Making of a GX470 daily drive light tow rig, armoring up and improving diamond in the rough project

[Lil'John]

I picked up this diamond in the rough to turn into my daily driver and 'light' tow rig:

This will not be turned into an overlanding rig

It is a 2005 with under 200k miles on the clock with the timing belt/water pump done at ~170k... and full synthetic for at least the last two years. Minus a slight leak from the driverside rack, it mostly looks good mechanically(no parking brake) There are a host of cosmetic stuff that I need to address(bumpers scuffed pretty well, same with running boards, and a few 'minor' issues inside)

Tow duties include FJ55 project(s) so the 6500lb rating squeaks in for being appropriate as far as the popo goes

4 wheel drive will be minor things like Gold Lake (clearance needed more than 4wd) and snow in the winter. So no lift is planned. The wheels have some problems(corrosion) so I'm eyeballing another set of rims and call these my winter rims

For daily drive duties, I drive a curvy hilly road in Wentworth Springs. After a couple of drives back and forth, I want to tighten the handling up(see below)

Due to driving Wentworth Springs and finding too many Rubicon goers who can't drive for shit, one initial goal is to get some armor on it which helps with getting rid of the cosmetic bumper/running boards I've got sliders on order from a local fab shop. Front/rear bumpers are still being looked into; I'm focused on more plate style than tubes. Tubular just didn't look right to me. I kind of like Coastal Offroad's do it yourself kits.

I'm also looking at upgrades to help with towing; brakes and transmission cooling. For the cooling, I've got a Hayden Automotive 678 cooler on the way. From research, it looks like 'minimal' fab work to get it installed and does a great job keeping temps down.

I'm not sure on the brakes but I hear the GX460 rotor and caliper are a bolt on front upgrade. I'm still researching what will help the rear.

Last 'big' project is upgrading/replacing the rear suspension. Two owners previous to me had replaced the ride height system so it got yanked(lines in bad shape, vacuum pod gone) and replaced with some 'unknown' kit. So far, I'm not really thrilled with the 'kit'. Part of that is due to flashing 'off' light for the ride height system. This kit did not include a 'centering' puck to locate the upper coil spring that I've seen other use. Is there a better spring to use? 4 runner?

Is there a stiffer bolt-in sway bar solution for front or rear?

The shocks seem to be working but is there a good replacement for them also?

Any additional "must do" mod recommendations would be appreciated. Ducks are out.

 

[Steve300xcw]

Front/rear bumpers are still being looked into; I'm focused on more plate style than tubes. Tubular just didn't look right to me. I kind of like Coastal Offroad's do it yourself kits.

Just did one of those. Plan on doing a bit more figuring than you think you will be doing. They do come out pretty slick though

 

[Lil'John]

Just did one of those. Plan on doing a bit more figuring than you think you will be doing. They do come out pretty slick though

I saw two videos(three) of their bumpers being fabbed up and it didn't look too bad. Just a lot of tack, check, tack, check, etc.

I was going to get their sliders but a local guy was doing a bolt on fully welded set cheaper than Coastal's kit. Hopefully picking up by end of month.

 

[Steve300xcw]

The paperwork that it comes with is a joke. So you are pretty much putting together a puzzle without having a pic of what its sposed to look like

Took me a ll bit to figure out the mounting and how the winch plate tied in. But after that its pretty much just hold it up in place and tack shit together. Could probly do one in 1/2 a day if you were serious about it.

 

[rockota]

I can’t imagine towing the pig with that!

 

[Lil'John]

The paperwork that it comes with is a joke. So you are pretty much putting together a puzzle without having a pic of what its sposed to look like

Took me a ll bit to figure out the mounting and how the winch plate tied in. But after that its pretty much just hold it up in place and tack shit together. Could probly do one in 1/2 a day if you were serious about it.

Ah... the videos I saw showed some instructions... but I guess that would be too easy :)

I can’t imagine towing the pig with that!

Regular cab S10 pulled it off with pucker It will have plenty power and better stopping. If the sway becomes an issue, I'll add a weight distribution hitch. Tow capacity is 6500lbs. Pig is a bit under 4000 lbs... depending upon outfitting, a bit less.

 

[Steve300xcw]

Ah... the videos I saw showed some instructions... but I guess that would be too easy :)

Oh they come with them

 

[Lil'John]

It is looking like I'll need to change the coils that were installed to replace the ride height system. It is looking like they used some lift springs which I have no intention of adding bigger tires.

I don't have the lines or tank... otherwise, I probably would have sprung $500 to put the OEM bags back on. I'm still trying to find if it has the compressor. So with that said, what is a good quality replacement that is zero lift and heavy duty to handle the tow duties?

I spent a bunch of time pulling some wires to the rear for lights. Somewhat easy but sometimes a pain. Getting prepped for rear bumper.

 

[Lil'John]

After a week of driving/using/crawling around it, my initial impression with it so far is mostly positive.

