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Project Gray Sky | 2004 DC 4x4

Discussion in '1st Gen Builds (2000-2006)' started by 87warrior, Dec 1, 2023.

  1. Dec 1, 2023 at 9:06 AM
    #1
    87warrior

    87warrior [OP] Whiskey Tango Foxtrot

    Joined:
    Nov 10, 2023
    Member:
    #106686
    Messages:
    101
    Gender:
    Male
    Kansas
    Vehicle:
    2004 DC 2uz 4x4
    My first Tundra! After shopping for a while, missing out on a few, and walking away from one that had a ghetto frame splice I finally picked one up. It's a 2004 double cab with 275k miles and Oak cloth interior. It appears to have simply been driven by the previous owners and things were fixed only when there was a problem. It is a southern truck that resided in Alabama, Georgia and Florida before ending up in Arkansas.

    PXL_20231130_213023671.jpg

    A good friend drove me to Fayetteville, Arkansas to meet the seller in hopes I would be able to drive this thing 375 miles back home to Dorothy and Toto's Kansas. The project name "Gray Sky" comes from the trucks paint color and the lyrics of Home on the Range. When in Arkansas the only place to do trip preparations in one of Sam Walton's parking lots. The Tundra made it back to Kansas despite a massive oil leak at the front of the 2UZ that required a 1/2 quart of oil to be added every 100 miles :annoyed: I determined the oil use was a leak based on the rainbow effect on the wet ground everywhere I went and the oil burning on the exhaust.

    The immediate plan for this truck is as follows:
    • Degrease the engine and front chassis to determine the source of the massive oil leak
    • Aisin Timing belt/water pump kit
    • Toyota Fan Bracket
    • Toyota valve cover gaskets
    • Iridium spark plugs
    • Denso Coils
    • Denso or NTK o2 sensors
    • Transmission fluid exchange
    • Transfer case/diff's oil change
    • Brake fluid flush
    • Lower door weather stripping needs re-attached
    • Toyota Ball joints
    • Toyota or Spicer carrier bearing
    • Treat the frame with Woolwax
    • Polish the headlights

    Things I don't know:
    • Every single cylinder shows a misfire code. I am hopeful new quality plugs and coils resolve that issue. I will run a misfire counter in Techstream to try and isolate the condition in which the misfires occur.
    • It is a sluggish dog between 65-75mph and has much less power than my 1999 Land Cruiser with 387k miles. I fully expected the lighter weight Tundra to do better. My hope is power will resume when the misfires are fixed.
    • The steering rack bellows are torn. I am not sure if the rack is leaking, but it probably is.
    • Previous owner installed new coil overs of an unknown make and the truck is real bouncy.
    • Driver seat buttons are not intact for some reason so I'll need to assess and reassemble.

    Future plans:
    • Firestone air bags
    • Level the ride with new shocks and coils
    • Replace the stock radio with something else. It has the JBL radio but the volume and tuning knobs don't work.
    • Redarc Tow Pro Elite brake controller

    This former Southern Belle truck is in for a Midwest shock. I'll continue to share it's journey here!
     
  2. Dec 5, 2023 at 8:09 AM
    #2
    The Black Mamba

    The Black Mamba Black Sneks Matter

    Joined:
    Sep 6, 2023
    Member:
    #103472
    Messages:
    2,438
    First Name:
    Ryan
    DFW
    Vehicle:
    Black 00 SR5 AC 5VZ PreRunner
    Imma keep it stock
    Awesome truck. Glad she made the trip safe (as if there were any doubts). Keep us updated and feel free to also post over on the Best gen discussion page. That's where the action is.
     
    87warrior[OP] likes this.
  3. Dec 6, 2023 at 5:40 AM
    #3
    DarkMint

    DarkMint just gettin by

    Joined:
    Apr 12, 2021
    Member:
    #61680
    Messages:
    408
    First Name:
    Ben
    Vehicle:
    2004 Tundra DC SR5 4WD
    Nice! Fellow 04 DC 4WD here.
     
