2003 4Runner Sport family beach buggy build

Brett_Murphy

New member
My first foray into building an SUV for beach buggy was a qualified success. The Xterra I picked up for $350 became a functional vehicle, but, well, I just didn't like it. I sold that, made a few bucks on it and started looking for a GMT800 Tahoe. Unfortunately, these are very popular around here, so the ones that were not ragged out and used up were out of my budget. I was about to give up hope when I noticed a 2003 4Runner pop up in my search. The seller had mentioned "Tahoe" in the ad, or I never would have seen it. I had discounted the 4Runners out of hand because they command prices greater than the Tahoes, usually, but this one was listed for about half of what 4Runners that are worth buying usually go for. There are plenty of shady car lots around here that buy wrecked cars and rebuild them, but this was a private party sale that claimed to own it since 2004. I decided to check it out.

The sellers had been using it for a family hauler with small children, so the interior was (and remains) dirty. It had 274k miles on it, which probably scares lots of people away, but the 2UZ-FE is known to go for 300k easily. There were cosmetic blemishes, such as rock chips and a cracked roof rail cover. There is no appreciable rust, all drive modes work, the tires are decent, the Toyota website showed that the dealer did most of the maintenance and the prior owners seemed to take it in for everything, including squeaks. However, the timing belt was overdue and the suspension was original and completely shot. Well, that explained the low price, I guess. I'm fairly handy, so I decided to roll the dice and I took it home for $5000.

The first thing I did when I got it home was park it. The belt had not been changed in 150k miles, so I was viewing every mile driven as a risk.

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This is the only V8 in my fleet right now, so was pleasantly surprised at how much room was in the engine bay. Tartan shop rags for the win.

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The timing belt was easy, but when I was done and putting everything back together, I stabbed the A/C Condenser with a screwdriver and had to replace that, too. I was also surprised at how tiny the transmission cooler was. I have plans for that, but that is a later project.

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The timing belt, fluids, hoses and accessory belts were all changed, so with that got it into driving condition, in my opinion. It was time to put some miles on it.
 
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Brett_Murphy

New member
I started using it around town a bit. The suspension's condition was appalling, though. My wife even commented on how loose and bouncy the ride felt when she drove it. I decided to go with a proven solution, and ordered up some Old Man Emu components. I went with 2885 springs with 90021 struts in the front and 2895 springs with 60004 shocks in the rear. I did some comparison shopping, but a guy on the Carolina 4Runners Offroad Facebook Group indicated that his shop was an OME distributor right when I was looking, and they beat many of the prices I'd seen online. I'd be able to get the units installed for what I'd pay for them elsewhere. The shop was a bit over an hour away, but that's "Local" in my book, and I like to support local shops when I can. Off it went for some much needed work:

Before:

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After:

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To say the ride was improved would be drastic understatement. It looks a bit leggy now, but it doesn't bother me that much and there is a lot of life left in the tires that are on it. I've pumped a fair bit of money into it getting it road worthy so far, so when these tires wear out maybe some sort of larger tire will be in the works, but I have to let the bank account recover a bit.

This weekend I took it for a longer trip to the beach. It worked great in the sand, even if I didn't catch anything. I did pick up a year-long beach pass, so there will be plenty of more opportunities, though.

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Roody

Adventurer
Good stuff, and props for taking on a vehicle that otherwise might have been near the end of its life
 

Brett_Murphy

New member
There's plenty of life in this one, yet. The lack of rust and the fact it is 100% paid for means that as long as parts are available, it will remain cheaper to fix this than buy a new one.

The family and I are probably taking it down to the beach again tomorrow. I'll be looking for weaknesses and more things to fix.
 

zidaro

Explorer
Nice ride!
I just picked up a 4th gen V8 with high miles myself! Same opinion. Maintain it and it will last forever. Look forward to seeing your build, issues, solutions, and adventures.
 

Brett_Murphy

New member
I noticed that the fender liners aren't really there any more. I'm considering adapting some rallycross knowledge and cutting up a Rubbermaid garbage can to fashion some new ones. I'll have to price a new set from the dealer versus the going rate on 33 gallon garbage cans to figure out what the best route will be.
 

Brett_Murphy

New member
Not much has happened since the last post. I had an original power steering line crack, so I replaced all of those. Other than that, we've just been driving it when we want or need to.

The big news is that the tires that were on it when I bought it finally wore out, so I had a chance to put on the FJ wheels I had hanging around and put some 265/70R17 Cooper Discoverer AT/3 tires on it as a replacement. I'm really liking the new look.

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Brett_Murphy

New member
When I was changing the oil, I saw that the front axles were a bit greasy. The boots are pretty worn out and are leaking, so they are due. I've heard that OEM, NAPA, or CVJ are the ones to get. Any opinions on this?
 

Loubaru

Adventurer
OEM or re-boot/rebuild your OEM ones which is what CVJ does. If they haven't been leaking for a long time you should be able to get away with just rebooting them.
 

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