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Northern Tundra Build

Discussion in '1st Gen Builds (2000-2006)' started by MK44, Sep 11, 2015.

  1. Sep 11, 2015 at 2:55 PM
    #1
    MK44

    MK44 [OP] New Member

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    2 years ago I began converting my 2002 Tundra from 2wd to 4wd, so far I have the entire front axle in including a total chaos long travel system and manual hubs. Eventually I am converting to solid axle or a custom built independent suspension, but for now here is how it sits...uploadfromtaptalk1441988182083.jpg

    Took the front bumper off and I am about to build a custom one as well as swap in the 4wd transmission and manual transfer caseuploadfromtaptalk1441992507109.jpguploadfromtaptalk1441992522843.jpg

    Lots of work and I am really slow stay tuned for more
     
  2. Sep 11, 2015 at 3:08 PM
    #2
    Sean266

    Sean266 #ThinBlueLine Staff Member

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    This will be a fun build!
     
  3. Sep 11, 2015 at 3:59 PM
    #3
    matluth

    matluth Fish On!

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    Aurora CO
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    2007 Slate Metallic 5.7L Tundra DC SR5 4X4
    18"X9" FN BFD's rims, 295/70R/18E Cooper Discoverer STT Pro's, upgraded to Old Man EMU coil-overs/shocks. Toytec shackles Next: true dual exhaust, new UCA's.
    Nice project truck.
     
  4. Sep 21, 2015 at 8:46 PM
    #4
    csuviper

    csuviper Moderator Staff Member

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    Broomfield, CO
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    Some Mods :) See build thread for details
    Interested in the build!
     
  5. Oct 27, 2015 at 3:07 PM
    #5
    MK44

    MK44 [OP] New Member

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    Removed piece of rear drive shaft from 4runner and swapped coupler to tundra coupler
    [​IMG]

    Need to get transmission to xfer case bolts and sealant to permanently mount it to transmission
     
  6. Oct 29, 2015 at 4:27 PM
    #6
    MK44

    MK44 [OP] New Member

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    [​IMG]

    Cut off factory bumper mounting brackets, getting ready to weld a filler in for bumper mount.

    [​IMG]

    Repairing warn winch

    [​IMG]

    Little corosion on the terminals cleaned it up and good to go
     
  7. Dec 25, 2015 at 3:07 PM
    #7
    MK44

    MK44 [OP] New Member

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    Transmission and case combined, 2004 auto transmission with 1990s manual shift case. Can't wait to get it installed

    [​IMG]

    Once the coupler was swapped everything fit like a glove.

    Going to have to get a vss since this case did not come with one.

    [​IMG]
     
  8. Dec 31, 2015 at 3:24 PM
    #8
    MK44

    MK44 [OP] New Member

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    Got a new welder and I am ready to go.... but then this happened to one of the snowmobiles

    [​IMG]

    Front coil over sheared completely off the mount on father in laws sled... shop is too full gonna have to hold off on going after swap this week...
     
  9. Jan 10, 2016 at 4:22 PM
    #9
    MK44

    MK44 [OP] New Member

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    Fixed the snowmobile and got my shop space back
    [​IMG]

    Drained the trans fluid and used some of my hillbilly engineering to remove the single piece 2wd drive shaft.

    [​IMG]
    [​IMG]
    [​IMG]

    Looks like rust got to the leaf springs and rear axle... thank goodness I didn't intend to keep those anyway

    Next up is the transmission swap.. stay tuned.
     
    Sean266 likes this.
  10. Jan 10, 2016 at 4:38 PM
    #10
    MK44

    MK44 [OP] New Member

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    Drive shaft out and 4wd transmission prepped.
    [​IMG]
    If you can't tell it's -13 here this evening.
     
    Sean266 likes this.
  11. Jan 10, 2016 at 4:51 PM
    #11
    TruckLife900

    TruckLife900 All Eyez On Me

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    Nice, looks like some work is going on there. :popcorn:
     
  12. Jan 10, 2016 at 5:31 PM
    #12
    MK44

    MK44 [OP] New Member

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    Dug up some old pics

    2wd spindle
    [​IMG]

    Swapped to 4wd spindle
    [​IMG]

    I have since replaced that spring and repainted the LCA.
     
  13. Jan 10, 2016 at 5:34 PM
    #13
    MK44

    MK44 [OP] New Member

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    Pic of the manual hubs

    [​IMG]
     
  14. Jan 15, 2016 at 8:44 PM
    #14
    MK44

    MK44 [OP] New Member

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    Removed electrical and plumbing from 2wd transmission jack is on it. The bolts come out tomorrow.
     