    87warrior[OP] likes this.
  4. Feb 20, 2024 at 9:17 AM
    #4
    87warrior

    87warrior [OP] Whiskey Tango Foxtrot

    Joined:
    Nov 10, 2023
    Member:
    #106686
    Messages:
    101
    Gender:
    Male
    Kansas
    Vehicle:
    2004 DC 2uz 4x4
    The first order of business was to get a proper repair manual. I was shocked at how much thicker the Tundra manual is in comparison to my 100 series Land cruiser manual.
    PXL_20231206_210752350.NIGHT (1).jpg

    My first repair was the massive oil leak. I isolated the leak to the oil cooler housing.
    PXL_20231202_205626083.NIGHT~2.jpg

    I replaced the big oil cooler o-ring (90301-67004), oil filter bracket figure 8 o-ring (15692-50020) and the oil cooler relief valve (15695-50010). While working in the area, I found both of the bolts that go through the AC compressor to the fan bracket were missing.

    According to the Toyota service records, this truck received the SSC 70B lower ball joint recall service 11/2009 @ 72k miles. Since there is no record of the lower ball joints being replaced again, I utilized the ball joint recall kit (04006-62134) as well as new bolts (90105-12316) to replace them.
    PXL_20231223_211415107.NIGHT (1).jpg

    While I was 'in there' I also replaced the front rotors and pads with Power Stop K2324-36 Front Z36 brakes. I have had great experienced with this kit on my Land Cruiser so I decided to try it out on the Tundra.
    PXL_20231223_211333895 (1).jpg

    I was eager to finally drive the truck around and even had fun in the snow.
    PXL_20240115_204626148.LONG_EXPOSURE-01.COVER~2.jpg
     
    jerryallday likes this.
  5. Feb 20, 2024 at 11:28 AM
    #5
    87warrior

    87warrior [OP] Whiskey Tango Foxtrot

    Joined:
    Nov 10, 2023
    Member:
    #106686
    Messages:
    101
    Gender:
    Male
    Kansas
    Vehicle:
    2004 DC 2uz 4x4
    As I continued to work around the truck I recognized it had more neglect that I needed to address.

    The carrier bearing was letting the rear drive shaft flop around like a wet noodle, so it was replaced with Spicer 5002007. I replaced the lock nut (90179-18009) and bolts (90105-10085)/nuts (90179-10059) on the flange. Then I purged a lot of nasty grease from the u-joints.
    PXL_20240210_203008984.PORTRAIT (1).jpg

    I then replaced the PCV (12204-50030), PCV vent hose (12261-50050), clamps for the hose (90467-15021) and the crankcase vent hose on the passenger side (12262-0F021). The fuel vapor hose (23829-50070) from the TB to the purge valve was also replaced with fresh clamps (96132-51300).

    With every 2UZ, the elephant in the room is the timing belt and water pump. After talking to the previous owner I determined the timing belt and water pump were replaced at around 165k miles with generic parts. At 275k miles, it needed done again. I tore into the timing belt and found the crank had skipped one or two teeth and was not in time with the cams:
    20240204_101611-COLLAGE.jpgTo my surprise the actual timing belt wasn't in terrible shape! None-the-less I went to work replacing a whole slew of parts:
    • Aisin TKT021 Timing Belt
    • Aisin FBT-002 Fan bracket
    • Tensioner (16620-0W101)
    • NSK Idler (70SPPV0408DDUL)
    • Gates heavy duty serpentine belt (K060908HD)
    • Radiator Cap (16401-20353)
    • Aisin THT-015 thermostat
    • Lower Radiator hose (16572-0F011)
    • Upper radiator hose (16571-0F031)
    • Radiator hose clamps (90466-41003)
    PXL_20240203_190840761.jpg

    I even managed to time it correctly.
    20240204_101538-COLLAGE.jpg

    I wrapped up work under the hood with new Iridium spark plugs (90080-91180), Denso coils (673-1303) and Denso oxygen sensors (234-4169). I also replaced the battery hold down (74404-0C020) and hold down bolt (74451-0C010) since the battery was strapped in with a bungee cord.

