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Thread: Doc's 05 Tacoma Build Thread

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  1. #1
    Join Date
    Dec 2005
    California Republic

    Arrow Doc's Toyota Tacoma Build Thread

    I am a big fan of Toyota trucks - Hilux, Tacoma, 4Runner and Land Cruiser.

    the fifth element.jpg
    Overland Journal article and photo by Chris Marzonie

    My first experience with Mr. Toyoda's legacy came in the form of a used '79 Toyota Hilux 3/4 ton long bed with a 20R/4 speed tranny, an old school Timberline shell, and some rust. That thing ran like a swiss watch and never complained through almost 200,000 miles of abuse from me with nothing but routine maintenance and tires. So began my love affair with all things Toyota.


    My second Toyota was a 1988 4Runner 4WD SR5 with the 22RE, R151 5-spd, and all factory options. That thing could go anywhere I pointed it with ease so long as I didn't try to go fast uphill on a long highway grade! 1st Gen 4Runners are solid machines and excellent off road in all conditions.

    My third Toyota was a 2002 Toyota Tacoma TRD PreRunner Xtra-Cab with the V6 in Lunar Mist which my wife sold when I was in Iraq in 2003. I came home to my fourth Toyota, a brand new 2003 Toyota Tacoma TRD 4WD SR5 Xtra-Cab in Lunar Mist. We quickly outgrew the cab size which brings us to my fifth and "final" Toyota, a 2005 Toyota Tacoma TRD 4WD Double Cab in Silver Streak Mica with all available factory options.

    The 2005+ Tacoma was based on the international Land Cruiser Prado 120 chassis and came the 1GR-FE 4.0 Liter V6 gasoline engine that produces 236 horsepower (176 kW) and 266 ftlbf (361 Nm) torque. This Tacoma is the North American version of the Toyota Hilux pickup sold in international markets.

    The project vehicle was purchased new in February 2005 at Toyota of San Juan Capistrano, CA, with a build date of January 2005. It is one of the very first trucks of this generation built at NUMMI in Fremont, CA, USA and was a dealer trade from Reno, Nevada.

    My buildup is an ongoing strategic process of parts selection and vehicle modification focusing on reliability, durability, and comfort in the field. The end result of all the time, money, sweat, and busted knuckles has been all the great memories made while enjoying the wonders of Overlanding in North America with family and friends!

    ************************************************** ************************************

    Make: Toyota
    Model: Tacoma Double Cab 4WD SR5 TRD Off Road
    Year: 2005

    Engine: 4.0 1GR-FE
    Trans: 5 spd Auto A750F, 3.35 low ratio: A750F
    T-Case: VF2A, low ratio 2:57:1
    Front Axle: Stock Toyota IFS, 4.88 Nitro Gears, Icon Tubular Upper Control Arms, Icon 2.5 Remote Reservoir Coil-Overs
    Rear Axle: Stock Toyota E-Locker, 4.88 Nitro Gears, All-Pro "APEX" Expedition HD leaf springs with Timbren bump stops.
    Tires: BF Goodrich MT KM2, 255/85R16
    Wheels: Stock Toyota TRD Alloys
    Brakes: Brakes: Slotted front rotors by Stop Tech, Power Stop Z36 pads (extreme truck and tow)

    ************************************************** ************************************

    3.0 inch lift via Icon Vehicle Dynamics Tubular Upper Control Arms, Icon 2.5 Remote Resi Coilovers, & rear Icon 2.0 Remote Resi's and All-Pro Offroad "APEX" Expedition HD leaf springs with Timbren bump stops.
    BFG MT KM2's, 255/85R16's, Stock Toyota TRD Alloys
    4.88 Nitro Gears from East Coast Gear Supply
    All-Pro Offroad APEX aluminum front bumper with Rigid Industries D-2 LED's
    Warn M8000 winch w/Viking hawse fairlead
    Warn wireless winch remote
    Viking 3/8 synthetic winchline (80ft) w/Safety Thimble and Winch Saver
    Rigid Industries grill and SR-20 LED light bar
    Rigid Industries SR-50 LED light bar mounted via SoCal Super Trucks brackets
    Bentup square rock sliders
    Demello Offroad custom rear swingout bumper
    Trimmed Rear Bed Quarters
    Rhino Lined fenders, rockers etc
    Cobra 75 WX ST CB
    iPad Mini navigation mounted via Bird Dawg Industries Tech Deck
    Hella air horns x3
    TRD Sport hood/grill
    Rear Diff breather extension
    TRD neoprene seat covers
    Weathertech floor mats
    Kenwood Excelon KDC-994 Head Unit, Bluetooth and iPod
    Kenwood KAC-7202 Amp
    PAC SWI-X steering wheel audio control adapter for Kenwood
    Image Dynamics IDQ10 v.2 D2 Subwoofer
    Alpine Type-S Door Speakers
    Total Sound Deadening - eDead v1 SE2 - Fatmat
    Quick Fist 4-D Mag Light mount
    Sears Die Hard Platinum P5 Group 35 Battery (main)
    Blue Sea Systems negative bus 12 circuit fuse block (cab power)
    National Luna Power Pack w/remote dual battery monitor and Odyssey PC1700 MJT Battery (house)
    Blue Sea Systems negative bus 6 circuit fuse block (house)
    80W Solar Panel
    Power Tank CO2 system
    Safari Snorkel SS135HF
    Console Vault
    On board hard mounted First Aid kit and 2.5 lb ABC fire extinguisher
    Full trauma kit
    Full recovery kit
    Frame and sliders corrosion proofed with full POR-15 treatment
    Engel MT-45 Fridge W/New Gen Engel fridge slide & Engel remote thermometer
    Adventure Trailers FlipPac, color matched w/AT LED lighting upgrade and Goose Gear custom interior module
    Fiamma F35 Pro awning w/custom enclosure made by SLO Sail
    Magnaflow CAT back exhaust system with high clearance crossover pipe. Wrapped and heat shielded.
    LED lighting upgrades: Tails, markers, rock lights. Custom interior lighting by Anti-Dark
    Stop Tech slotted rotors and Power Stop HD disc brake pads

