Toyota 120 Platforms Forum
Google only search Toyota120

Go Back   Toyota 120 Platforms Forum > General Tech > 4th Gen 4Runner & Hilux Surf

Reply
Thread Tools Display Modes
Unread 11-19-2006, 03:30 PM   #1
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default Field Repair guide

As discussed on the Randsburg trip while fixing RObert's truck, it will probably be a good idea to make a field repair guide with the factory drawings of key areas with the right TQ specs of the various bolts,etc.

I will scan in the FSM pages as we go along. Obviously it is a mandane task so it will take some time to get all the pages scanned.

Attached is the Front and Rear suspension.

I will add the following in this thread:
- front and rear axles
- front and rear brake assemblies (this will also be easy to use to replace a lug nut)
- Transfer case
- Steering components that can be serviced in the field
- Serpentine belt (if I can find usefull info in the FSM)

WIll probably work the best to print it double sided and then laminate the pages, and finally use a little ring binder for a nice booklet for field and garage use.
Attached Files
File Type: pdf Front Suspension.pdf (502.6 KB, 2262 views)
File Type: pdf Rear Suspension.pdf (284.2 KB, 1256 views)
__________________
andries
K9BDG

03 pavement princess
06 toaster

Last edited by bulldog; 11-19-2006 at 03:35 PM.
bulldog is offline   Reply With Quote
Unread 11-19-2006, 04:38 PM   #2
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Got lazy with scanning and just downloaded the files from the Toyota Tech site.

Front and rear diffs with axles attached to this post.
Attached Files
File Type: pdf Front Diff V6.pdf (82.5 KB, 680 views)
File Type: pdf Front Diff V8.pdf (72.0 KB, 494 views)
File Type: pdf Rear Diff.pdf (85.7 KB, 662 views)
File Type: pdf front axle.pdf (42.1 KB, 753 views)
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 11-19-2006, 04:38 PM   #3
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Rear axle.
Attached Files
File Type: pdf rear axle.pdf (60.1 KB, 615 views)
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 11-19-2006, 04:40 PM   #4
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Front and rear brake assemblies as well as parking brake assembly and rear cables.
Attached Files
File Type: pdf front brake.pdf (42.0 KB, 710 views)
File Type: pdf rear brake.pdf (37.8 KB, 575 views)
File Type: pdf parking brake drum.pdf (41.7 KB, 501 views)
File Type: pdf parking brake cable.pdf (23.1 KB, 441 views)
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 11-19-2006, 04:40 PM   #5
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Steerign and serpentine belts
Attached Files
File Type: pdf steering.pdf (103.1 KB, 585 views)
File Type: pdf serpentine V8.pdf (28.7 KB, 389 views)
File Type: pdf serpentine V6.pdf (36.1 KB, 407 views)
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 11-19-2006, 04:41 PM   #6
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Transfer cases and radiators.

And that concludes the field repair guide.

If something is missing please post up and lets see if we can get it in here.

EDIT: I added the relay locations as well. I think folks should keep this handy as well. If you look carefully it will show which relays are interchangeable and you can decipher what each one does. Might come in handy down the line, so keep it in your truck when you go out, with the rest of the field repair guide.

http://www.toyota120.com/forum/attac...6&d=1176187503
Attached Files
File Type: pdf transfer case V6.pdf (249.0 KB, 413 views)
File Type: pdf transfer case V8.pdf (248.6 KB, 340 views)
File Type: pdf radiator V6.pdf (43.2 KB, 365 views)
File Type: pdf radiator V8.pdf (51.7 KB, 286 views)
__________________
andries
K9BDG

