Allow me to introduce to you my main adventure vehicle, my 1996 Toyota 4Runner as well as the build sheet! This particular build is near and dear to my heart as you could say it was made for me! Before 1996, my parents owned a baby blue 1998 4Runner (1st gen). With family life, the 2-door entry made it difficult to strap me into the car seat. As a responsible family would do, my parents decided to purchase a brand new 4Runner in 1996 that had a layout better suited for family life.

In the 1990s, there was still a stigma for manual vehicles. The trust for electronics was growing, but some people had issues with certain electronic components failing. My dad, also being mechanically inclined, preferred the option of completing repairs at home, so they opted for a base model 4Runner. In the time of the Limited models, power windows and even a sunroof, we got the base model of base models! Fitted with a 3RZ 4 Cylinder engine, W56 5-Speed Manual Transmission, hand cranked windows and no AC, no one realized how awesome this platform would be in an off-road application at the time. 

I grew up with this car, so it was fitting I eventually learned how to drive it. I learned to drive manual, using it to pass my driver’s license and eventually learned how to offroad with it. At this time, I spent most of my time at Stave Lake (West Access) taking it to the muddy shores. With road radials spinning in the mud, I learned how to play in the mud, and some basics of FSR driving.

I eventually moved to Kelowna to take up some University courses, spending my spare time mountain biking. I ended up finding a neat FSR with shuttling options for the bikes. When biking season slowed, I started exploring the trail with the old 4Runner as a way to de-stress from exams. During the winter, I explored too far off the beaten path and ended up getting stuck on a sled trail while attempting to turn around. With no preparedness kit or tools, I began attempting a few techniques to break the wheels free from the snow. I remember making a quiet promise that if I got out on my own accord, I would build the 4Runner into an offroad weapon. Soon after, shifting 1st and reverse as quickly as possible, I was able to rock the truck out of the deep ruts. Now, yes I should have known this, but being fairly inexperienced with snow at the time, it was a huge relief to figure this out.

I continued to drive it for a few years after to and from work/school. During a summer work term, I began getting antsy to spend some money on it. Saving up some work money, I purchased a set of used 31” mud tires with the stock alloy wheel installed. Right away I had to take it to Stave Lake to test it out! After a few visits, I went through 8 sway bar links, the rear axle brake line and managed to pull the upper control arm mount off the axle. At this point, we parked the vehicle deeming it unsafe and even attempted to sell it during this time.

After going through a phase of playing with newer and different rigs, I decided to get away from payments and dedicated my time and money for 2 straight months getting the 4Runner back on the road. At this point it had been sitting for 4 years. Every evening, every weekend, any spare time I had, I spent rebuilding the 4Runner. With this being my only offroader, I was rushed in getting it together so that I could enjoy exploring with it in the Summer. 

The truck underwent a frame down cleanup and upgrading session. I replaced the broken control arm mount with a used axle housing from an American truck purchased through Craigslist. I ground the axle and exposed frame painting them with primer and a rubber asphalt coating to protect it more. I had the bearings and seals replaced with new backing plates and went about the transfer of components to the new housing. 

While replacing the axle, it seemed like a great time to start working on the suspension. I researched a few different options and ended up going with a plan I regretted not doing with my previous Jeep build. I installed ARB Old Man Emu springs and Pro-Comp E9000 Shocks. I would have preferred Bilstein 5100s, but due to Covid-19, all of the major suppliers had a wait list of about 4-6 months.

Moving on to the front, we built Bilstein 5100 struts with ARB Old Man Emu springs. Somehow I lucked out as the shop I purchased them from received a return on the Bilsteins. The previous customer purchased them for the same 4Runner, but ended up totalling the truck. During the overhaul, I also replaced the clutch, changed all of the fluids before testing it out on the local trails. 

In this discovery, I found out the Bilstein struts don’t come with mounting hardware, so we had to purchase those extra. Make sure you also read the clutch markings as they are useful in installing the disc the correct way! I had to install and reinstall the clutch twice as a result!

Continuing with the preparations, the front suspension angles were rather sharp. I installed SPC adjustable control arms to restore the castor and alignment back to stock. I chose these over the uniball system as the sealed greasable ball joint operates better in our cold and wet climates. 

I also ended up purchasing a used set of 33” Pro Comp All Terrain tires with Ion Alloy wheels. There was some trimming required around the bottom edges of the front wheel wells. It still rubs mind you, but most of it is isolated to the front bumper. This will get rectified in the future with the upgrade to a new winch mount front bumper. The other thing to note with these wheels is the tire poke. They stick out at least 2 inches, so the option of fender flares will be explored. 

At this point, the build is still in progress, so we will be adding things as we go. I am very happy with the outcome, it does drive a lot better than before and feels proportionate. I will also add to the list of mods installed as I go below.

Alfred 

November 21, 2021

List of Components:

Drivetrain:

• Luk Clutch Kit

Armour/Exterior:

• Reese Hitch Mount

Front Suspension:

• Bilstein 5100 Front Struts

• Monroe Strut Mate

• Bilstein Shock Mount Hardware

• ARB Old Man Emu Springs

• SPC Performance Front Control Arms

Rear Suspension:

• Pro Comp ES9000 Shocks

• ARB Old Man Emu Springs

Wheels & Tires:

• 285/75/R16 Pro Comp All Terrain 

• 16x8.5 -15mm Offset Ion Alloy Rims