I did start pulling the truck apart recently. I was at the limit of running a single shock and am not interested in being an under-dog. Trying to make it work ended up bending some core tubes in my engine cage and I have been chasing a couple cracks for awhile now so it's all getting cut out and replaced. While it's down I'm going to upgrade to 37s which will involve some firewall work, adding a hydraulic ram assist, and really am pushing to hook up the A/C.
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The biggest change I am looking into is adding 4wd. I picked up an '06 Explorer 8.8 rear diff which tucks up well to 1UZFE oil pan. I also got stock axles modify to bolt on a fixed 930 joint on the inside to use all 45 degrees of angle to salvage down travel. The outer joint is a stock F150 joint that allows off the shelf 930 shafts. Front hub will be a Dodge 1500 unit bearing with 5/8 studs that I'm really hoping will hold up as well as the stock 2wd Toyota or Dana 44 hubs did. I don't have the CAD design as far along as I would like but total travel looks good, ride height should be where I have been wanting it, and it looks like ground clearance will be manageable. Adding a transfer case is still a bit of an unknown though. I need a driver drop, want to use my Lexus A341E trans, and want a manual case. Currently weighing options of an FJ box and prerunner adapter, or a Jeep AW4 tail section and some Jeep box which adds the benefit of clocking up. Either way the floor is coming apart again and the exhaust will be redone. Stay tuned for updates involving lost of cutting, pretty CAD pics, and a bit of fab.
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