Budget ‘90 4Runner Trail Rig/DD

Mint_spec

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Joined
Aug 10, 2024
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12
Been looking for a place to chronicle my 4Runner build and discovered this forum so here we go. Started out as a bone stock 1990 4Runner that I bought when I was 18. Factory 22re 5speed that I learned manual in.

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Eventually did some small mods, lunchbox locker, small lift, trail gear rear bumper, lce header to a full 2.5” tig welded by me exhaust with a fender exit. Basically whatever my 19 year old self could slowly afford.

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Eventually I moved out to Colorado and sold my jet boat which I used most of the funds from to embark on a solid axle swap.

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I drove 12 hours to Salt Lake and picked up a complete ‘83 pickup axle for 500 bucks. Fit like a glove in the back of my Forester. Then spent the next month sourcing the rest of the needed parts. I loaded up the 4Runner with the axle, all the parts, and my welder and drove back to use my parent’s garage in Missouri to do the swap.

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I used a Sky’s off-road design kit, Procomp 3” lift leaf springs, a used 4x4 labs high steer kit, Bilstein 5100s, and two front driveshafts I welded together (totally eyeballed it but it barely even vibrates). I learned a lot and had a few major headaches, namely cutting holes in the frame for the shackles without a torch or plasma cutter, but about 4 days of working with very minimal tools later my buddy and I got it driving and I headed back to Colorado.

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Next up in the list was a regear and front and rear lockers. I picked up a set of slightly used t100 housings with 4.88s and Yukon grizzly lockers for a steal of a deal.

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Built a front bumper out of some scrap tubing we cut off my buddies rig around a trail gear winch plate.

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The second biggest fab project I tackled on it was swapping the stock coil springs in the back to leaf springs. I ended up doing this project in my gravel driveway which sucked ass and definitely added more time to the project but I got it done. I used Ford 57 springs, a Slag factory kit and Barnes u bolt eliminator spring perches.

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I now have way more flex on leafs all around coming from the stock rear suspension links with 3” lift coils that I was running.

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Currently sitting on some 35s on 15x10” wheels. It cruises ok and is a solid wheeler for now. It’s also my daily driver 85% of the time as well. I’m juggling building this, downhill mountain biking, skiing, and gun stuff so it takes a while on my limited budget to progress the build. Still have a long way to go before it’s what I am envisioning but over the last year it’s come a long way.
 
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It’s been a hot minute since I’ve done any major updates to the build but here we are. Just wrapped up putting hydro assist on and completely redoing my steering links. Before I had some 4x4 labs high steer arms that put the tie rod behind the axle. I didn’t like that I had to bend that link to keep it from hitting the frame at flex. As I’m on a budget I reused those by swapping them side to side and drilling new holes for the tie rod and trimming off the excess. Got the ram mounted in a decent spot. Tapped my steering box and got everything bled. I pieced this whole deal together for about the price of a new trail gear hydro assist kit. And I’ve got the links and heims included in that too. Surplus center rules.4C1DC83E-2518-4FBF-9DA7-AC0DBFB1BA9E.jpeg
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Just wrapped up doing a ruf spring swap. Got the axle 2 more inches forward so it clears the firewall where it was rubbing at full lock with ease now. Pretty stoked on this bitchin pitman arm I had to make since the drag link was sitting on top of the tie rod with the axle pushed forward. Got a bit more up travel out of it and put on some 5” boomerang shackles on. Going to have to do a square tube driveshaft now since I’m out of slip at full droop.
 
Younger me wasn’t that smart when I did the sas and didn’t reinforce the shock towers at all. I finally ripped both of them off the frame last time I was in Moab. Built a quick disconnect bar tying in both the tops of the towers and plated the frame while I was at it. I was just finishing up and the tig setting on my welder kicked the bucket.😑 Hopefully I don’t need to weld anything for a bit.E61565C9-55E2-4AEE-BF47-207E6D3CB07A.webp28D8F7B3-343E-41D2-8A7C-F750C7BF0077.webp
 
6889533D-C02A-48F6-9464-3BA79D3AF57F.webpFinally picked up a set of dual cases. I’ve been meaning to do this for years. Scored from a guy going v8 and automatic in his first gen. Both stock gears, twin stick, trail gear crawl box, trail gear crossmember and mounts, front and rear driveshafts so I can ditch my front square tube one. He even threw in a trail gear rear bumper with a broken weld on it for free. I can’t say no to free junk.
 
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My buddy and I got the duals slapped in in 3 hours after work the other day. I buttoned a couple things up yesterday and we test drove it at the neighborhood rock piles. I know all the guys that have been playing with Toyotas longer than me know the world of difference it is but it’s crazy. I cleaned this section through a bunch of square chunk rock first go and then hit it a second time and immediately double diffed out since the rocks had shifted. The cars driving by didn’t seem too impressed. Had to walk home and grab my truck to winch out to. Pretty much the only thing left is to make my e brake assembly jive with the speed sensor. The sensor runs straight into it at the moment.
 
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My buddy and I got the duals slapped in in 3 hours after work the other day. I buttoned a couple things up yesterday and we test drove it at the neighborhood rock piles. I know all the guys that have been playing with Toyotas longer than me know the world of difference it is but it’s crazy. I cleaned this section through a bunch of square chunk rock first go and then hit it a second time and immediately double diffed out since the rocks had shifted. The cars driving by didn’t seem too impressed. Had to walk home and grab my truck to winch out to. Pretty much the only thing left is to make my e brake assembly jive with the speed sensor. The sensor runs straight into it at the moment.
The dual cases are seriously a cheat code until they are not haha.. Double diffed sounds like something I'd do haha . Next you gotta throw some 4.7 gears in the rear case and you'll been even more blown away. Truck will just idle over shit in 1st no clutch needed. If you cant sort the ebrake.. The T Case ebrake is pretty money. https://trail-gear.com/brands/kit-e-brake-rf1a-transfer-case-79-95-toy-pickup-85-95-4runner.html



🤘 keep the updates coming !

E
 
That ebrake might be the move. Mine is only hooked up to one rear wheel after I did the ford leaf springs so it sucks anyway.
 
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