dj's 1990 toyota pickup / vw tdi hybrid utilitarian build

djtc

Adventurer
Picked up an e locker ,switch ,ecu , spare housing and a rare 4.30 front diff to match the rear.

Excited to get it installed!Im dropping from 4.56 to 4.30s hopefully it will lower my rpm at highway cruising speeds
 

djtc

Adventurer
Update:

I just got back from my first trip with the truck and it performed great with some small hiccups!However before talking about the trip and showing you guys the pictures, I will first talk about the e locker I retrofited prior to going on the trip.

It all started when I found an accidented 3rd gen limited 4runner north of Toronto.I called the guy , settled a price and went down with a friendto remove it.Because its a 4.30 the front diff is a little hard to find in that ratio for this generation. However luckily I had found a 4.30 front diff out of an 88 pickup about 1hr away from the 4runner but it was $$$$.So we took the drive down on a friday morning got the e locker + switch+ecu , front diff and a spare axle housing off a 1990 pickup like mine.

A week later I had dropped off the housing at a big rig body shop nearby to get sandblasted.

Before:


After:



Gave it a shot of primer


First time I opened the e locker motor, I was expecting much worse but it was clean!


E locker taken appart, sandblasted the cover and internals cleaned up akmost ready to be greased and sealed with blue rtv.


custom e locker harness ( still missing relay and switch)


button/e locker switch only fits upside down for some reason.


Painted up and ready to be installed.



Front diff all cleaned up
 

djtc

Adventurer
Part 2

I had ordered a u bolt flip kit online but the mounting plates and u bolts were way off in measurement...so I made my own with 3/8 plate with reinforcements and 3" ID u bolts.These plates dont even budge at all when torqued.



I had shock mounts with 1/2 holes but found out that the shock bushing was much bigger .So I took two small SS pipes ,pressed them together to make a bushing and voila!





She's back on the ground functioning e locker ,little bath before heading out to vermont Overland rally!


Got these puppies for the trip diesel/water


Fast forward to vermont..

First trail ride prep, check the locker....I hear the actuator move but no green light. I take off the actuator motor and find out that the e locker sleeve will not slide in the diff manually either.I left it opened for the weekend and I will take it appart again when I have the time home.

First trail ride with a diesel fj62 ,my truck and 3rd gen 4runner.


Few pictures from other runs


Only time I had to be winched out .Stuck on the rocker..

result



I have other pictures and videos from the event but I am having a hard time uploading them for some reason.

Overall , the event was great! The truck performed well over my expectations as to what it can do with a stock suspension and some 33""tires, really amazing!Too bad I couldnt get the e locker to engage ,but even then not much stopped this truck even with both diffs open.
 
Last edited:

djtc

Adventurer
small update:

Got some 4.7 transfer case gears for the old girl,h4 headlight conversion, new taillights to replace the smashed ones and I am also planning a trip to Colorado/Utah either May 2015 or August 2015... any suggestion which month would be better?
 

djtc

Adventurer
I need your guys' opinions on something that I have been debating over. I have a softopper and also a hard shell topper for my pickup . I am looking to build a rack for the truck to install an awning and also to carry my canoe. Now my first plan was to make a rack that would fit both tops.Essentially it would be mounted externally to the bed rails and wrap around and over the tops. However, after measuring both tops , an external rack system with the hard top would stick out too far for my liking.

Keep in mind that I sleep in the back of my truck and I will be building a platform.

So my options are:
1. build a roof rack that bolts on to the hard top (cheap and easy)
pros: nice weather proof solution ,somewhat more secure. cons: heavier than the softopper and I would have to remove it if I wanted to haul something taller than the shell.

2.Build an external rack that wraps around the softopper.
pros:lightweight and versatile (can fold down in 1min). cons: not great for sleeping in wet conditions , not as "secure", rear visibility sucks, not great in winter when folding over (very stiff).

3.Build both and keep both tops
pros: options! cons: storage, cost.

pictures of both. (yes the softopper does look better)

 

djtc

Adventurer
Its not only that, the front corners let water drip in when it rains which is problematic with a sleeping platform...
 

Clutch

<---Pass
Pretty much personal preference. I prefer the fiberglass toppers over the soft tops...look cleaner to me. Smoother surfaces have less to snag on really tight over grown trails.

482816_10151523274514630_1726158531_n.jpg


528813_10151523275049630_1847303676_n.jpg
 

surlydiesel

Adventurer
I think you'll be able to get a tight fit around the hardtop. I've seen mini truck ladder racks that fit around a shell and they don't look bad with the cap off. The soft topper does look cool but it doesn't offer any of the key cap items I look for. Security and weatherproof but they look awesome. Did I mention that already? I've switched to contractor shells as well, being about to reach into the bed via the sides is just too handy. The windoors are ok on caps but opening the whole side is really slick. Also, they have far nicer locking mechs on them.

So my vote is hardtop with carefully and tightly built exo-rack.

-jorge
 

Clay

Adventurer
I vote for the hard top too. Soft tops are great, but being weather tight is pretty important!
 

djtc

Adventurer
Needed more interior room , so I sold her and bought a 4th gen 4runner. I miss the old diesel rumble :(
 

mantree91

Member
So it looks like you have ifs on the truck. Were there any issues with clearance for the oil pan with the front dif? I have a 90 4runner with a 22re that is about to give up the ghost.
 

djtc

Adventurer
Depends on how you make the mounts. I had it sitting low and notched the pan. But many have installed the motor with any notches. Go for the swap it makes the truck a little torque beast off-road.it also hauled pretty well on the highway.
 

mantree91

Member
Depends on how you make the mounts. I had it sitting low and notched the pan. But many have installed the motor with any notches. Go for the swap it makes the truck a little torque beast off-road.it also hauled pretty well on the highway.
So is the tdi a rear sump? Hom much did you have to notch out of the pan?

Sent from my SM-G900V using Tapatalk
 

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