    It runs pretty smooth but is not near as quiet as the 2UZ in my Land Cruiser with 380k miles, but the Tundra definitely has more giddy-up. The sluggish nature and wildly inconsistent cruise control I experience with the truck at purchase seemed to have been fix with a correctly timed timing belt. This is an at idle video of the 2UZ in the tundra after a fresh timing belt.
    https://photos.app.goo.gl/SvWqP5GCnKLSTAR38
    *Yes, I know the brake fluid is still overfilled and gross!
     
  6. Feb 20, 2024 at 11:37 AM
    #6
    Ebrperk

    Ebrperk New Member

    Joined:
    Oct 7, 2021
    Member:
    #69066
    Messages:
    75
    Gender:
    Male
    Vehicle:
    2016 SR5 4wd Crewmax
    Factory LED headlights with ihacker harness, Bilstein 6112,s at 2" lift and 5100 in back, SABM, rear diff breather mod, Firestone Destinations AT2, metal oil filter mod, fumoto oil drain, stock skidplate mod to access oil filter
    Coming along nicely, Great looking truck, I'm not sure if I would tackle a timing belt on a daily driver Where in Kansas do you reside
     
  7. Feb 20, 2024 at 11:47 AM
    #7
    87warrior

    87warrior [OP] Whiskey Tango Foxtrot

    Joined:
    Nov 10, 2023
    Member:
    #106686
    Messages:
    101
    Gender:
    Male
    Kansas
    Vehicle:
    2004 DC 2uz 4x4
    Thanks! It is slowly coming back together. Honestly, the timing belt is pretty fool proof. It's just nuts, bolt and verifying a few marks are lined up. I am located near Junction City.
     
  8. Feb 20, 2024 at 11:55 AM
    #8
    87warrior

    87warrior [OP] Whiskey Tango Foxtrot

    Joined:
    Nov 10, 2023
    Member:
    #106686
    Messages:
    101
    Gender:
    Male
    Kansas
    Vehicle:
    2004 DC 2uz 4x4
    While spending more time behind the wheel of this truck I grew exceedingly frustrated with the malfunctioning volume and tuning knobs on the radio. My initial thought was to throw in one of the old 2DIN radios I had on the shelf. Since I am kind of an OEM+ kind of person meaning I like to keep things mostly stock, I went to ebay to find a replacement stock JBL radio. To my surprise, I stumbled across an auction for a factory E7006 navigation radio that hadn't taken off. I placed the first bid and won the auction with embarrassingly low bid.

    I ripped out the old radio and dropped in the E7006 navigation radio with a Bingfu GPS antenna and USA Spec BT45-TOY Bluetooth interface.

    PXL_20240131_234954270.jpg

    PXL_20240131_235512935.jpg
    PXL_20240131_235518974~2.jpg

    Now I need to get the backup camera installed and working. I have a UC100 cable and a camera that should make the install straight forward, but there are no guarantees. :fingerscrossed:
     
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    #8
    Kimosabe likes this.
  9. Feb 20, 2024 at 12:19 PM
    #9
    Ebrperk

    Ebrperk New Member

    Joined:
    Oct 7, 2021
    Member:
    #69066
    Messages:
    75
    Gender:
    Male
    Vehicle:
    2016 SR5 4wd Crewmax
    Factory LED headlights with ihacker harness, Bilstein 6112,s at 2" lift and 5100 in back, SABM, rear diff breather mod, Firestone Destinations AT2, metal oil filter mod, fumoto oil drain, stock skidplate mod to access oil filter
    Nice area, probably best in Kansas, I lived in Wamego for several years before getting moved to Wichita. I tend to be the same concerning OEM, in my mind just makes sense to stick with OEM, unless an OEM supplier has improved on the original design, Good to hear the your truck is running better after all the work you put into it
     
    87warrior[OP] likes this.
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