2004 Lexus GX470 - Customization & Buildup

This is our '04 Lexus GX470 as delivered, all ready to go to the ski resort. Little does it know, its fate will be tougher than some little ol' snowstorm.

This is our '04 Lexus GX470 as delivered, all ready to go to the ski resort. Little does i

Project TraiLex, Part 1
Project TraiLex, Part 2
Project TraiLex, Part 3
Project TraiLex, Part 4

OK, we've heard you. And we've read all the hate mail and heard all the jokes. The Lexus GX470 has won our Four Wheeler of the Year award two years in a row. We know all you readers out there think we've gone soft and can't tell a capable trail-mobile from a Lazy Boy recliner any more. Well, we're here to prove we still know potential when we drive it. So here is the plan: We're going to take our brand-new '04 Lexus GX470 over California's infamous Rubicon Trail, in front of our Four Wheeler TV cameras, for the whole world to see. We'll also be following our TraiLex's adventures in the pages of Four Wheeler, starting with this article.

First off, let's get one issue out in the open and be done with it. There are damn few, if any, new SUVs on the market today that are capable of traversing a trail the caliber of the Rubicon in bone-stock condition without considerable body and/or mechanical damage. The Lexus is no exception. So, like most 'wheelers, we plan some mods to help it out. No, we're not jacking it up and rolling a '70s-era live-axle truck chassis under it. It will remain a Lexus through and through.

Project TraiLex poses in the same spot where, a month before, it looked like every other mallwagon. All the plastic body cladding has been removed and the lower body panels have been sprayed with Diamond Linings bedliner in a dark gray that accents the Lexus silver. The suspension has been lifted 3 inches and considerable trimming has been done to the front and rear fenders.

Project TraiLex poses in the same spot where, a month before, it looked like every other m

We are doing the same modifications to TraiLex that most any 'wheeling enthusiast would perform to his or her new rig before subjecting it to tough trails. Our mechanical modifications will be limited to the usual stuff: a mild lift, which we fabricated ourselves, bigger wheels and tires (33s from Pro Comp wrapped around Trailready beadlock aluminum wheels), an axle-ratio change from 3.73s to 4.88s (for the tire size and crawlablilty) and ARB Air Lockers front and rear.

The biggest changes will come through body protection. Again, we're fabricating our own, as there isn't much demand for Lexus armor at the local 4x4 emporium. We're the first to admit the Lexus has more than its share of useless, low-hanging body parts that may fend off bumps at the mall, but have no business on a 4x4. We don't design 'em, but we do look under them. We can tell a capable chassis when we see one, even if it's hidden behind plastic. The Lexus is stout underneath, and we plan to expose it and let the world know it can 'wheel.

Check out the photos and captions of what we've done so far. By the time you read this, some of you may have seen TraiLex running around Moab during Easter Jeep Safari. The Rubicon trip will take place sometime this summer and will air on Four Wheeler TV sometime after that.

This was our first removal, and the one we enjoyed the most. Why, we must ask again, do they put running boards on 4x4s?
This was our first removal, and the one we enjoyed the most. Why, we must ask again, do th
Anybody need some plastic? This is a shot of all the rubber-baby-buggy-bumper cladding we removed from TraiLex. Most of it came off with a good yank, or a yank plus removal of a couple of 10mm bolts. Note how the remaining body already looks more like that of a trailmobile.
Anybody need some plastic? This is a shot of all the rubber-baby-buggy-bumper cladding we
With the plastic out of the way, there was still a lot of trimming to do to clean up the fenders and create tire clearance. All those holes were for holding the plastic fender lips. They were covered with masking tape and then sprayed over with bedliner--an easy way to get rid of several hundred unwanted holes.
With the plastic out of the way, there was still a lot of trimming to do to clean up the f

With no plastic to hide it, the rear of the rig presented the bigger challenge in the ugly department. Part of the lower rocker area has since been trimmed away for a better departure angle. The frame extending beyond the body also had to go.
With no plastic to hide it, the rear of the rig presented the bigger challenge in the ugly
Whack! Nothing like a hot wrench on a brand-new vehicle. So long, too-long frame.
Hello, new rear crossmember with built-in receiver. We've tucked the frame up close to the body and triangulated it from behind for strength. The ends of the frame were boxed in with brackets that will hold the new 2x4-inch rectangular bumper in place.
Hello, new rear crossmember with built-in receiver. We've tucked the frame up close to the

