1999 Toyota 4Runner Dana 44 Straight Axle Conversion & Rear Leaf Spring Conversion.

Swap started in February 2005 and the truck was completely done in May of 2005.

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Photo 1: Fully Rebuilt Dana 44 front axle from a 1988 Jeep Grand Wagoneer.
Photo 2: Fully Rebuilt Dana 44 front axle from a 1988 Jeep Grand Wagoneer.
Photo 3: Toyota IFS Pitman arm on the top and 1997 FZJ-80 Pitman arm bottom, The FZJ-80 arm had the tie rod end re-reamed to 1 ton Chevy tie rod taper.

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Photo 4: IFS still installed building the front shackle hanger.
Photo 5: IFS still installed building the front shackle hanger.
Photo 6: Front shackle hanger from the top.

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Photo 7: Front shackle hanger from the top.
Photo 8: Front shackle hanger from the bottom.
Photo 9: Stock Toyota rear axle splines on the left and stock Dana 44 front axle splines on the right.

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Photo 10: Stock rear axle bearing and ABS ring which was removed since the entire ABS system was removed..
Photo 11: Rear axle flange, seal and ABS sensor.  The sensor was pulled and replaced with a block off plug from a Tacoma.  Seals were replaced with the TSB dual lipped seals.
Photo 12: Stock Toyota rear axle shaft and stock Dana 44 front axle shaft.

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Photo 13: High pressure side power steering hose banjo with AN (Army-Navy) TIG welded and 4 way brake line T reduce to 3 lines, by TIG welding the front hole shut.  TIG Welding by Richard Stubbs.
Photo 14: IFS unbolted and the brackets are beginning to be cut off.
Photo 15: IFS brackets cut off, frame rail still needs to be ground smooth.

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Photo 16: Steve cutting the IFS brackets off with the Miller 375 Plasma Cutter.
Photo 17: Steve cutting the IFS brackets off with the Miller 375 Plasma Cutter.
Photo 18: Steve cutting the IFS brackets off with the Miller 375 Plasma Cutter.

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Photo 19: Steve cutting the IFS brackets off with the Miller 375 Plasma Cutter.
Photo 20: Steve cutting the IFS brackets off with the Miller 375 Plasma Cutter.
Photo 21: Steve cutting the IFS brackets off with the Miller 375 Plasma Cutter with Adrian looking on.

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Photo 22: Front IFS differential dropping out of the truck.  Adrian pulling the front diff out from under the truck with a floor jack.
Photo 23: Steve welding on the front shackle hanger with the Miller 210 welder.
Photo 24: Steve welding on the front shackle hanger with the Miller 210 welder.

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Photo 25: Steve welding on the front shackle hanger with the Miller 210 welder.
Photo 26: Parts that were pre-sold before the swap.  There was another pile for "junk".
Photo 27: Steve welding extensions on the front shackle hanger before final installation.

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Photo 28: Steve working on the front shackle hanger with a Hitachi grinder and 50 grit abrasive discs.
Photo 29: A Webcam still image of Steve plasma cutting with the Miller 375 and Adrian grinding with the Hitachi grinder.
Photo 30: Starting to work on the rear main eye leaf spring mounts.

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Photo 31: Working on the rear leaf spring mounts for the front leaf springs.  At this point the frame has been ground smooth.
Photo 32: Working on the rear leaf spring mounts for the front leaf springs.  At this point the frame has been ground smooth.
Photo 33: Working on the rear leaf spring mounts for the front leaf springs.  At this point the frame has been ground smooth.

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Photo 34: Passenger side pad built to hold the rear leaf spring mount.
Photo 35: Drivers side pad built to hold the rear leaf spring mount.
Photo 36: Weld added to the motor mount to replace the upper shock support that was cut out.

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Photo 37: Genuine Mopar Jeep YJ front leaf spring main eye bracket welded to the frame/platform we just created.
Photo 38: Genuine Mopar Jeep YJ front leaf spring main eye bracket welded to the frame/platform we just created.
Photo 39: Genuine Mopar Jeep YJ front leaf spring main eye bracket welded to the frame/platform we just created.