• It gained the agility I wanted over the Tacoma... nice tight turning radius. Plus less ass in the way.
• Oodles of power when compared to the Tacoma. It is a bit hard to keep out of the gas
• AWD is keeping the power on the ground; Tacoma had issue with 'burnouts' on even the mildest off camber start. I'll grant you no weight over rear axle hinders the Tacoma but I've got a soul sucking camper shell adding weight.
• Comfort is there. But again, comparing to 20 year old Tacoma with seats breaking down I did have to order front seat arm covers due to excessive wear. I like the ass heaters but it would be nice if it included the seat back also.

The negatives I've run into so far:

• Lack of lighter ports; I've only found two in the front cab. Not a single one to be found in the 2nd or 3rd row. Fucking really? My Tacoma had three in the front The lack of a port in the 2nd row is beyond shocking... but it does have a DVD entertainment center back there. It does have a 110v port in the cargo area... but it seems like it is maybe 1amp so I'm not sure what use that is. I've got a GPS and dash cam that are much have... I've got one free USB port available but it would be nice to have two or so handy to charge head band lights.
• Lack of storage. I'm a bit shocked at lack of general storage handy. Again, the Tacoma did better with two center console places in addition to the glove box. There is a cubby in the cargo area(perfect for recovery gear). There is the saggy net in the rear door. I'm trying to 'hide' a med kit but there is a lot of general shit I'd like to stash in the front area.
• I'm not enamored with the touch screen interface... it feels like I have to pull my eyes from the road for too long to get shit done. I hate that but for the more used functions, I've got tactile buttons.

I'm not sure if it is a negative or not but so far, gas seems on par with the 3.4L Tacoma... maybe a hair lower(1mpg) Since I wasn't expecting Prius gas mileage, I'm satisfied... lots of smiles per gallon when I get on the gas

As a result, I'm looking at a few 'upgrades':

• New coil springs to get rid of what appears to be a lift when the ride height system(noted above). The goal is to get back to no lift and hopefully a heavier spring rate. Is there a stock height kit? Or is there a certain 4runner I should be looking for? I wouldn't cry over losing 1" over stock.
• Upgraded front and rear sway bars. I'd like to pull in the body roll a bit more. Are there heavier stock applications for the 4 runner I should look for? Or who is out there for aftermarket?
• Heavy duty links in the rear (I'm trying to bullet proof the links so zero lift is a goal) I know there is a kit to weld on the bottom links. My preference is replacement links though.
• Maybe full float rear... was there an out of market 4th gen 4runner that came full float similar to older land cruisers? Somewhat pipe dream but would be nice to have 'safety blankey' for towing. I'm curious about 'stock' replacement over a custom unit like Front Range(??) does.
• Front and rear plate bumpers as noted. Is there a better option than Coastal Offroad? I'm looking at looks/price. I could talk to one of my usual local fab guys but I can't imagine the bill for a plate bumper from them
• Front upgraded brakes. Using GX460 caliper and rotor are recommended. Any other options?
• Rear upgraded brakes. I'm still searching but I need to rip into the back to see what is going on with ebrake so I figure an upgrade might be worth doing while it is apart.
• Saggy net replacement. I've seen numerous 'Molle' replacements. I'm hoping to find something a little more simpler; a 'bolt over' template for the recess, a ~2" deep lip, and tabs on both side for bungie/elastic band across. So far, my search is fruitless. Anyone have a good idea?

Any opinions on the above upgrades? I already know the full float is borderline retarded but tend to go off reservation at times

 

[DMG]

Does arb make heavier rear coils for that? They really helped our 100 series

 

[Lil'John]

Does arb make heavier rear coils for that? They really helped our 100 series

I will took a look at ARB direct... I was actually checking Old Man Emu(OME) and didn't find a zero lift replacement. For some reason, I thought OME was ARB company.

 

[tsomctl]

I will took a look at ARB direct... I was actually checking Old Man Emu(OME) and didn't find a zero lift replacement. For some reason, I thought OME was ARB company.

They are an ARB company.

 

[DMG]

I will took a look at ARB direct... I was actually checking Old Man Emu(OME) and didn't find a zero lift replacement. For some reason, I thought OME was ARB company.

They are

 

[Lil'John]

After looking on ARB site, I was left more confused than not. They didn't provide shit about lift of their springs. We'll see if their support helps.

I searched all the part numbers on Summit Racing and it appears all are lift springs... although for two of the rears(2896 and 2895) they claimed 0" to 2". Not sure how they figure that out

Is the air system not worth adding back in? I haven't looked at the shocks but I'm assuming they are non-electric style. But I am missing the air tank along with all air lines. Plus the compressor doesn't look in good shape... I haven't done a functional test.

I know new rear air bags are $500(OEM). I can get the tank for about $80 that looks in good shape. Same for the air compressor. I would need the air lines as well as replace the shocks. So maybe $1.5k(no idea on price of shocks) in parts to get back to stock if I do the labor.

 

[Cameronswmp9]

Dobinsons may have coils like you are looking for, but I may be thinking 1" lift plus spring rate, think overland springs.

I would probably try springs before sway bar upgrades, as the springs may take the body roll enough without adding the bars.

