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| Photo 1 | Photo 2 | Photo 3 |
Photo 1: Entering California.
Photo 2: The Marlin Crawler shop.
Photo 3: My 1999 4Runner and Marlin's 1983 pickup.
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| Photo 4 | Photo 5 | Photo 6 |
Photo 4: Pile of Toyota
transfer cases & transmissions.
Photo 5: Pile of 1979-1985 Toyota front axles.
Photo 6: Stock transmission and transfer case.
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| Photo 7 | Photo 8 | Photo 9 |
Photo 7: Marlin detailing the
game plan.
Photo 8: Beginning to build the crawler.
Photo 9: Building the MC09 crawler.
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| Photo 10 | Photo 11 | Photo 12 |
Photo 10: Building the MC09
crawler.
Photo 11: Building the MC09 crawler.
Photo 12: Building the MC09 crawler.
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| Photo 13 | Photo 14 | Photo 15 |
Photo 13: Building the MC09
crawler.
Photo 14: Building the MC09 crawler.
Photo 15: Building the MC09 crawler.
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| Photo 16 | Photo 17 | Photo 18 |
Photo 16: Building the MC09
crawler.
Photo 17: MC09 with 4.7 Japanese made gears.
Photo 18: Beginning to work on the gear driven case housing.
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| Photo 19 | Photo 20 | Photo 21 |
Photo 19: Clearanceing the
gear driven case for the 4.7 gears.
Photo 20: Clearanceing the gear driven case for the 4.7 gears.
Photo 21: Clearanceing the gear driven case for the 4.7 gears.
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| Photo 22 | Photo 23 | Photo 24 |
Photo 22: Punching in the
serial numbers.
Photo 23: Ready to assemble the gear driven cover.
Photo 24: Adding the cover to the 4.7 gears.
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| Photo 25 | Photo 26 | Photo 27 |
Photo 25: Building the MC09
crawler.
Photo 26: The serial number book of who has purchased the units.
Photo 27: Building the MC09 crawler.
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| Photo 28 | Photo 29 | Photo 30 |
Photo 28: Marlin dictating
what serial numbers will be applied.
Photo 29:Complete MC09 crawler with 4.7 low range gears.
Photo 30: Stock transmission and transfer case from the 1999 4Runner.
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| Photo 31 | Photo 32 | Photo 33 |
Photo 31: Transmission
removed clutch visible.
Photo 32: Separating 5-Speed transmission from the transfer case.
Photo 33: MC09 Crawler, Stock Transfer case and 5-Speed transmission.
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| Photo 34 | Photo 35 | Photo 36 |
Photo 34: Transmission and
transfer case removed.
Photo 35: Pulling 26 to 26 spline coupler which will be replaced with a 26 to 23
spline coupler.
Photo 36: 5-Speed ready for the crawler to be installed.
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| Photo 37 | Photo 38 | Photo 39 |
Photo 37: Clutch flywheel,
you can see where I burned it wheeling.
Photo 38: Flywheel removed.
Photo 39: Assembling the crawler / transfer case / transmission.
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| Photo 40 | Photo 41 | Photo 42 |
Photo 40: Assembling the
crawler / transfer case / transmission.
Photo 41: Assembling the crawler / transfer case / transmission.
Photo 42: Assembling the crawler / transfer case / transmission.
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| Photo 43 | Photo 44 | Photo 45 |
Photo 43: Assembled the
crawler / transfer case / transmission.
Photo 44: MC09 crawler.
Photo 45: 5-speed shifter seats. The green one ($10.00) came in the 2.7
and the blue one ($30.00) came in the 3.4. The blue one is much better
according to Marlin, so
I upgraded to the blue seat in my transmission.
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| Photo 46 | Photo 47 | Photo 48 |
Photo 46: Completed
transmission / crawler / transfer case.
Photo 47: Lifting the unit up into the truck.
Photo 48: Lifting the unit up into the truck.
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| Photo 49 | Photo 50 | Photo 51 |
Photo 49: Starting the custom
shift levers by cutting a stock lever into 3 pieces. Converting to short
throw as well.
Photo 50: Welding the shift lever back together with the short throw bottom.
Photo 51: Custom lever installed in the 4Runner.
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| Photo 52 | Photo 53 | Photo 54 |
Photo 52: Front boot
re-installed.