    Yaesu 2M Radio

    Attachment 261002

    My complete Hilux Safari Snorkel install write up for 05+ Tacomas featured at Cruiser Outfitters:

    Feature Vehicle, Overland Journal Summer 2010 issue:

    ************************************************** ************************************

    States, Destinations and Events visited so far in this vehicle:
    -CA, OR, WA, NV, AZ, Baja California
    -Grand Canyon NP, Death Valley NP, Anza Borrego SP, Mojave NP, Joshua Tree NP, Olympic NP, Crater Lake NP
    -Parque Nacional de Constitucion de 1857, Mexico
    -Expedition Trophy 2006; 2nd Place finish on the Sand Course
    -Overland Expo 2010, Amado, AZ
    -Overland Rally, Hollister Hills SVRA, CA - Expedition Trophy 2010
    -SoCal Desert Rendezvous 2011
    -Overland Expo 2011, Amado, AZ
    -Overland Rally, 4W Ranch, Ellensburg, WA - Expedition Trophy 2011
    -SoCal Mountain Rendezvous 2011
    -Expoberfest 2011, Julian, CA
    -Overland Rally, Hollister Hills SVRA, CA - Expedition Trophy 2011
    -SoCal Desert Rendezvous 2012
    -Overland Expo 2012, Mormon Lake, AZ

    Trails and Destinations completed in this vehicle:

    Wynoochee River Valley
    Quinalt River Valley
    Chehalis River Valley
    Humptulips River Valley
    Columbia River Gorge
    Upper Columbia River
    Lake Quinalt
    Olympic NF
    Olympic NP
    Okanagan NF
    Wenatchee NF

    Rogue River Valley
    Siskiyou NF
    Crater Lake NP
    Columbia River Gorge

    Big Bear
    John Bull
    Holcomb Creek
    Gold Mountain
    White Mountain
    Rattlesnake Canyon
    Bradshaw Trail
    Coyote Canyon
    Johnson Valley
    Saline Valley Hot Springs
    Panamint Springs
    Darwin Falls
    Death Valley NP
    Teakettle Junction
    Ubehebe Crater
    Mengel Pass
    Striped Butte
    Geologists Cabin
    Stellas Cabin
    Briggs and Stone Cabins
    Titus Canyon
    Panamint City
    Mesquite Springs
    Furnace Creek
    Toro Peak
    Anza Borrego
    Ocatillo Wells
    Bailey's Cabin
    Hauser Geode Beds
    Joshua Tree NP
    Salton Sea
    Lake Shasta
    Lake Tahoe
    Pickle Meadows
    Mojave Desert
    Colorado Desert
    San Bernardino NF
    Cleveland NF
    Sierra NF
    Inyo NF
    Angeles NF
    Tahoe NF
    Lassen NF
    Sequoia NF
    Kern River
    Lake Isabella
    Thomas Mountain

    Las Vegas
    Hoover Dam
    Valley of Fire
    Lake Tahoe

    Colorado River
    Hassayampah River Valley
    Coronado NF
    Kaibab NF
    Coconino NF
    Grand Canyon NP

    Sierra de Juarez Mountains
    Laguna Hanson
    Puntas Cabras
    Parque Nacional de Constitucion de 1857

