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2001 Toyota Tacoma Buildup - Project Venture Toy

Posted in How To on September 1, 2009
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If you've been following along over about the last nine months here in the magazine, you've seen us building up our latest trail Toyota. What started life as a 2001 2WD Prerunner has transformed into a rig capable of crawling rocks or transporting us to our favorite back-country camp spots.

When we decided to build up an early Tacoma, we chose to use the Prerunner as our base as they are often readily available in good condition and cost a few thousand less than a comparable 4WD model. Both models use the same frame and we had plans for replacing all the drive train, save for the 3.4L V-6 motor and the four-speed auto tranny. Both of these have proven to be reliable and to perform well.

We shed the truck of all the axle, suspension, and steering parts and then reinforced the rear frame rails and raised the gas tank about 3 inches for clearance. We decided to keep the bed length stock, but opened all the fender wells to make room for articulating 37-inch rubber. We also trimmed the tail sheet metal so we could build a bumper tucked up high so that we keep the tail from dragging when we cross deep ravines.

Our foundation started with a set of Solid Axle built D60 units to provide plenty of axle strength. The front is 65 inches from flange to flange and the rear full-floater comes in at 64 inches. This yields us an outside track width just shy of 80 inches. This width provides good stability while still being able to fit through tight trails without a lot of fuss. The Solid D60s are stuffed with ARB air lockers, Yukon 5.13 gears, 35-spline alloy shafts, and Warn hubs up front. Both differentials are high-pinion units and use 1350 yokes.

To turn the 2WD into 4WD, we installed an Inchworm-built adapter onto the Prerunner auto tranny and mated that to a 23-spline, 2.28:1 Toyota gear reduction box. Behind that comes an Advance Adapters kit that mates the reduction unit to a 3:1 Atlas II transfer case with 32-spline outputs and 1350 CV yokes. From this we get four transfer case ratios and some deep gearing for slow crawling when we want. This combination works great and we can use the low gearing for effective compression braking on steep ascents.

Front suspension comes from All-Pro Off-Road. We took their Taco Supreme kit and mated it to the D60 with some bracket changes at the axle end. This three-link kit went cleanly on the frame after all the stock IFS was cut and ground away. Twelve-inch-travel Walker Evans coil-overs provide a smooth ride and a comfortable spring rate both on and off the highway. We're using the adjustable reservoir model and like being able to tweak the dampening to suit the terrain we're on.

All-Pro leaf packs prop up the rear and their 5-inch version spring gives us good ride height and we are pleased with how well they flex to compliment the front articulation. We use Bilstein 7100 reservoir shocks for dampening at the tail.

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Peer inside and you'll find an Off-road Solutions cage, Mastercraft Baja RS reclining seats, Alpine stereo, Cobra CB, and added volt and transmission temperature gauges. For longer trips and times when inclement weather might spoil our bed cargo, we have a Bestop Supertop that can be added. The soft top installs easily without any holes added to our bed, and can be removed when we want the bed area completely exposed.

With the truck essentially complete, we've been getting out on the trail and doing some camping and wheeling after the lengthy build process. We're pleased with the results and look forward to getting some more trail miles behind us.

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Broomfield, CO 80038
Poway, CA 92064
Advance Adapters
Paso Robles, CA 93446
Walker Evans Racing
Riverside, CA 92516
Ramsey Winch
Tulsa, OH 74116
Performance Steering Components
Azle, TX 76020
Reading, PA 19605
All-Pro Off-Road
Hemet, CA 92543
Inchworm Rock Walkin' Gear
Shingle Springs, CA 95682
Yukon Gear & Axle
Everett, WA 98204
Lenoir, NC 28645
Crown Performance
Vista, CA 92081
FK Rod Ends
Southington, CT 06489
Innovative Balancing
Rochester, NY 14610
Sky Manufacturing
Springfield, OR 97477
Stubbs Welding
Susanville, CA
J.E. Reel Drive Line Specialists
ARB 4x4 Accessories
Daystar Products
OMF Performance Products
Advanced Air Systems
Offroad Solutions
Solid Axle Industries, LLC
Abbott Enterprises, Inc.
Rancho Toyota Truck & SUV Recycling

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