For the air system, I imagine getting the lines in any shape would be the hardest part, much less in good usable shape. I imagine people pull them off when it doesn't work, and however they come off is the way it is, with the trash being the target. Lexus may still be able to get them, but I doubt they will be inexpensive plus the shocks and all to go with it. For the cost, a set of good aftermarket shocks may be ticket, especially something like a king or fox you can adjust valving within

 

[Hooligan]

My brother and two good friends wheel their GX. There is a very active FacePage they use a a resource.

For rear axle, think the FJ Cruiser was bigger maybe 8.4 vs 8.2 , and has rear locker. Think that is the only factory bolt in option.

 

[Lil'John]

Dobinsons may have coils like you are looking for, but I may be thinking 1" lift plus spring rate, think overland springs.

I would probably try springs before sway bar upgrades, as the springs may take the body roll enough without adding the bars.
<snip shock info>

Thank you for Dobinson idea... ARB 'tech' support was useless in this case Dobinson web page so far is VERY helpful with their info. I'm still trying to figure out how to id their front/rear springs but they give 'lift' info and how a gx470 differs from 4runner A couple of bucks more than ARB but seems like they might be a better option.

I was going to swap springs first but I'm not holding my breath on excessive sway. I'm trying to ride the fine line between comfortable ride and handling without going super stiff springs.

I did find one new line without looking too far... it was ~$70. But you are right, when someone is removing the bags, they are going to just cut it and fug it. and I don't blame them. The shocks on the other hand... wow I may see how the Fox or King line up.

My brother and two good friends wheel their GX. There is a very active FacePage they use a a resource.

For rear axle, think the FJ Cruiser was bigger maybe 8.4 vs 8.2 , and has rear locker. Think that is the only factory bolt in option.

I forget who the bolt in was. I'm not worried too much about the 8.2" diff... AWD plus auto help offset any shock load that would kill it. Plus no real wheeling. I was mainly looking at factory full float option for another layer of 'safety'. I know I could fuck around with an FJ80 axle... been there, done that. The bracketry is what would 'kill' me.

 

[Lil'John]

I've had a few parts on order and finally had some show up.

The most important is the cup holder because the stock one sucks:

The bad with this one is I can't use Gatorade cups but so far so good.

Actually, real update was a set of sliders from a 'local' guy. He is down in Rocklin(1 hour drive) with a website of www.elevatemetalcraft.com He is a small in the garage fab guy. I'm working on painting them and then mounting them the next day or two... I threw on a coat of primer that took well over a full can

My pictures don't do a great job at showing his welding but it is above average... definitely a welder and a not a grinder like me They are bolt on and included all the hardware to mount it.

I also got a set of his grab handle Molle Mounts:

The above isn't mine... I am going to get mine powder coated interior color. I am going to mount a GPS on the driverside and a dash cam on the pass. I hate dealing with the window suction cups fall off the windshield.

I can't get them coated until I get my roof shelf coming by slow boat from China(actually FedEx from Poland):

The lack of storage space in the rig sucks. No, I'm not going expedition rig. No Molle window covers or any of that shit going up. From the same company(Bison Gear), I've got some brackets for under the rear of the front seat that provide 'strapping' for flashlights/etc and a pouch setup to replace the rear tailgate net:

From my searching, Bison was the only place with 'plain' roof shelf system... every other US company decided their roof shelf was Nascar and had huge logos on them and in general cost more than Bison.

 

[Cameronswmp9]

There are some good storage options here: 4th Gen 4Runner: Cross Country Runner

I haven't heard of Bison, I like some of those options and worth a look!

 

[Lil'John]

There are some good storage options here: 4th Gen 4Runner: Cross Country Runner

There are definitely some good ideas in there. None would work for me since I'm trying to maintain 'easy use' of the existing cargo space... so cabinets, full shelves, etc won't work. My cargo needs vary wild when I need them.

I haven't heard of Bison, I like some of those options and worth a look!

Bison seemed like a good company to me at least as far as 'simple/clean' solutions without putting badges/icons as big as the product on the product I can't really comment about the quality of it yet but aside from the pouch, it is bent and/or cut metal with no welding... so to me, hard to fawk that up OTOH, I outsourced the rack so that says something

I got an 'emergency' call into work this morning so I got a little delay on getting the sliders painted up and ready for install. I ended up with two coats of primer and then two coats of satin black on top of it... now I'm working on two or three coats of Herculiner on the round tubing and the top of the first flat bar. So far, no Herculiner on the hootus yet It is exactly like I remember it twenty years later; a sand slurry that is a little bit on the wet side when painting it on. Hopefully my results are the same as when I did the back of the 99 Tacoma: hard shell that can't even get gouged off

Also can confirm that Herculiner will store 5+ years in the garage

 

[Cameronswmp9]

There are definitely some good ideas in there. None would work for me since I'm trying to maintain 'easy use' of the existing cargo space... so cabinets, full shelves, etc won't work. My cargo needs vary wild when I need them.

Was really thinking more about shoving random tools (or pouches, depending on your storage needs) in inconspicuous areas out of the way.

I don't have the use of the shelves and all, feel the same way about the "easy use". I have a tote in the back of my 4Runner and I don't like it, but it's an easy way to store some things, so give/take kinda deal....