Off Road Solutions Manual Hub conversion kit.

Myself and Mark Mason installed this kit on my 4Runner. Holy Macaroni is it allot of work! It took us from 9 am to 5 pm even with Mark's in-depth knowledge of how to pull the front end of the truck apart.  It is indeed a major re-build of the front drive train.  In fact it is so far out there, I'm not even going to post install pics.  Only an extremely well equipped shop can pull this off, we even had to "make" a tool.  Read the instructions very carefully and you will need to buy or make a special install tool to torque the brass nut to 203 pounds.

Stock 4Runner center shaft bottom, ORS custom heavy duty 4Runner center shaft top.

Stock 4Runner ADD CV joint top, Tacoma manual hub CV joint bottom.

Stock Tacoma ADD CV joint bottom, Tacoma manual hub CV joint top.

Inner CV on a 4Runner axle left, Inner CV on a Tacoma axle right.  Notice the thickness of the arched part at the top.  The tripod bearing is inserted into this housing.  Notice that the 4Runner housing and bearings are almost twice the size of the Tacoma bearings.  The actual 4Runner tripod bearing can be seen in the photo titled: "Stock 4Runner ADD CV joint top, Tacoma manual hub CV joint bottom" above. 

ORS custom 4Runner manual hub center shaft left and stock Tacoma ADD axle shaft right.  The ORS shaft is thicker and a bit longer as well.  On the trail I asked Mike Caskey of ORS why he made the shafts longer.  He said that it was needed because the aftermarket hardened outer CV's they use are a bit shorter.  Stock Toyota Tacoma manual hub axles will work just fine with this kit as well, but they do not have the thicker and heat treated center shaft or the heat treated outer CV.  ORS wanted to use all brand new parts as well for the kit.

Complete 1999 4Runner front axle shaft dis-assembled.