Build 92 4Runner rebuild, 3 link front with new front frame section

J.Cole

J.Cole

Red Skull
Joined
Jul 14, 2020
Member Number
2296
Messages
205
Loc
Northern California
Now that i finished my toy hauler rebuild it's time to get back onto my 4Runner. The plan is to 3 link the front with coilovers and build a new front frame section. I started tearing stuff apart in Sept 2023. It's been almost a year since I've really put some work in on it. The new parts I'll be using are:

-Trail Gear Rock Assault Tacoma Width Housing
-4Wheel Underground Front 3 Link Kit
-Radflo 2.5x12 remote reservoir coilovers
-Radflo 2x2 air bumps
-TK1 Racing aluminum links
-Elrod's Limit Straps

Here's a short back story for anyone that cares. This 4Runner was my first vehicle when I got my license at 16 years old. Gathered all the parts for sas while in high school. Did the solid axle swap in 2013 in my parents 2 car garage with the help of some friends. Wheeled it and upgraded things as time went on. In Dec. 2019 I started to tear some things out and redo them to my standards at that point. One thing led to another and i ended up doing a cab swap lol. The more i tore into the old cab, the more i wanted to just start fresh. Took a while but found a complete white 1990 4Runner... with a blown head gasket lol. Swapped the body, built new bumpers front and rear, cleaned up a bunch of little things, and extended the rear wheel wells backwards. I tinkered on some small stuff here and there but for the most part its been the same since the cab swab.

I've wanted to 3 link the front for a long time now. I always thought I would end up with a D60 / 14B in it, so it was "I'll wait to do the 3 link then". Then after the body swap I kinda decided to keep this rig on Toyota axles. So with my mind made up on that, I started to gather parts. I also decided to cut the stock front frame section off and build a new one.

As it sits right now, I have the new front frame section built and welded on. The link brakets are tacked onto the axle. The frame side lower link brackets on clamped in place. The next thing I need to do is built motor mounts, front body mounts, and the figure out a transfer case mount. Once those are done I can raise it up on the lift and roll the axle in place and get links mocked up.

Time for some pictures. From when I first put it on the lift and started taking / cutting things off.

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Got the drive train all supported on jacks then cut the frame off.


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This poor frame has been cut / welded / ripped / cracked / patched back together so many times over the years lol. I/m happy to have a fresh start with the new one

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Continued in next post.
 
Pictures of the new frame section. The original plan was to use 2x3 square tubing. Then I saw how Alex and Orrie (exquisitemetalworksllc on instagram) did 4x4toyotatyler’s frame and wanted to copy it lol.

I started by making cardboard templates, then drew them on the computer. Then with the help of a friend got everything cut out on his plasma table.

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Put a couple bends in with the press brake to match the original frame shape.


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Soaked the pieces in a vinegar bath to take the mill scale off.

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Out of the vinegar and wiped clean

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All tacked together in one piece

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The big window towards the back of the frame is for the vin number.

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I also put internal gussets / supports inside the frame. I drilled a small hole for them to key into place. This part was an after thought. I wish I had this in mind from the start, it would have flowed together a little better lol.

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That's a ton of welding on the new frame section, but looks great!
 
GREAT work! Love the new front frame section and can't wait to see how it turns out. Planning to redo the front of mine sometime next year hopefully.

Can you tell me how much above the axle centerline the lower link mounts are? I was always told this was a bad Idea and would cause axle hoop. I see lots of guys using these kits so that obviously isn't true! Just curious on how much they are raised. Looks like 2"-3" but hard to tell with no reference.
 
2 86s said:
Yeah, you definitely have more patience, motivation, and skills than me. Kind of ****ed up the grading on a curve for the rest of us!
Click to expand...

Lol thank you!

fl0w3n said:
Damn! That things clean for 13 years of "abuse"
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I've kept it clean since I did the cab swap lol. The old cab got beat pretty good. I'll dig up some pics later of the progression of it

Blase said:
GREAT work! Love the new front frame section and can't wait to see how it turns out. Planning to redo the front of mine sometime next year hopefully.

Can you tell me how much above the axle centerline the lower link mounts are? I was always told this was a bad Idea and would cause axle hoop. I see lots of guys using these kits so that obviously isn't true! Just curious on how much they are raised. Looks like 2"-3" but hard to tell with no reference.
Click to expand...

Thank you! I'll get some measurements for you when I go to the shop tomorrow.
 
Damn nice work, I’ve been on the fence with 3 linking mkt 4Runner. Definitely along for the ride.
 
I'll be watching this one, for sure. I've had my 93 4Runner since I was 16, as well, seems to be a pretty rare thing these days. Keep up the great work, dude :beer:
 
Blase said:
GREAT work! Love the new front frame section and can't wait to see how it turns out. Planning to redo the front of mine sometime next year hopefully.