03 pavement princess
06 toaster

Last edited by bulldog; 11-04-2008 at 04:35 PM.
bulldog is offline   Reply With Quote
Unread 11-20-2006, 12:58 AM   #7
my034runner
Toy120 Uber Mod
 
my034runner's Avatar
 
Join Date: Nov 2005
Location: Las Vegas, NV
Posts: 6,332
Default

Thanks for taking the time to do this. What about electrical systems? Is this something to be considered also?
__________________
NVTTORA Prez..My034runner: DR/ICON coil overs, Icon 2.5 resis in the rear, custom coil springs, AllPro sliders, BudBuilt skids, KurtFab Lower links, AllPro Upper links, WabFab endlinks, Blackout safari rack, FourTreks HiLift mounts, 285/75/16 BFG's Ko's, MagnaFlow exhaust, Optima Blue&Red top, ShrockWorks bumper, MileMarkerE9000 winch, Engel MT-60 fridge, Sirius, Garmin60 Csx, Factory nav etc...
my034runner is offline   Reply With Quote
Unread 11-20-2006, 01:08 AM   #8
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Quote:
Originally Posted by my034runner
Thanks for taking the time to do this. What about electrical systems? Is this something to be considered also?
I was thinking about electrics, but honestly it is a maze in terms of info.

Will need a whole book. I might just bring the files soft copy on a laptop on trips. And troubel shooting electric problems on the trail is virtually impossible apart from the very basics for which you don't need diagrams.
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 11-20-2006, 12:08 PM   #9
Mikestang
Don't follow this guy
 
Mikestang's Avatar
 
Join Date: Jun 2006
Location: The wild wild west
Posts: 4,421
Default

Good info, thanks.
__________________
'07 Ltd 4Runner v8 4x4 - Midland 75-822 + Wilson 5000, Garmin 276c, Magnaflow catback, Kurtfab front diff brace, 265/70/17 Goodyear ATA on Robby Gordon Signatures, Spidertrax, 3/4" BL, BajaRack, 2wd sway, Icon front, Overland Warehouse rear, Kurtfab v2.1 LCAs, MedicLinks, Slee SS lines, BB skids, Demello sliders & LCA ramps, All-Pro diff guard, TC full gusseted front, SW bumper
www.mikestang.com
Mikestang is offline   Reply With Quote
Unread 11-20-2006, 01:44 PM   #10
05sport4x4
Driver
 
05sport4x4's Avatar
 
Join Date: Sep 2005
Location: Whittier, CA
Posts: 455
Default

Thanks for posting this, it might come in handy one day
__________________
John
KJ6JJC

05 4Runner Sport V6 - Goodyear SA 275/70/17, Donahoe Adj C/O', Custom rear colis, Hanna sliders
89 Extra Cab 4x4 Pickup, 22re, 31x10.5 w/4.56's & ARB in rear
05sport4x4 is offline   Reply With Quote
Unread 11-20-2006, 04:06 PM   #11
my034runner
Toy120 Uber Mod
 
my034runner's Avatar
 
Join Date: Nov 2005
Location: Las Vegas, NV
Posts: 6,332
Default

Quote:
Originally Posted by bulldog
I was thinking about electrics, but honestly it is a maze in terms of info.

Will need a whole book. I might just bring the files soft copy on a laptop on trips. And trouble shooting electric problems on the trail is virtually impossible apart from the very basics for which you don't need diagrams.

Well that makes sense. But what about electronics as they pertain to the 4wd system? I'm just throwing stuff on the wall and see what sticks!
__________________
NVTTORA Prez..My034runner: DR/ICON coil overs, Icon 2.5 resis in the rear, custom coil springs, AllPro sliders, BudBuilt skids, KurtFab Lower links, AllPro Upper links, WabFab endlinks, Blackout safari rack, FourTreks HiLift mounts, 285/75/16 BFG's Ko's, MagnaFlow exhaust, Optima Blue&Red top, ShrockWorks bumper, MileMarkerE9000 winch, Engel MT-60 fridge, Sirius, Garmin60 Csx, Factory nav etc...
my034runner is offline   Reply With Quote
Unread 11-20-2006, 04:15 PM   #12
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Quote:
Originally Posted by my034runner
Well that makes sense. But what about electronics as they pertain to the 4wd system? I'm just throwing stuff on the wall and see what sticks!
Hehehehe, maybe I'm wrong but you can still get home of the electronics on the 4WD system fails. It wont stop the truck from driving. It is more the engine and transmission electrical systems, which is pretty much beyond field repair apart from the common sense basics IMHO. If the ECU craps out on you that will pretty much be it, unless you feel like carrying spares and equipment to pinpoint it. The probability is pretty low for that to happen though.

