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Thread: 04-4-4-4 Conversion/Build

  1. #1
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default 04-4-4-4 Conversion/Build

    In late 2003 I was set on purchasing a 4cyl Tacoma. The vehicle's primary role would be a DD, and a DoubleCab would enhance that function. In the 4 cylinder it was either 4WD or 4 doors, not both. I had an acquaintance at NUMMI and I had hoped that they would be able to build a 4cyl DC. In the end, the doors won, and I purchased a 2004 PreRunner in April of that year (getting it through NUMMI):
    1.jpg
    For 60,000 miles I drove the truck stock with no issues. In 2005-06 several individuals were completing PreRunner conversions with great success. I joined the ExPo and began to research. A special thanks goes out to SARSquid (Jamie) and Pray4Surf (Rick) for all their technical support and R&D. Both have saved me numerous hours of pain and suffering. I appreciate it. I would also like to thank all the members here that I've PM'ed over the years. Thank you for your insight and willingness to help. Here's the 04, 4cyl, 4 door, 4WD build:

    Started with a spacer lift/tires/wheels:
    2.jpg

    Then the topper:
    3.JPG

    Got rid of the chrome and went to black stock parts:
    4.jpg
    5.jpg
    6.jpg
    7.jpg
    8.JPG

    Alignment:
    9.jpg
    10.jpg

    TBC:

  2. #2
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default Continued

    First step in conversion, spindles:
    11.JPG

    Then, towed to transmission shop for output shaft swap (I had a connection at a transmission shop that could handle the swap...Thanks Mario!):
    12.JPG
    13.JPG14.JPG15.JPG16.JPG17.JPG
    The center console was sourced from eBay, and the shifter was bought new from Toyota.

    Drove for a while like this (no front diff or axles):
    18.jpg

    Got rid of the spacer lift (went with OME...Thanks Kurt-Cruiser Outfitters!)
    19.jpg20.jpg

  3. #3
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default Continued part 2

    more OME:
    21.jpg22.jpg23.jpg

    Then an ARB bumper with end-cap mod (Thanks Wil @ Sierra Expeditions!):
    24.jpg25.jpg26.jpg27.jpg28.jpg29.jpg

  4. #4
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default Continued part 3

    Then some sliders (Demello):
    30.jpg31.jpg32.jpg33.jpg34.jpg

    Frame reinforcements (Demello):
    35.jpg36.jpg37.jpg

    TBC:

  5. #5
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default Continued part 4

    The frame reinforcements were for the Outdoor Logic rear bumper and swing out:
    42.jpg43.jpg44.jpg45.jpg46.jpg47.jpg

    Spindle gussets:
    38.jpg39.jpg40.jpg41.jpg

  6. #6
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default Continued part 5

    Back to steelies (the '05's have a different offset than the earlier models...found that out the hard way!):
    1.jpg2.jpg3.jpg4.jpg

    Receiver for ARB:
    arb hitch.jpg

    Back to the conversion...pressing out the bearings/hubs to make way for manual hubs (had to make a jig for the press....Thanks Mark Hogan!):
    1.jpg2.jpg3.jpg4.jpg5.jpg

  7. #7
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default continued part 6

    Pressed in the new bearings, hub, abs tone ring, etc. Also had to "customize" a hub socket to fit...and torque to 205 ft lbs.:
    1.jpg2.jpg3.jpg4.jpg

    axle re-build, and installation:5.jpg6.jpg7.jpg8.jpg9.jpg10.jpg

  8. #8
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default continued part 7

    11.jpg

    No build is complete without:
    1.jpg2.jpg3.jpg4.jpg5.jpg6.jpg

  9. #9
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default continue part 8

    The BudBuilt belly skid wouldn't work on a PreRunner without modification....it seems the crossmember is too far forward:
    1.jpg2.jpg3.jpg4.jpg5.jpg6.jpg7.jpg8.jpg9.jpg

  10. #10
    Join Date
    Feb 2008
    Location
    central valley, CA
    Posts
    44

    Default continued part 9

    Had the gears done (5.29's...thanks for the advice TangoBlue!) and ARB's front and rear installed at Central 4 Wheel Drive in Sacramento. The compressor install:
    10.jpg11.jpg12.jpg13.jpg14.jpg15.jpg

    After trying several configurations...I settled on the compressor inboard from the battery. It seems to fit better there. The hold-down bracket still needs to be modified.

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