‘97 4runner build/adventure thread

[castlerunner]

This is my 97 4runner. It is 4x4 manual and currently shows 172xxx miles on the clock. I purchased it just over two years in completely stock and largely original form. It had 141xxx miles when purchased

This is about a week after I got it

Since then I have been catching it up on maintenance and modifying as well

Maintenance completed.
-New timing belt, water pump and ALL associates seals parts
-rear axle seals and bearings
-LBJs
-new front axles
-new clutch and all clutch hydraulics
-spark plug and wires
-new valve cover gaskets and ALL associates seals
-regular fluid changes
-new o2 sensors to pass smog
- and more I’m sure I’m forgetting.
All parts were replaced with OEM or better

All work done myself with the exception of breading the bearings off and on the rear axles and resurfacing the fly wheel when new clutch was put in.


Modifications in order - All mods installed/built by me.

My first real mod was a lift. The lift has evolved over the last two years

The first iteration of a lift

Front - Tundra bilsteins with medium duty OME springs set at about 2” (this remains in place today)

Rear - the rear has seen some changes.
I originally put in OME 906s I believe. Medium duty 2” lift. This sat okay but could not handle the weight of camping gear and modifications that were to come.

This is after first lift install

Since then I have upgraded to LC coils with appropriate length Bilsteins. Also have an eimkeith PCK to correct axle location after lift.

I will likely be moving to OME 861s to support the additional weight I have added

In the above photo you can also see my roof basket. This is a curt basket with 2 extensions. With a little work, I got a full length rack for about $250. This rack has since been modified.

This is a camping rig so storage/ organization is important. That is why I built a rear drawer system

Next big mod was the addition of the TRD supercharger with URD 7th injector.

Terrible picture but it’s a super charger. Nothing pretty.

This was installed because my GF and I just ordered a new Hiker off road camper trailer and some additional power will be very appreciated. I have just about got it tuned perfectly.

My current project is my rear bumper. It is a plate/ square tube bumper I built off of the factory hitch. The hitch had to be modified significantly to get it sit up like it is.

You can also see how I modified the roof basket. Removing approximately 4” of height giving it a much better profile and picking up some much needed clearance as I frequently have to go into parking garages as this is my daily.

Still lots of work to do but it’s coming along nicely.

After the bumper is completed my next big mod will either be the tundra brake upgrade or gears/locker(s).

That’s it for now. I’ll update with some of the adventures we’ve been on along the way in a bit.

 

[borison]

Looks good. You’ll have to show some more of your roof rack. I’ve never liked the look of those Curt baskets, too high and spindly looking. It looks like you may have addressed those issues well, I wasn’t sure they would take to modifying because of the thin metal. Bumper looks well thought out.

 

[castlerunner]

The roof rack was a PITA. I cut all verticals just below the top rail. The had to break the factory weld to remove all pieces of vertical tubing. I then cut approx 4” out

The metal is very thin. Especially for my flux core welder. But I got a solid bead on every vertical. It is pretty strong for the amount of weight I put up there. The truck is only rated for 120lbs on the roof and I know it’s that strong.

These sections look terrible. Brazing would probably be best. Flux core is not really appropriate but again, given the weight, it’s fine. I could clean up with some body filler but I’m not worried about it.

This job could be done much cleaner with more appropriate tools. But for the money I have into it, I’m happy.


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