  15. Jan 16, 2016 at 6:48 PM
    #15
    MK44

    MK44 [OP] New Member

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    Thought things were going good then snap... broke a bolt off in the transmission. Gonna have to get the extraction kit out.
     
  16. Jan 17, 2016 at 3:09 PM
    #16
    MK44

    MK44 [OP] New Member

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    Transmission out

    [​IMG]

    Gonna give it a rest for the weekend, too cold... started the 2010 and let it run for a bit... -22 degrees with a wind chill of -40 degrees.

    [​IMG]

    Looks like the bolt I broke is sticking out enough to back it out.
     
    Wvmoonshiner and TruckLife900 like this.
  17. Feb 4, 2016 at 11:26 AM
    #17
    MK44

    MK44 [OP] New Member

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    [​IMG]

    Using my shop crane

    [​IMG]

    Shifter hole
     
  18. Feb 17, 2016 at 8:53 AM
    #18
    MK44

    MK44 [OP] New Member

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    After a whole day of marking drilling changing bits drilling more then heating cooling drilling more then filing then finally using a smaller tap to run the bolt out the other way I have removed the broken bolt.
    [​IMG]

    Here is how close I got to center with my pilot hole
    [​IMG]

    The smaller tap was the only thing I could get to send the piece out the other side after I tried using the vice grips to pull it out the other way, using the bolt extractor nuts and several times cursing it
    [​IMG]

    This may be the highlight of my build just getting that bolt out. Now I need to find some replacements and repair the threads in that hole.
     
  19. Feb 17, 2016 at 8:57 AM
    #19
    MK44

    MK44 [OP] New Member

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    Went for a ride this weekend as well
    [​IMG]
    Picture of my lovely wife and her kitty (arctic cat snowmobile)
     
  20. Feb 17, 2016 at 9:42 PM
    #20
    MK44

    MK44 [OP] New Member

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    Mounted transmission and got shifter in. Gonna have to lose the bench seat as the shifter hits it in 4wd.
     
  21. Feb 19, 2016 at 10:00 PM
    #21
    MK44

    MK44 [OP] New Member

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    Front drive shaft is in... need to buy a new bolt to replace the one broken off.
     
  22. May 17, 2016 at 6:35 PM
    #22
    MK44

    MK44 [OP] New Member

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    Makes me feel as though I am in college again.

    [​IMG]

    Put that tarp there to keep prying eyes off of it but over the drive the tarp was destroyed.
     
    Wvmoonshiner and TheBeast like this.
  23. May 17, 2016 at 11:02 PM
    #23
    MK44

    MK44 [OP] New Member

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    Fabricating new x-member and the torch ran out of oxygen.

    [​IMG]
     
    FirstGenTundra likes this.
  24. May 21, 2016 at 11:55 AM
    #24
    FirstGenTundra

    FirstGenTundra ΜΟΛΩΝ ΛΑΒΕ

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    How have I not seen this thread yet! I loved my first gem! :D Looks awesome!
     
  25. Jul 24, 2016 at 1:45 PM
    #25
    MK44

    MK44 [OP] New Member

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    Swapping pans onto new transmission
    [​IMG] off the old

    [​IMG]
     
    FirstGenTundra likes this.
  26. Aug 10, 2016 at 9:13 AM
    #26
    MK44

    MK44 [OP] New Member

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    New rear drive shaft in
    Fabricated my own crossmember and that's in.
    Need to swap pans, get a vss, and fill fluids.
    And redo my exhaust seeing as I cut parts out to install new transmission
     
  27. Aug 17, 2016 at 7:43 AM
    #27
    MK44

    MK44 [OP] New Member

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    Shortening bolts on the lathe.

    [​IMG]

    Bolts were a bit too long for companion flange on drive shaft and I did not want to go into town to get more.
     
  28. Aug 21, 2016 at 9:33 PM
    #28
    MK44

    MK44 [OP] New Member

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    Fluids in, just need a VSS
     
  29. Sep 4, 2016 at 12:37 PM
    #29
    MK44

    MK44 [OP] New Member

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    Accidentally ran over a hacksaw

    [​IMG]
     
  30. Sep 7, 2016 at 1:27 PM
    #30
    MK44

    MK44 [OP] New Member

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    4wd works :) and I have a new pot hole in my drive... looks like I need lockers and more flex....

    [​IMG]

    Glamor shots with both of my trucks.

    [​IMG]
     
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