4Runner Solid Axle Swap

[Someone]

Well after months of waiting for parts and procrastination my parts are starting to come in, which means it is time to get to work. I decided to go with a Trail Gear SAS kit for this swap, as it is my first big job like this and it makes things a lot simpler and comes with all the little things like an axle rebuild kit. Everything in the kit looks nice so far, the only things that look a little cheap are the Front leaves... but they can always be upgraded later. For the rear of the truck I went with a set of Skyjacker springs because I got a great deal on them. Here are a couple pics of the truck on its last trip out up at the Coke plant in... april?.. I think?

3" Body, 2"susp 33X9.5 BFG A/T's



I think when I am done I should have 5" of suspension and the 3" body... I will propably end up removing the body lift, but I will try it out at first.. As of now it looks like I am going to be running a set of 36X12.5" TSL's.

A shot of my new axle still in the donor truck


IFS removed brackets still hanging


I cut most of the brackets off of the drivers side last night, the hardest part seems to be grinding down the welds to smooth out the frame, Maybe I need a courser grinding disc or something.

Got all of the front end stuff in this week.... I have alot of work ahead of me as this NEEDS to be done for the august long weekend... or I have missed a whole summer of wheelin'

[Someone]

I got most of the crap taken off my frame, just a couple more things to cut off and clean up, My buddy went a little deep in one spot, I will have to fill it in.




I got most of the axle cleaned up, just waiting on some studs and a couple new nuts tommorow, I hope to have it gusseted and painted and ready to go tommorow.




I was looking threw my parts and am missing the steering stabalizer kit and some shock boots so I am going to have to get on them about that tommorow.

[LiftedAWDAstro]

Looking pretty good so far. Keep the pics coming.

[Someone]

It has been a slow week but stuff is getting done, started cutting the holes in the frame for the shackle mount, welded up all of the axle reinforcement, and got one side of the spindle on last night. hopefully tonight the axle will be rolling and I can get some more of the welding done on the truck itself.





I also swapped out my master cylinder, booster and calipers for the larger V6 parts

[astrozam]

Lookin good Tristan, as Dean said keep them pics comin

[Someone]

After a really busy weekend I have a few more cuts and bruises but almost have a finished truck aswell... just have to do the timing, pull it out of the garage and put the tires on it tonight, hopefully I can get it in for an emissions test tommorow morning.

I am a little worried it is going to fail the smog test as it has not really been driven in almost 2 years now and the cat has been punched out, but it did pass last time withthe cat punched. I will have to take it for a good boot tonight to make sure it passes tommorow so I can get my stickers so I can drive it upnorth on thursday.... cutting it close once again!

Axle complete








Not only was I doing the finishing touches on my truck all weekend, I was helping out on two other lifts aswell.. a 3" lift in a tacoma and a 6" in a K5 blazer






and my tires are mounted ready to go on


and some more tires for another 4runner


Hopefully tommorow there should be some pics of it complete... well actually I still have to make up a front driveshaft aswell

[astrozam]

Cool pics,one day i'm gonna have to get my lazy butt out your way and drop in to take a look at these projects

[Someone]

Just a couple of finishiing touches left to do... front drive shaft should be done tonight, needs a couple bulbs and a few things here and there but all in all in drives great and looks even better... cant wait to try it in 4 wheel drive!

[astrozam]

Looks good Tristan,gonna have to get some shots of er all mudded up.

BTW,I saw your post on A.S re: emissions testing,I've used that gauranteed to pass twice now and it worked the 1st time but not the second time, I've seen a couple posts that mentioned using some other stuff (Methyl hrydrate ,MAYBE,not sure) a search should come up with whatever the stuff was,but the main thing is to get er good and warmed up,although with a punched cat I'm not sure if that will matter,good luck with it,let us know how you make out.

[Someone]

Well I have to admit, she ran awsome all weekend, had a couple of small issues on the trip out to bobcaygeon because it had not been driven in a couple years... I popped a waterr pump on the 401, got it delivered and changed it, then I blew a rear heater hose on #35 but it was easy enough to fix. after that she ran and drove mint.. I made my front drive shaft a little to short, I pulled it apart on one rock from to much flex, so I will have to make it longer... no biggie.

I was very amazed at how easy it went threw everything, propably went about 15 KM up the bass lake road trail, and did not even spin the tires once, just walked threw everything!








and a couple other trucks that were with us... I was most impressed by my buddys stock 98 4runner, the thing was flexing like crazy, I could not believe what it went threw, blew the YJ away that was with us by far!

[Rockwerx]

Excellent report! One could adapt alot of your project to swapping a solid axle into an Astro.

Love your offroading pics! It is hard to beat a stock Toyota 4x4 when it comes to 4 wheeling. A few friends of mine run them with only two mods...high arch springs and 35 inch tires. That will get them into (and out of) some very tough terrain.

[astrozam]

Sweet pics,looks like alot of fun

[99s10]

Whats the chances of you finding another pair of axles like those in your forerunner? Im looking for a pair with the steering stuff

[e7ats]

Great picks.

I still have the itch to work on my van. Just need time and $$$$$

[potskie]

Awesome! The picture of all those tires gave me goose bumps seeing all those pretty tires just laying there waiting to get the air let out and mud packed in em