Can you tell me how much above the axle centerline the lower link mounts are? I was always told this was a bad Idea and would cause axle hoop. I see lots of guys using these kits so that obviously isn't true! Just curious on how much they are raised. Looks like 2"-3" but hard to tell with no reference.
Click to expand...

They are 2" above the axle center line

Ask92 said:
Just ordered a 4wu 3 link for my 2nd gen runner as well so will be watching this thread! Undecided if I am going to modify the frame yet or not.
Click to expand...

Do it. I'd use 2x3 if I had to do it again but so far it's nice to have a fresh start to work with,

NorCalJalopy said:
Damn nice work, I’ve been on the fence with 3 linking mkt 4Runner. Definitely along for the ride.
Click to expand...

I was on the fence for a while tool. Even once I had all the parts I was going back and forth lol
4RunnerKid said:
I'll be watching this one, for sure. I've had my 93 4Runner since I was 16, as well, seems to be a pretty rare thing these days. Keep up the great work, dude :beer:
Click to expand...

Thank you! This is the only vehicle that I own that I will never sell lol
 
Finally have some post worthy updates.

I got the t-case crossmember all tacked in place. I'm going to run the ring style that bolts to the back of the transfer case. I cut the ring out on my friends plasma table, got some Energy Suspension bushings, and got a small chunk of angle iron. I want to add some triangle gussets under the frame side tab but besides that I'm pretty happy with it.

Also going to do a skid plate too, but I want to wait a little bit until I build that. My friend with the plasma table I've been using designed a skid plate for his Toyota that i'll proably end up using a verison of.

Next up is motor mounts. That's what I plan to work on this week. I have the engine sitting where i want it so now it just make some templates and cut them out.

I also got my lower link brackets tacked onto the frame. Since they bolt into the factory t-case crossmember holes it was easy to figure out where they go.

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Made some motor mounts yesterday.

I had originally made some a couple weeks ago but didn’t like the way the motor was sitting. I thought it was sitting too low and it kept bugging me lol. So I rolled the gantry over and got it raised up to where I was happy with it.

Next up is front body mounts on the radiator core support.


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Also, I wanted to keep the oem motor mounts. I have a friend that just finished a Toyota build and he used DOM bushings for his motor mounts and said it will vibrate your teeth out lol. I've also heard the "bomb proof" style mounts vibrate bad too so I decided just stick with the factory ones.
 
J.Cole said:
Also, I wanted to keep the oem motor mounts. I have a friend that just finished a Toyota build and he used DOM bushings for his motor mounts and said it will vibrate your teeth out lol. I've also heard the "bomb proof" style mounts vibrate bad too so I decided just stick with the factory ones.
Click to expand...
I just got done swapping out TWO busted OEM mounts for Bomb proof. I noticed no difference in vibrations. Sure did suck when they both broke on the same trip and shortened my weekend!
 
NorCalJalopy said:
This is better than porn, where do I send my deposit for mine to be next?
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Lol thanks for the compliment. There's no way I could have done this job and made a profit but thats just me. I don't understand how some places do it lol.

Blase said:
I just got done swapping out TWO busted OEM mounts for Bomb proof. I noticed no difference in vibrations. Sure did suck when they both broke on the same trip and shortened my weekend!
Click to expand...

Good to hear on no more vibration then oem. I'll keep that in mind.
 
Got a few updates to post.

I got the axle mocked up and moved under the 4runner. As soon as I got it underneath i realized I needed a rear sump oil pan. Ordered the V6 rear sump pan kit from Sky's Offroad. Ended up only using the pan and oil pickup tube and got a 3.4l windage tray off Ebay.

Here it is with the new pickup tube and windage tray. I had to drill and tap 4 holes for the windage tray.

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Since I'm putting the drag link under the steering arms, I had to use some offset heims to clear the diff.

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Got the axle where I wanted it and made some mockup lower links and a mock upper. Got a panhard, tie rod and drag link cut, beveled, and threaded bungs tacked in. Then started to cycle the axle on both sides.

So far the 4wheel Underground front 3 link kit has been a breeze to set up. Once I got the axle underneath, all the other brackets pretty much fall into place.


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After cycling it a bunch, I got the bump stops tacked in place. I took the plastic bump pad off the bump stops when I set them.

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Next up was front core support mounts. I drew some up on the computer cut them out on my friends plasma table. Threw in some dimple dies for extra style points.

Also started mounting the steering box. I drilled the bottom holes. I'm gonna wait to make the top mounting hole until after I cut the front clip off.

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Last night I got the core support mounts welded together, and tonight I'm gonna get them welded onto the frame. This weekend I'm going to get the core support bolted up the the new mounts, then cut the inner fender portion of the front clip off and run a piece of 1.5" tube from the firewall to the core support to hang the fender off of. Should make it a bit easier to mount the shocks and make. the top mounting hole for the steering box.
 
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