant help that

[xcmountain80]

Hmmm sounds to me like you need to break out the whip and get it cracking over someone. How much do you think this will end up costing once all is said and done.

Aaron