    ************************************************** ************************************


    tacoma pre vinyl.jpg

    BryonDorrAAValleyOfTheGods 1.jpg

    Rack and Eezi-Awn version

    Coyote Creek, Anza Borrego, CA

    ExPo trip with HMR's rig and ours, Anza Borrego, CA, 2006/7-ish

    ExPo Death Valley trip

    Camped near Striped Butte with the new FlipPac, Nov 2009

    Joshua Tree NP, rarely seen snow-capped Idyllwild in the background, photo by Chris Marzonie

    ************************************************** ************************************

    New BFG MT KM's at 56,500 miles (21JUL09)
    POR-15 corrosion proofing project on sliders and frame completed (23JUL09)
    OME Dakar HD rear springs and OME Nitrocharger shocks at 57,500 miles (28JUL09)
    Nitro Gear 4.88's from ECGS at 58,200 miles(30AUG09)
    New cataytic converters x2 and new MAF under warranty at 80K (20OCT10)
    Icon Vehicle Dynamics 2.0 rear remote reservoir shocks at 102K (20OCT11)
    Icon Vehicle Dynamics 2.5 front remote reservoir coilovers and Icon billet upper control arms, front end alignment at 102,000 (25NOV11)
    New BFG MT KM2's at 102,11 miles (29NOV11)
    New OEM rear 2 piece drive shaft (SEP12)
    Magnaflow CAT back exhaust with high clearance crossover (DEC12)
    Disc brakes upgraded to Power Stop slotted rotors and extreme HD pads at 112k (DEC12)
    New All-Pro Expedition rear leaf springs & polyurethane bushings w/Timbren bump stops. Front end alignment at 113.6k (JAN14)

    - 60,000 Mile Service (12OCT09): Front and rear diff fluids changed. Transfer Case fluid changed.
    Engine Oil and filter. Transmission fluid flushed @ dealer. New OEM front brake pads, rotors machined @ dealer. OEM air filter, new wiper blades.
    - 72,500 Mile Maintenance (5JUL10): Denso spark plugs, OEM engine air filter, OEM cabin air filter. Engine oil change, OEM filter. U-joints greased.
    - 77,000 Mile Maintenance (10OCT10): Engine oil change, Bosch filter.
    - 80,700 Mile Maintenance (6NOV10): Engine oil change, OEM filter. Tires rotated. U-joints greased.
    - 85,420 Mile Maintenance (22FEB11): Engine oil change, OEM filter. OEM engine air filter. New wiper blades.
    - 86,500 Miles (26MAR11): New OEM rear drum brake shoes (replaced early, 30%+ remaining on old shoes). Tires rotated.
    - 90,700 Mile Service (21MAY11): Denso spark plugs. Engine oil change, OEM filter. MAF cleaned. Front and rear diff fluids changed. Transfer Case fluid changed. U-joints greased.
    - 91,500 Mile Maintenance (3JUN11): New OEM front brake pads. (only had 31k on this set...) Topped off coolant with OEM Toyota pink engine coolant.
    - 93,768 Mile Maintenance (17JUL11): Engine oil change, OEM filter. U-joints greased. Brake fluid flushed and replaced at dealer.
    - 98,500 Mile Maintenance (18SEP11): Engine oil change, OEM filter. U-joints greased. OEM engine air filter.
    - 103,000 Mile Maintenance (15DEC11): Engine oil change, OEM filter. U-joints greased. Brake fluid flushed.
    - 106,817 Mile Maintenance (10MAY12): Transmission fluid flushed, Cooling system flushed, Power steering fluid flushed, new serpentine belt.
    - 110k Mile Maintenance (DEC 12): Engine oil change, OEM filter. U-joints greased. OEM engine air filter.
    - 112k Mile Maintenance (OCT 13): Engine oil change, OEM filter. U-joints greased.
    - 113.6k Mile Maintenance (JAN14): Denso spark plugs, MAF cleaned. U-joints greased. Tires rotated.

    ************************************************** ************************************

    Spark Plugs: If it's your first time changing the plugs, you will notice that the Driver Side has NGK, and the passenger has Denso Plugs. Toyota has been doing this for eons, and I really cant confirm why they do this.

    Using 6 identical Denso plugs is what I recommend, gapped @ .040 to .041. OEM does not use iridium so I recommend non-iridium plugs per OEM engine build specs.