The guide was more assembled to help members who like to destroy drivetrain and other components on trips

Joking aside it is a getcha home information, so folks can easily see the assembly as well as the TQ values of critical components that have a higher probability of breaking or failing on the trail. So it ends up being a small booklet that you can easily carry with in the truck on trips. Not meant as a FSM.
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 05-19-2007, 07:50 PM   #13
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

I think RObert was right, some electrical info would be useful too. SO I attached the relay and fuse locations. See above posts.

Might be a life saver down the line, but ONLY IF YOU ACTUALLY PRINT IT AND HAVE IT IN THE TRUCK

Hopefully most folsk takes this with, so someone in the group will have it handy.
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 07-21-2007, 09:30 AM   #14
JohnD
Senior Driver
 
JohnD's Avatar
 
Join Date: May 2007
Location: Fullerton, Cali
Posts: 535
Smile

Quote:
Originally Posted by bulldog View Post
I think RObert was right, some electrical info would be useful too. SO I attached the relay and fuse locations. See above posts.

Might be a life saver down the line, but ONLY IF YOU ACTUALLY PRINT IT AND HAVE IT IN THE TRUCK

Hopefully most folsk takes this with, so someone in the group will have it handy.


Printed and put in a 3ring binder, now if i can only remeber to pack it up when we wheel! lol

GOODSTUFF!!!
__________________
054runnerv8 4x4, Dr coilovers & UCA's,Rr Kings Rezi 2.5's & Cust.coils,33"BFG's,KNCAI,S/Wsliders&Bullbar,D/O Frt.Skid,Dual optimas,On-board shower,A/O roof rack, Ezi-awn 1200 RTT,Mt45...
JohnD is offline   Reply With Quote
Unread 07-21-2007, 05:11 PM   #15
expat
White Boomer (Kangaroo)
 
expat's Avatar
 
Join Date: Jun 2005
Location: SoCal
Posts: 5,737
Default

Andries - I have the additional copies (electrical) to add to your and my binders. Laminated and ready to go. Will give them to you next time we wheel or whatever.

Cheers
Mark
__________________
Mark
04 V8 SE, RST Twin stick conversion, RST Tacoma Front Axle conversion, 17x9 MT ClassicLocks, 37" Cooper STT Mud, SW Sliders & Bullbar, ARB Locked F&R, 4.56's, Smittybilt 10,000lb winch, Radflo 2.5 remote resi coilovers and Radflo 2.5 rear shocks, 1.5 4Crawler BL, Flowmaster, CB and 2m/70cm Ham, Sat. Radio, CO2 system, Lightforce, African Outback Rack, Budbuilt, Front Runner RTT.
expat is offline   Reply With Quote
Unread 07-21-2007, 05:34 PM   #16
my034runner
Toy120 Uber Mod
 
my034runner's Avatar
 
Join Date: Nov 2005
Location: Las Vegas, NV
Posts: 6,332
Default

Quote:
Originally Posted by expat View Post
Andries - I have the additional copies (electrical) to add to your and my binders. Laminated and ready to go. Will give them to you next time we wheel or whatever.

Cheers
Mark


Nice. Mark, did you laminate them yourself, or did you take it to Kinko's, or someplace like that?

I really need to print it out, maybe late at night, here at work. Use their paper and ink!!
__________________
NVTTORA Prez..My034runner: DR/ICON coil overs, Icon 2.5 resis in the rear, custom coil springs, AllPro sliders, BudBuilt skids, KurtFab Lower links, AllPro Upper links, WabFab endlinks, Blackout safari rack, FourTreks HiLift mounts, 285/75/16 BFG's Ko's, MagnaFlow exhaust, Optima Blue&Red top, ShrockWorks bumper, MileMarkerE9000 winch, Engel MT-60 fridge, Sirius, Garmin60 Csx, Factory nav etc...
my034runner is offline   Reply With Quote
Unread 07-21-2007, 06:03 PM   #17
expat
White Boomer (Kangaroo)
 
expat's Avatar
 
Join Date: Jun 2005
Location: SoCal
Posts: 5,737
Default

Quote:
Originally Posted by my034runner View Post
Nice. Mark, did you laminate them yourself, or did you take it to Kinko's, or someplace like that?