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Photo 40: Front leaf springs, shackles and axle bolted into place.
Photo 41: Front leaf springs, shackles and axle bolted into place.
Photo 42: Steve tightening up the U-Bolts on the custom made drivers side drop Dynatrac U-Bolt flip kit.

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Photo 43: Front leaf springs, shackles and axle bolted into place.
Photo 44: Getting ready to lower the truck down on the Dana 44 axle for the first time.
Photo 45: Getting ready to lower the truck down on the Dana 44 axle for the first time.

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Photo 46: 4Runner lowered down onto the Dana 44 front axle.
Photo 47: 4Runner lowered down onto the Dana 44 front axle.
Photo 48: 4Runner lowered down onto the Dana 44 front axle.

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Photo 49: Cutting the extra threads off the U-Bolts.
Photo 50: Sitting on the axle with steering links added.  The weld together drag link was replaced with a once piece Shakerbuilt draglink.
Photo 51: Starting to plate the inside and outside of the frame rails.  Both the inside and outside of each front rail were plated with 3/16" plate.

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Photo 52: Plug welds ground smooth on the frame plating.
Photo 53: Steve working on welding the frame plates on.
Photo 54: Steve working on welding the frame plates on.

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Photo 55: Brent drilling the 3/4" holes for the frame sleeves for the bolts that will secure the FJ-62 steering box to the frame.
Photo 56: Brent drilling the 3/4" holes for the frame sleeves for the bolts that will secure the FJ-62 steering box to the frame.
Photo 57: Brent drilling the 3/4" holes for the frame sleeves for the bolts that will secure the FJ-62 steering box to the frame.

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Photo 58: Smoking burned out 1/2" Craftsman drill.  It ended it's life drilling the 3/4" holes for the steering box frame sleeves.
Photo 59: Inserting the 3/4" OD - 1/2" ID seamless tube.
Photo 60: FJ-62 steering box installed.  The FJ-62 box has 4 frame mount holes and a forward facing pitman arm as well as outside frame mounting.

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Photo 61: Steering box installed.
Photo 62: Brent drilling the 3/4" holes thought the double 3/16" plates and the stock frame.
Photo 63: Steering box and draglink installed.

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Photo 64: Steering box mounted working on the steering shaft.
Photo 65: passenger side of the frame rail, plated and ground smooth.
Photo 66: Original mock up of the steering shaft with what we had on hand early Sunday morning.  Mock up of upper front shock mount.

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Photo 67: Brent drilling the 3/4" holes.
Photo 68: Adrian taking a break.
Photo 69: Brent drilling the 3/4" holes.

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Photo 70: Adrian drilling the 3/4" holes.
Photo 71: Adrian drilling the 3/4" holes.
Photo 72: Adrian drilling as Steve and Brent look on.

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Photo 73: Original Sunday morning steering shaft mock up.
Photo 74: The truck rolls out for the first time.
Photo 75: The truck rolls out for the first time.

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Photo 76: 4Runner back together with everything but a steering shaft.
Photo 77: 4Runner back together with everything but a steering shaft.
Photo 78: 4Runner back together with everything but a steering shaft.

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Photo 79: Steering box without a steering shaft and original front shock install.  Bilstein instructs you to install the shocks with the reservoir up, but I have to flip them around down the road.
Photo 80: Richard Stubbs turning part of the original steering shaft on his lathe.
Photo 81: Stubbs truing up the shaft before welding.  The only way you will get a custom made steering shaft straight is on a lathe.

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Photo 82: Richard Stubbs TIG welding the original steering shaft on his lathe.
Photo 83: Completed original steering shaft.
Photo 84: Original steering shaft we made for the truck.  The shaft had two problems: the U-joints were out of phase and the "rag" joint was producing a lot of slop.

