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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 Mr. Clean Staff Member

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

    matluth Winning!!!!!

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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, and S/T Maxx's, upgraded to Old Man EMU coil-overs/shocks. Toytec shackles. Custom dual true dual exhaust. Next...new UCA's.
    Nice project truck.
     
  4. Sep 21, 2015 at 8:46 PM
    #4
    csuviper

    csuviper Moderator Staff Member

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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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    2010 Tundra 4x4, 2002 Tundra 4x?
    Removed piece of rear drive shaft from 4runner and swapped coupler to tundra coupler
    fad70d85844a707249e1c83afe49fb6b_aa1be4fa0ce921d3fa2fb62c3b25fa714eca1506.jpg

    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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    63977eb098bf5d4aaca6e0b7b4b398bd_d6ac39d0b34f28ac488e1254607dae545381a8a2.jpg

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

    e1e67a4ec5860c171f32c4146405429b_b7fc4a4489ee46645b9284482203269d9f7d5819.jpg

    Repairing warn winch

    34eb60b2cc11a7a8a6b495bffd81491e_53236a5f2e7f2e835320619db6c59db6416530c0.jpg

    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

    0dfa875bd314983a45a91899a5640e8e_aec4ede9aec82683bf130f0b26e2ed8dbbd61fad.jpg

    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.

    4dbd3d2cf03baea020647ca084f8401b_a8568557bd1c2575a1a32692fcc11753b13c1176.jpg
     
  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

    1c7316443972e43dc4e267b7a766a25f_38367a111a115600eecc310f3f6b47ccfe86b4fc.jpg

    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
    2b5439339ce12da38241778369fa9c4e_7fe24c7d24b089a725d49e6443569846c24a1968.jpg

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

    53520e8ad9378fa0e35cdd705d2c282b_093169a25375239ce7c03eb722c7b6e96608a1b1.jpg
    5fb78ffd99a54b1d6a69e63e1729e12f_8ed9a1c318e66b33db90898eceaecf45af5aca9c.jpg
    26083d97c0005bbd1af8b8f66f21c738_0ef544888daece85f19cac17c2620b4e4f162eb9.jpg

    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.
    5009ea1cfa4d125a4d0ba09f25463196_b63b3af2c7cae90742e9efb32a9a4ad0013884b8.jpg
    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 I'd rather B hunting

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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
    9931c29d71445d960a9c61ca21d10f6b_7816ff21289b51fb3f0fe5fa7c1e616aa396d445.jpg

    Swapped to 4wd spindle
    4e4c442aaae3143a730711fd1729d885_39d05cbfc34a2fc17e9b6642b9d63af2a436d03e.jpg

    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

    540d965f114ef3618a943b7dcd959804_aa044dd098ab9cb4de37d719b115493fce7c6dbd.jpg
     
  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

    0e32a0c7325855cfc3534c4cac825ab9_158be857f6affafbbd7b5bdab4387a54cdf61207.jpg

    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.

    6d5fb475dc8434f3b28b9fd157229938_cc85f21b905ff17c3d3375568a9d54f17c7015ec.jpg

    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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    e11267b327665dd780c6e4676c6786aa_badb9dd4a7e8454efb325ae9a45392e67ef3b0ee.jpg

    Using my shop crane

    5e7072bdf660239c3f87ba84d953927c_c4dacf6e9642fe4426b1b89a5c423e3fc3af1b36.jpg

    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.
    fbfc528c25313dcb888e0d5b9770e9e9_568a8644edcd29ca62cb85065994ca147b55ab57.jpg

    Here is how close I got to center with my pilot hole
    4f3f82c070323e21db3cc87efc60b3b9_1268547214f697c7a71f9374b8894049db810c28.jpg

    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
    2448d7ec570c386fa159175e9db1f468_1ac0fff4c3344f68b807d7809068a2c893a4838a.jpg

    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
    3b3beadf9d7cfc090cec0893443d9c7d_a561bfca410c8374afdaed6febe350ef95da7439.jpg
    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.

    721c4db167902e0aeef9707d4c066110_cbbe0be968e45601b807a031cd6ce742e3e75dc5.jpg

    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.

    9ba0dc8a53be2ef5a2ef7767fb7dc18e_ecca9d7c9745839423512fdddb8e0112f6fe82f6.jpg
     
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  24. May 21, 2016 at 11:55 AM
    #24
    FirstGenTundra

    FirstGenTundra ΜΟΛΩΝ ΛΑΒΕ

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    Northern Virginia
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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
    87763d59ff792f3000ca2dabd1bdd463_59c356c51aa2407c017631b82475048654bdd098.jpg off the old

    1fa4e509df6b02b5e0aa8a92d805b8a0_b458740e7738ead3bd5ad333900d5acc7ae4bcfa.jpg
     
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  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.

    d0546b8d5fbff5acc1258eccadd6fdef_bb8dcc29dd2aa29d3154819171c6b9b329758ca0.jpg

    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

    0910d7a361efa64d05259ba5cf955f8f_f3f4eacafbe58bfd5293efeaca09f1a64f324b38.jpg
     
  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....

    7944c7e6b15a45c30f2e41ed624fbb75_b049e938b3da150da32bfe13df4eb3159c962c61.jpg

    Glamor shots with both of my trucks.

    8fcbda34b8a2689cd296bef3f5b18e59_0556fa6c32b8344f9d1c55417b046368ee261ea6.jpg
     
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