I really need to print it out, maybe late at night, here at work. Use their paper and ink!!


Great minds think alike! Work allows us to do some personal stuff so I copied and laminated two full copies for Andries and I when he first came up with the idea. It stays in my truck all the time in the small storage compartment where the jack is supposed to be. Laminated means it will survive oil, grease. dirst, rain etc.
__________________
Mark
04 V8 SE, RST Twin stick conversion, RST Tacoma Front Axle conversion, 17x9 MT ClassicLocks, 37" Cooper STT Mud, SW Sliders & Bullbar, ARB Locked F&R, 4.56's, Smittybilt 10,000lb winch, Radflo 2.5 remote resi coilovers and Radflo 2.5 rear shocks, 1.5 4Crawler BL, Flowmaster, CB and 2m/70cm Ham, Sat. Radio, CO2 system, Lightforce, African Outback Rack, Budbuilt, Front Runner RTT.
expat is offline   Reply With Quote
Unread 07-21-2007, 06:20 PM   #18
my034runner
Toy120 Uber Mod
 
my034runner's Avatar
 
Join Date: Nov 2005
Location: Las Vegas, NV
Posts: 6,332
Default

Quote:
Originally Posted by expat View Post
Great minds think alike! Work allows us to do some personal stuff so I copied and laminated two full copies for Andries and I when he first came up with the idea. It stays in my truck all the time in the small storage compartment where the jack is supposed to be. Laminated means it will survive oil, grease. dirst, rain etc.


That's a great idea!! I take it you have means to a laminate machine at school then, that beats me. But, I do have a $6000.00 bad ass color printer to use!!!
__________________
NVTTORA Prez..My034runner: DR/ICON coil overs, Icon 2.5 resis in the rear, custom coil springs, AllPro sliders, BudBuilt skids, KurtFab Lower links, AllPro Upper links, WabFab endlinks, Blackout safari rack, FourTreks HiLift mounts, 285/75/16 BFG's Ko's, MagnaFlow exhaust, Optima Blue&Red top, ShrockWorks bumper, MileMarkerE9000 winch, Engel MT-60 fridge, Sirius, Garmin60 Csx, Factory nav etc...
my034runner is offline   Reply With Quote
Unread 07-22-2007, 07:01 PM   #19
bulldog
Admin
 
bulldog's Avatar
 
Join Date: May 2005
Location: Morgan Hill, CA
Posts: 12,196
Default

Quote:
Originally Posted by expat View Post
Andries - I have the additional copies (electrical) to add to your and my binders. Laminated and ready to go. Will give them to you next time we wheel or whatever.

Cheers
Mark
Cool stuff, thx. I still need to put mine in a binder.

I have all the manuals for the 4Runner electronical now, and will put in my laptop to take with on trips as well. Will make a nice backup with full intsructions to the guide.
__________________
andries
K9BDG

03 pavement princess
06 toaster
bulldog is offline   Reply With Quote
Unread 06-28-2008, 10:56 AM   #20
Carl44
Driver
 
Carl44's Avatar
 
Join Date: May 2008
Location: Disneyland
Posts: 459
Default

WOW! Thanks for taking the time to do this. It is highly appreciated.
__________________
'08 Grocery Getter
Carl44 is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Repair Manuals expat Maintenance 19 03-17-2007 01:35 AM
Toyota Repair Manuals, wiring diagrams and more online bulldog Maintenance 0 07-26-2005 11:53 PM


All times are GMT -7. The time now is 04:28 AM.


Powered by vBulletin® Version 3.7.4
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Copyright 2005-2013 Toyota120.com