Photo 53: Three parts to the shift lever. Tooth, ball and lever.
Photo 54: Rear lever installed in the 4Runner.
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| Photo 55 | Photo 56 | Photo 57 |
Photo 55: Drive shafts after
being lengthened and shortened.
Photo 56: Transmission / MC09 crawler / Transfer case installed in the 4Runner.
Photo 57: MC09 crawler, the serial numbers can be seen.
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| Photo 58 | Photo 59 | Photo 60 |
Photo 58: Crawler installed
in the 4Runner.
Photo 59: Back in Arizona.
Photo 60: On the drive home the shifter bases rubbed the body so I got the
dremel out and cleaned up the openings.
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| Photo 61 | Photo 62 | Photo 63 |
Photo 61: Shifter holes after
being dremeled looser back in Arizona.
Photo 62: Front boots re-installed.
Photo 63: The 3 levers: 5-speed, crawler box with 4.7 gears & stock transfer
case. The rear cup holder & brake handle was retained in the stock
location.
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| Photo 64 | Photo 65 | Photo 66 |
Photo 64: Marlin has a few
R.O.R.E. e-locker skid plates, so I picked one up as an impulse purchase and
installed it when I got back to Arizona.
Photo 65: Rear support bracket I made for the transfer case. The longer
assemble was hitting the body with the shorter drive shaft and the extra length.
Photo 66: Rear support installed with Daystar poly shock bushings for dampening.
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| Photo 67 | Photo 68 | Photo 69 |
Photo 67: Final interior shift levers. Two stock transfer case knobs looked the cleanest to me.
Photo 68: In January of 2004 the Crawler box was removed to swap the front adapter plates.
Photo 69: The front plate Marlin installed in Fresno was apparently machined incorrectly
so they shipped me a redesigned front adapter plate. The crawler box was burping gear oil out the shifter base.
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| Photo 70 | Photo 71 | Photo 72 |
Photo 70: With only 1 cup
holder the passenger was left without a place to put a drink. I found this
fancy folding German cup holder made by a company called Fisher. I mounted
it to the passenger door.
Photo 71: I found an original Toyota OEM 4WD shift lever knob with the actual
shift pattern of the crawler box. This knob is from a 4WD 2003 Toyota
Sequoia, Toyota Part # 36303-34030.
Photo 72: The three genuine Toyota shift knobs, all showing the actual shift
patterns of the levers.
I also installed a 1" Body Lift from Roger Brown to create more clearance for the levers under the center counsel and for the relocated stock case under the body. This is needed to prevent the Tacoma style transfer case from hitting the bottom of the body.
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| Photo 73 | Photo 74 | Photo 75 |
Photo 73: The poorly designed
Tacoma short throw base Marlin installed in May 2003 has always made a
"sewing machine" noise when driving. In May of 2004 I finally
tracked down the cause of the chatter.
Photo 74: I re-installed the stock Toyota shift base and made an aluminum lift
block with a channel in the bottom for the spring that pushes the lever back
toward the 4H side.
Photo 75: The stock base has much higher quality pins and a rubber seat to
dampen any noise and ensure a proper fit. The lift block made out of
aluminum converts the stock base a short throw. This is the same way Roger
Brown of 4Crawler makes a short throw kit with a non-weld on pin extension.
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| Photo 76 | Photo 77 | Photo 78 |
Photo 76: In July of 2004 out
the two transfer cases came again. The transmission was leaking gear oil
into the front case, resulting in a lower oil level in the transmission.
Photo 77: Here you can see the custom block I made for the stock base and the
Marlin short throw base on the older gear driven case.
Photo 78: Installed here is the new seal Marlin sent me. It is different
than the stock seal, since his custom coupler is a slightly different diameter,
if you look close in photo 36 above you can see that the stock seal was not
originally swapped out in June of 2003. In January of 2004 I replaced the
seal with a new stock one, not knowing there was a custom one needed. The
stock seal leaves a 1mm gap all around the coupler. The custom seal is a
perfect fit for the new crawler 26 to 23 spline coupeler.
Final Drive Ratio:
2.7L 5 speed first gear transmission ratio: 3.954
Chain driven transfer case: 2.566
Marlin Crawler box: 4.70
Ring and Pinion: 5.29
3.954 x 2.566 x 4.70 x 5.29 = 252:1
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