    1GR-FE Spark Plugs:

    1GR-FE Throttle Body Cleaning:

    Great Electrical Reference:

    Hypoid gear oil APL GL-5
    Above -18 C (0 F): SAE 90
    Below -18 C (0 F): SAE 80W or 80W - 90


    Transfer Case:
    API GL-4 or GL-5
    SAE 75W-90

    Rear Diff - 3 QTS, APL GL-5 SAE 90 (torque fill and drain plugs (24mm socket) to ONLY 36 ft lbs per OEM specs!)
    Front Diff 2 QTS, APL GL-5 SAE 90 (same as above, 10mm allen socket)
    Transfer Case - 1.1 US QT, APL GL-5 SAE 75-90 (same as above, 24mm socket)

    Engine Oil SAE 5W-30, OEM recommended. 5.5 US QTS, 4.6 Imp QTS




    Resetting the "Maintenance Required" light on 2005+ Tacoma:
    1. Turn ignition key to 'ON' and press the odometer button until the display reads actual mileage... not Trip A or B.
    2. Turn ignition key to OFF.
    3. Hold in the same button you used in step 1.
    4. While holding the button in, turn ignition key to 'ON'.
    5. The 'Maint Reqd' light should blink and go out!
    Last edited by Dave Bennett; 12-21-2014 at 10:15 PM.
    Member #203

    Adventures in and out of your vehicle: AMERICAN ADVENTURIST

  2. #2
    Join Date
    Oct 2005
    Hayward, CA
    I have an '06 with the factory shell. I'm getting it ready for some light off-road camping and the like. One day when I have Scott's budget I'll go a bit further.

    For now, I have some Thule rack parts to install on the shell, various tools/axe/shovel/rope and the like in the back, some Hella Rallye 4000s on order, and will also buy a Kenwood dual-band transceiver soon.

    This weekend, I'm going to remove the front mudflaps.
    2006 Toyota Tacoma

  3. #3
    Join Date
    Sep 2005
    Now I Can't wait to see this build up. What cab config do you have how bout a good pic or two.

  4. #4
    Join Date
    Dec 2005
    California Republic
    Last edited by Dave Bennett; 07-24-2006 at 12:11 AM.
    Member #203

    Adventures in and out of your vehicle: AMERICAN ADVENTURIST

  5. #5
    Join Date
    Jun 2005
    Prescott, AZ
    After visiting SEMA this year, the parts are coming... There were more 05 Tacos on display than any other model, and the bumpers, caps, lockers, suspension, etc. is all coming out.

    ARB has released the new 05 Bull Bar, and the front locker can now be sourced. Deaver and Donahoe have released suspension systems as well.

    You are doing the right thing, focusing on the camping equipment. This type of fourwheeling puts an emphasis on camping and passenger comfort, as so many days and nights are spent in the bush.

    I am really looking forward to following this build.
    Scott Brady
    Instagram - @globaloverland

    Overland Journal
    G-Wagen | Defender 110 | Land Cruiser BJ74 | Moto Guzzi V7

  6. #6
    Join Date
    Sep 2005
    Rowlett, TX
    Doc, I think you have a great starting point for you with your 05. However, I really like the RPK, Well, except when they were pointed at me. Anyways, welcome Doc, and remember "If you ain't CAV you ain't Sh@#". Glad to have ya here, Semper Fi. Tu Compadres, Suty. 3/2 Cav
    " The only necessity for evil to triumph, is for good men to do nothing." Edmund Burke
    " I'm not as good as I once was, but , I'm as good once as I ever was." Toby Keith

  7. #7
    Quote Originally Posted by 05TACODOC
    Here's a few pics, truck and self...
    The Tacoma is a good foundation, no?
    Hey, It's good to know about more stuff coming out for the 05+ tacoma. I love to show mine off, I plan on getting a front bumper to mount a winch to, but I also saw a portable winch, so maybe a proper rear bumper could allow it to work on either side. Here are the pics that finally uploaded on TS (they moved the thread to q&c):

    That's cool that you want to build a baja ready truck. I'd like to do the same eventually but it will take a bit more money, time, etc. Maybe we could start a military team or get the Marine corps or Army to sponsor a vehicle. They have circle track racers but I haven't seen much on the offroad team which would seem more pertinent to me, especially in the desert arena.

    By the way, that's a PKM, not an RPK. RPKs are magazine fed.
    Last edited by scrmntaco; 05-11-2006 at 11:25 PM.

  8. #8
    Quote Originally Posted by TACODOC View Post
    Here's a few pics, truck and self...
    The Tacoma is a good foundation!
    Nice Tacoma! I like it. How much it cost you with that one?

  9. #9
    Join Date
    Dec 2005
    California Republic
    Throwback: Cool spin on one of the Overland Journal photos for the Summer 2010 issue by Chris Marzonie...

    the fifth element.jpg
    Last edited by Dave Bennett; 10-18-2014 at 02:59 AM.
    Member #203

    Adventures in and out of your vehicle: AMERICAN ADVENTURIST

  10. #10
    Join Date
    Nov 2007
    Are you sure the arb weighed 175lb? Mine felt less than a 100lbs, maybe 175 with a winch. I didn't use a scale, just my girlish arms.

    *some restrictions apply, void where prohibited

    007's Tacoma build

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