Build Bella, The Fam Runner

I bought this '86 4Runner 7 years ago with the intention of building a basic trail rig to take the family on the Rubicon and other Sierra trails.

I have been wheeling my '86 CJ7 since 2004 and it has been a great and reliable rig. It has seen a lot of trail over the years.

With a family of 4, and only 2 seats in the CJ, I am relying on my brother inlaw's rig for a seat for one of the kids. Wife hasn't been on the trail since we have had kids. I always wanted to build a 2nd gen Xtra cab Toyota but it would have the same problem with a lack of seats. Decided I should do the same build with a 4Runner to get everyone camping/wheeling together.

We have enjoyed the Toyota around town, snow wheeling and running forest roads in it. Over the years I stock piled all the parts I needed and knocked out small projects along the way. Rear bumper, rear ARB, rock sliders, Chevy 63 spring swap, dual cases with stock to stock 2.28 gears, and put on 31" BFG KM3. I bought a front Diamond housing 5 years ago and all the parts needed for the front 3link in 2022.

Lack of time has been my biggest nemesis and the reason I have waited so long for the SAS. That and we were enjoying it and I knew once I cut it apart it would sit unused for a long time. With the kids getting older it is time to get this thing on the trail! Currently, the IFS has been cut off and the frame is plated. The housing is under it and I'm trying to figure out where everything will live.

I've never linked anything so this is all new and I'm getting analysis paralysis. I'm counting on people who have done this to answer questions and help with problem solving along the way.

Don't expect quick updates and whole weekend fab benders but I do hope to make some gradual and steady progress from here on out.

I'll add some pictures to this point as I have time.

Here's some pictures of it over the years and some small projects I completed.

Rock sliders and rear spring swap.

Dual case build and install.

Current situation.

It now has 35" BFG KM3s and once the 3 link is set up, I will be building the front and rear axles with 5.29 gears, ARBs, front RCV axles and RCV hub gears. Should be plenty of beef for a trail rig and all around driver.

Got the stock pitman arm off with a combination of tricks. Cut an X on both sides, liberal application of Free All, grease on the threads, etc., and a C-clamp on the puller to prevent the cheap HF puller from spreading apart.

I'm planning to move the box forward as much as possible without too many modifications and keep some angle rather than standing it up vertical to improve steering shaft angles like most OE boxes are set up. Thoughts?

Next steps are plating the inside of the frame and getting the steering box in place, then build a tie rod. Planning to mount that off the bottom of the steering arms using heim joints. Has anyone run a drag link to the bottom of the steering arm? Would help with up travel but might end up on top.

Love it, clean simple family wheeler.

2 86s said:

Dual case build and install.

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I'd dial in those triples a little better. I got all three dead even on my 88' when in 2wd Hi.

Nice build

Diablo169 said:

I'd dial in those triples a little better. I got all three dead even on my 88' when in 2wd Hi.

Nice build

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I had them built reverse throw. Everything forward is Low, Low, 4X4.
I had them all lined up on the bench but ended up bending them to miss all gears in the transmission in any position and away from my knees. At 6'4" I'll take any leg room I can get!

Looking good dude, keep up the good work.

Sluggy said:

Looking good dude, keep up the good work.

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Appreciate it Sluggy. I need to get back on this and make some progress!

Nice! What's the WMS of the front axle?

betterbuckleup said:

Nice! What's the WMS of the front axle?

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62" with IFS hubs. I'll run 1 1/2" spacers in the rear for a 61" WMS.