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Photo 85: Original steering shaft installed and I could now drive the truck at least.
Photo 86: The 4Runner is drive able again.
Photo 87: I pulled the truck and all the steel out of the garage for a through cleaning after all the cutting, grinding and welding.

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Photo 88: Rolling around town with no front bumper and the front end several inches higher than the rear.
Photo 89: The entire ABS brake system was removed and replaced with the complete non-ABS brake system, with one small exception.  A manual rear proportioning valve was used instead.
Photo 90: The simple zip tie to the radiator power steering cooler was replaced with a B&M stacked plate high volume cooler mounted to it's own bracketry.   

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Photo 91: Jacking up the front leafs up at night to help settle them in a bit.
Photo 92: Since I was not happy with the original steering shaft we built, I started collecting the "best of the best" Toyota steering shafts to work with and eliminate the rag joint.
Photo 93: Top two shafts are from an FJ-62 Land Cruiser and the lower shaft is from a 1979-1983 SA Mini Pickup.  The 79-83 Mini P/U shaft went to Brian Drawhorn for his 85 4Runner.

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Photo 94: The second and final steering shaft which was absolutely "perfect".  Richard Stubbs TIG welded this 1999 4Runner/1989 FJ-62 creation together.
Photo 95: FJ-62 steering shaft installed in the 4Runner to the FJ-62 steering box.
Photo 96: FJ-62 shaft installed and the 4Runner now steers like it did with the IFS steering rack.

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Photo 97: Front Range Off Road Fabrication Tacoma cross member installed.
Photo 98: Here both of the factory cross members have been cut out and the frame rails ground smooth.
Photo 99: Front shocks flipped around providing more room to stuff the tires.

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Photo 100: Wilwood Proportioning Valve and custom made aluminum cover TIG welded together by Steve.  This valve reduces the pressure sent to the rear drum brakes
Photo 101: Welding on new custom made 3/8" thick TJM T-17 mounting brackets.  The wood is to keep the horns straight during welding.
Photo 102: New Non-IFS TJM T-17 mounting brackets made from 3/8" plate.

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Photo 103: New Non-IFS TJM T-17 mounting brackets made from 3/8" plate.
Photo 104: New Non-IFS TJM T-17 mounting brackets made from 3/8" plate.
Photo 105: New Non-IFS TJM T-17 mounting brackets made from 3/8" plate.

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Photo 106: New Non-IFS TJM T-17 mounting brackets made from 3/8" plate.
Photo 107: TJM T-17 installed on the now leaf sprung 4Runner.
Photo 108: Passenger side of the TJM T-17, some of the battle scars from the IFS days.  A lot of these are from the Lower Terminator trail.

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Photo 109: Drivers side of the TJM T-17, some of the battle scars from the IFS days.  I think a lot of these came from Martinez Canyon.
Photo 110: Center section of the TJM T-17, these scratches came from Lower Terminator and Charouleau Gap .
Photo 111: Side view of the just re-installed front bumper.  I later very minorly trimmed the front opening of the fenders to provide more stuff for the tires.

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Photo 112: TJM T-17 reinstalled.
Photo 113: Here is my 5.29 geared rear electric locker.  I have not had it out in years and it still looks fine.  The Yukon gears were made by US Gear.
Photo 114: All of the rear link brackets have been cut off and a set of FJ-62 rear leafs were installed using all Toyota OEM bracketry.

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Photo 115: Alcan FJ-62 rear leafs installed.  The leafs were ordered for 3.5" of rear lift to match the height of the front Jeep YJ leafs.
Photo 116: Stock rear Toyota axle tube seconds before all of the link brackets were cut off.
Photo 117: Completely clean rear axle tube with all of the link brackets removed and the tube ground smooth.

