Jacob's journey began with finding a rust-free 1987 4Runner, a challenging task in itself given the vehicle’s age. Jacob envisioned building this classic platform into a robust rock crawler while maintaining its ability to comfortably drive on public roads. Over three carefully planned years, this vision transformed from a collection of parts into an extraordinary off-road machine.
"This was definitely my dream build and it came out great and is even better to drive then I imagined."
Parts Sourcing & Preparation
Jacob’s meticulous preparation took up the first two years of the build, dedicated to sourcing critical components. He gathered front and rear Toyota 80-series axles from East Coast Gear Supply, Hellfire knuckles, Yukon 5.29 gears from East Coast Gear Supply, chromoly axle shafts, Fox coilovers, and Tom Woods driveshafts. This strategic gathering of parts allowed him to efficiently begin the build when it finally entered the shop.
Build Specs
- Front & rear ECGS 80-series axles (rear centered)
- Hellfire knuckles
- Yukon 5.29 ring-and-pinions
- Chromoly axle shafts & locked diffs front and rear
- Three-link front suspension with 12″ Fox coilovers
- Leaf springs in rear, six-inch lift
- Tom Woods driveshafts & AA dual transfer-case setup
- 37″ STT Pro tires
- Original 22RE engine (300K miles) unchanged
Shop Build Acceleration
During the third year, the project transitioned to a trusted professional shop. The shop’s involvement accelerated progress significantly, enabling Jacob to see his dream realized faster than if he had tackled the project himself. I don’t have a good place to work on vehicles for an extended period, and I knew a shop could do it faster,
Jacob explained. The additional cost was more than justified by the convenience and speed at which the build was completed.
Engineering Challenges
A notable challenge Jacob encountered involved deciding what to do with the rear axle. Originally, he intended to keep the axle’s passenger-side drop, ensuring standard shaft lengths. However, the 4Runner’s centered transfer case complicated this decision, potentially causing driveline vibrations. Ultimately, Jacob chose to center the rear differential, necessitating custom-length chromoly axle shafts. This modification proved essential, ensuring smooth highway driving while maintaining robust off-road capability.
Testing & Validation
Upon completion, Jacob wasted no time putting his 4Runner through rigorous testing. Its maiden voyage was an ambitious 2,500-mile round trip to Windrock Offroad Park, a demanding destination for even well-proven vehicles. Impressively, Jacob’s freshly built 4Runner—equipped with a nearly 40-year-old, unaltered 22RE engine—handled intense off-road challenges and extensive highway miles flawlessly.
"Everything on the truck was untested, brand new, or nearly 40 years old, and it performed better than I imagined." -- Jacob proudly recalls
Transformation & Performance
Jacob describes the transformation as remarkable, emphasizing how significantly the vehicle’s capabilities evolved. Coming from his moderately built FJ Cruiser, the difference was night and day. The combination of Yukon 5.29 gears and 37-inch STT Pro tires provided an ideal balance, excelling both on challenging trails and regular roads.
Unique Features
One aspect Jacob believes sets his 4Runner apart is its street legality paired with the unique use of a centered 9.5-inch 80-series rear axle. While he acknowledges others may have undertaken similar modifications, the rarity and meticulousness of his particular adaptation stand out.
"Don’t compromise. Define your goal clearly, save and plan meticulously, and avoid settling for short-term solutions you’ll regret later. Even if the build takes longer, ensuring it meets your vision is worth the extra effort."
Future Upgrades
Although the 4Runner is now fully functional and trail-tested, Jacob already has further improvements in mind. His future plans include adding an exoskeleton roll cage, rebuilding the venerable 22RE engine that’s nearing 300,000 miles, and giving the body a fresh coat of paint.
Conclusion
Jacob’s 1987 Toyota 4Runner stands as a testament to clear vision, thoughtful planning, and unwavering dedication—proving you can build an impressive off-road rig that’s as enjoyable on the street as it is on the trails.
What’s Your Story?
We love championing builds that go beyond horsepower and gear ratios. Jacob’s 4Runner is proof that, with the right parts (and a lot of elbow grease), you can create a one-of-a-kind masterpiece. Got a project that deserves the spotlight? Send your story and photos to [email protected] for a chance to become our next Customer Spotlight. Who knows—your dream project might just inspire someone else’s next adventure.
Ready to Tackle Your Own Project?
Whether you’re chasing speed, exploring backroads, or looking for a dependable weekend warrior, East Coast Gear Supply has the parts, expertise, and passion to help. Get in touch, gear up, and let’s build something remarkable—together.