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That yellow rendering sure looks like it might have a solid rear axle. It'll be a lot cooler if it does.

When I was in undergrad, my roommate and I both left town for the summer for internships ...and he stopped paying the power bill. We returned the day before classes started again to a similar fridge/freezer situation. Horrific is an understatement.

I realize it's spilled milk but why did they have the sensor unplugged in the first place?

I drove over some land this weekend, does that count as overlanding?

Glad to see some updates. This is such a great project.

When I was in high school I had a 97 Yukon and was collecting parts for a 60/14 SAS. Turns out that's not a feasible project on a high school budget, but I love seeing these OBS trucks get refreshed and built. ESPECIALLY in a road salt state.

This truck is so cool.

For what it's worth I spent probably 3 years chasing a vibration exactly like you describe on my 01 4Runner. Three sets of tires, two sets of wheels, ECGS diff bushing, two sets of CV axles, adjustable rear upper control arms, and three driveshafts. It ended up being the rear driveshaft, and I...

Good luck. I think I've exhausted the extent of my knowledge on these so I'm interested to see what you find.

I’m pretty sure I can hear it rusting from here. Ugh.

There are a lot of us hoping you can get this thing back on the road and reliable soon. Good luck.

I wouldn't try to operate it without that cover in place, as I don't think there's anything retaining the pinion gear other than that cover. It's been a little while since I've had it apart though, so I could be wrong. That said, if the actuator is moving at all, even to the wrong position, it...

The actuator also controls the CDL, so if you try to engage or disengage it you'll be moving that shift rod. Have you checked your tcase position switches for function? I'm curious about your dash lights showing it's fully in position when it's actually not. That's an uncommon issue, so I'd...

The older style inserts were installed with the flange on top and the C-clip on the bottom. That instruction sheet looks like it's for the new style. OP can you tell what happened? Is the groove in the insert damaged like the clip pulled out of it? Or did the clip maybe break and fall out?

For real. I lose sleep over what are minor annoyances compared to stuff like this. Hope your luck with this thing changes soon!

I can't really speak for 5th gens, but I have a 4xInnovations rear bumper with swingout on my 3rd gen that is one of my favorite upgrades I've made. It's super well made, and has taken a ton of rock hits over the years, but I do more rock crawling day trips or whatever than I do long term...

BFG sells a LOT of KO2s, including 37s, to the US military, for what that's worth.

You get it. We've been doing a lot of one-way rentals for the exact same reason. I don't hate your first option, because that opens up some other possibilities.