Toyota Connection

Solid Front Axle Swap on a 1992 Toyota Independent Front Suspension 4runner

I am writing this short article to share the experience of doing a solid front axle swap on my 1992 IFS Toyota 4runner.

Work started at noon on Friday August 14, 2009

Step 1:  Find a reputable shop that has experience in doing this conversion. There are a few "gotachas" that need to be aware of. Missing these can lead to  poor drivability and low durability down the road. A total disaster occur if one makes an error on measuring the frame modifications.
Get your truck on a ramp that you don't need as it will be staying there for a while. Get the front wheels off and stored safely. Get to work taking off all the independent front suspension parts off the frame. At the end of the process you should have a pile of parts similar to the picture on the right. Mine had a Procomp stage II 4" lift kit so your pile might look a little different.
   
Step 2: If you are going to do engine work it is a good idea to remove the engine. This makes cutting and grinding a whole lot easier. The picture on the right is engine top view and it  illustrates how much easier it is to reach the hardware that needs to go. Not to mention potential damage to engine hardware from molten metal spat out by the Plasma cutter.

Click on any picture for a larger view

More of the story to follows on the next page >>