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Photo 118: Original rear leaf configuration, the 12" travel shocks were switched to 10" travel shocks and the boots were removed.
Photo 119: With the axle tube tilted upward a bit the cable guide on the back of the diff was too low.  I cut the original bracket off and plug welded this identical bracket from the top of an IFS steering box on in it's place up higher.
Photo 120: These are all of the parts that were destroyed in the press off/press on rear axle swap to the Poly Performance rear Tacoma axle shafts.

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Photo 121: Another view of the rear leaf springs, notice the original cable spare tire winch gave out and I replaced it with a chain driven one from an 1980's Toyota P/U.
Photo 122: There is nothing stock about that hub, these are Poly Performance Rear Axles, which are CNC machined from high quality 4340 material .  These axles have never been broken.
Photo 123: Rear Leaf spring view.

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Photo 124: Stock 1988 Jeep Grand Wagoneer Dana/Spicer Model 44 front axle and 760X U-Joint.
Photo 125: Superior Evolution Series Model 44 front axles and CTM Racing U-Joint.
Photo 126: First test out on the trail with the rear still at IFS lift height.

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Photo 127: 1999 & 1996 4Runners, both have 1" BL and Yokohama 315/75/16 on 16x8 rims.  The 99 has a spring under Dana 44, the 96 has the stock Toyota Tundra Coil lift with the top out.
Photo 128: Second time out on the trail.  The rear is lifted up with the stock coil/link suspension still installed.  This was a very poor match for the front leaf springs and a rear leaf conversion is necessary.
Photo 129: Second time out on the trail with the rear lifted to match the front.  OME 891 coils and FZJ-80 rear shocks.  It flexed well but was unbalanced with the leaf front.

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Photo 130: Poly Performance Rear Axles, Superior Evolution Series Front Axles and CTM U-Joints.
Photo 131: Stock Dana/Spicer and Superior Evolution Series short side axle shafts.
Photo 132: First time out on the trail with the rear leafs.  I had to switch from the 12" travel shocks to the 10" travel shocks.  Spring under is all up travel so matching the right shock is vital.

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Photo 133: The completed truck filling up at the local Tempe Quicktrip.  You can see this is no Monster Truck by any means.
Photo 134: The stock Jeep Grand Wagoneer steering stabilizer and placement worked fine for the 3.5 and below trails but once I upped the ante to the 4.0 and higher trails, it bit the dust and an Old Man Emu FJ-62 stabilizer was installed.  The Americans like to put the stabilizer on the tie rod and Toyota put the FJ-62's on the draglink so I did this as well using the stock Jeep bracket.
Photo 135: Testing the OME steering stabilizer and the 10" travel Bilsteins on the Upper Woodpecker trail.

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Photo 136: Out on the Upper Woodpecker trail.  Yes I have done Yellow Belly ledge in Martinez Canyon with the Dana 44.
Photo 137: Final configuration of the front axle - Front View.
Photo 138: Final configuration of the front axle - Rear View.

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Photo 139: Final Configuration on the rear axle - Front View.
Photo 140: Final Configuration on the rear axle - Rear View.
Photo 141: Final Configuration of center section of the truck.  Stock cross members cut out and Front Range Off Road Fabrication - Tacoma cross member installed.

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Photo 142: Final FJ-62 steering box and FJ-62 Steering shaft.
Photo 143: Final FJ-62 steering box and FJ-62 Steering shaft.
Photo 144: New windshield washer fluid box made from a Nalgene Bottle and FZJ-80 lid and filter.  Custom bracket secured the bottle in the location the ABS controller once occupied.

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Photo 145: Non ABS brake Master Cylinder and frame vent hose that now has a little "import" air filter on it.
Photo 146: Finished truck as it looks today.
Photo 147: I stated out with fender skirting on the IFS and wanted to add that back on with the Dana 44 for a factory clean look.  Drivers side fender skirt.

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Photo 148: Passenger side fender skirt.
Photo 149: At the beginning of the climb up Cadillac Hill on the Rubicon Trail.
Photo 150: Up on a 38" Super Swamper Tire, all 4 tires are still firmly planted on the ground.  On the "slabs" Rubicon Trail.