A feature that helped the Lexus win FWOTY is its fullsize spare, mounted underneath the rig (no muddy flat in with your clean luggage). That tire is surrounded by a real truck-like frame--no wimpy unibody here. Note the factory tow hook on the left rail--all are features that we like to see on stock 4x4s, and things we take note of in our FWOTY tests. Unfortunately, the tire had to go because the spare is now a 33 and wouldn't fit underneath. At least we have a frame to weld to. The new rear crossmember contains a receiver, which we feel is the best point for a recovery hook.
A feature that helped the Lexus win FWOTY is its fullsize spare, mounted underneath the ri
Here is our 3-inch front lift kit. The stock Lexus front coilover shocks feature adjustable damping and are easily up to controlling 33-inch tires. Stock tires measure 30.5. The bottom mounting eye is part of a 2-inch-long, 5/8-inch-diameter shaft that extends to the shock body. We simply cut the shaft in two, did some careful measuring, and then machined a 21/4-inch spacer which press fit into the two stubs. We then welded the assembly into a solid piece and voila!, 3 inches of lift at the axle hub. The rear lift is already built in with the GX470's air-ride rear suspension, which, on its "high" setting, lifts the vehicle 3 inches. With our 3-inch front lift, the rig sits level and fits 33s with no problem.
Here is our 3-inch front lift kit. The stock Lexus front coilover shocks feature adjustabl
Here is a shot of our 3-inch lift kit installed. We had the truck realigned and everything fell into spec, no problem. At stock height, the axleshafts actually went "up" from the diff to the hub. Now they slope slightly down (like normal) nd are far from binding in any position. Note the huge anti-roll bar tube in the foreground. That is part of Lexus' new-for'04 Kinetic Dynamic Suspension System (KDSS.) It's an automatic disconnect system. When the suspension is articulated, the anti-roll bar mounts float hydraulically and force fluid front to rear and vice versa, forcing opposite tires down. The system makes a difference, as our '04 FWOTY RRI test proved. The '04 rig ramped a 519, while the '03 tester without KDSS could only twist to 428.
Here is a shot of our 3-inch lift kit installed. We had the truck realigned and everything

This is the air pump for the rear air suspension. It was mounted behind the left rear wheel on, and slightly below, the framerail. It had to move to accommodate our planned departure angles. Once again, the Lexus adapted easily. Just above the air pump's old mounting spot, inside the vehicle in the left quarter panel, is a little door opening to a space for the factory jack. Since we plan to carry a Hi-Lift jack, this made a perfect new home for the air pump.
This is the air pump for the rear air suspension. It was mounted behind the left rear whee
Ah, yes. We knew there had to be an engine under that Darth Vader disguise. Now we can not only see the condition of things like belts and hoses, but we can even work on them if we have to. There is now also ample room for the ARB compressor and possibly an onboard welder.
Ah, yes. We knew there had to be an engine under that Darth Vader disguise. Now we can not
We just had to install some rollers that you'd never see on a Lexus. Beadlocks at the Country Club? We wanted an aggressive mud tire with the traction and strength to handle the Rubicon, but also tires with good street manners that can keep quiet. These 33x12.50R17 Pro Comp Mud Terrains fit the bill nicely. We would have liked a little more sidewall for flex when aired down, but had to go with 17-inch wheels to clear the front brakes.
We just had to install some rollers that you'd never see on a Lexus. Beadlocks at the Coun

The guys at Trailready made us these good-looking wheels. They started with 17x8-inch Alcoa aluminum wheels with a 41/2-inch backspacing. To these, they added their special lipped beadlocks. The lip, shown in the photo, centers the tire bead on the wheel and allows for a very true-running tire that can be balanced. Trailready powdercoated our wheels in satin black, which sets off its signature brushed-aluminum locking rings beautifully. The wheels weigh 30 pounds each, complete with hardware. With 33-inch Pro Comps wrapped around them they tip the scales at 85 pounds. The Lexus' suspension and chassis don't notice the tire/wheel change.

Project TraiLex, Part 1
Project TraiLex, Part 2
Project TraiLex, Part 3
Project TraiLex, Part 4