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Ken's 90 Series Overhaul
Well getting the old 4WD sorted out for camping and touring at last.
She is a 1997 Toyota Prado GLX 3.4 V6 Petrol with 197000 kms on her, of which I have done about 25,000 of in the 3 years I’ve had her.
I have my Prado in the shed in bits, undergoing some much needed upgrades and service work.
Some pics of the work so far
http://s1275.beta.photobucket.com/us...ado%20Overhaul
I was to busy doing the work to take more
I will take a few more and post however
I have so far completed the following;
The 2-inch lift with new Iron Man springs and 40mm foam shocks, also fitted the Firestone airbags in the rear springs.
All new, Fulcrum super pro bushes front and rear, new upper and lower ball joints, new rack ends and tie rods, both front CV’s overhauled to premium quality units, new CV oil seals fitted in the font diff.
Replaced the front sway bay link rods as the passenger side one had snapped.
Replaced the oil in the Front and rear diff, along with the transfer case.
Painted the front-end components, wishbones, front sway bay, steering rack, steering knuckles and front hub units etc with zinc primer and black epoxy paint.
Other miscellaneous painting, ie under battery.
Painted the chassis and cross members with zinc primer, black chassis paint and then sprayed with stone guard, just a little bit of the rear to go.
Did a service on the Auto, drained the oil from the Auto, remove the pan, cleaned the filter (Toyota says clean, not replace) and magnets. Did a flush via the cooling lines to get the old oil out of the torque converter.
Fitted a new auxiliary oil cooler and plumbed it all up.
New cam belt, idler and tensioner fitted.
Inspected the water pump, bearing felt OK, and no sign of leakage, so I didn’t replace it.
Overhauled and adjusted the clutch in the fan, was very little silicon oil in it when I opened it up. Refilled with 2 x 18mm Toyota 10,000 cSt Silicone oil.
New belts and hoses fitted.
Radiator and engine chemically flushed and rinsed through several times.
Cleaned the Idle and MAS sensors.
Engine oil and filter change.
New Air cleaner fitted.
New Fuel Filter.
Greased prop shafts and ball joints.
I am Currently in the middle of painting and then overhauling the front brake callipers, along with the fitting of the snorkel and the removal of the power antenna motor unit, so I can get the busted bits of the old mast out.
I will be stone guarding the inside of the inner guards while I have the plastic covers off.
I can then get the front feet back on her and get the back end up on the stands again and do the overhaul and painting of the Rear Calipers and complete the stone guard on the rear of the chassis.
Then I can get it in for the wheel alignment.
YEAH.
Still have the following to get done.
Remove clean and test the fuel injectors.
Inspect/replace the knock sensor wires.
Do the valve clearances.
Fit extended breathers to the diffs, transfer case and gearbox, this requires the removal of the centre console etc.
Replace the 3 busted air vents in the dash.
Kick out old windscreen, clean and repaint mounting sill areas. Refit new screen.
Make roof console and fit new C/B radio and antenna.
Fit new in-dash radio, have a great one on flea Bay for $500, with reverse camera input, mine works but CD is a bit dodgy.
Fit and wire up the reversing camera.
Make and Fit duel battery Tray and wiring fuses etc for 2nd battery.
Run Power wires to back end from the 2nd battery, one for cig plug, and heavier wire for Anderson type plug.
Remove the seats and rest of the carpet so I can complete the clean up and touching up the interior floor pan paint, has a few little bits of rust staining starting.
Get the driver’s side refurbished, RH edge is soft and lacks support for butt and leg.
Fit the passenger side window monsoon cover.
Remove the stuffed window tinting and replace with new film, RH 2nd and 3rd seat windows are very bad, kids pulled the film off.
Make the HD roof rack bars. Thinking of going for a roof top tent and awning set up. Make the front basket and over bonnet removable extension.
Wire up the LED sidelights.
Make the rear storage module fridge slide (drop type slide would be good), draws, cargo barrier, water storage and pump system.
Replace the busted read door trim with a fold out table system.
Make reversing light mount off the spare wheel carrier, and wire up new reversing light.
Fit and wire up the new LED light bar.
Get in behind the dash and clean out the A/C evaporator.
Make and fit recovery point’s front and rear.
Look at fitting some better under body bash plates, ie Bush skins, Brown Davis or Iron Man. Iron man includes the gearbox and is $430 delivered off EBay, need to see what they cost in Cairns. Bushskinz and others look like they are only front part under engine, no gearbox protection, which I need being an Auto. Found Iron man cheaper by googling it
Remove door trims, inspect door interiors and spray with fish oil or stone guard.
Suss out fitting the new A/C Condenser, mine is on the way out, the alloy fins disintegrate if you touch them, and getting the system re-gassed, new filter dryer etc.
Might see if I can borrow some gear from my mates dad who is a fridge tech, save a bloody lot of $$$ if I could !
I have the ARC license but no gear at home to do it.
Suss out headlight upgrade, hear the X100 are a good upgrade, as HID upgrades are not legal due to the requirement that they be fitted with washers and wipers.
Sus out making a winch mount behind the alloy bull bar, and fitting a winch. Maybe just get a hand winch for now off E Bay. Buy recovery gear.
Should see me busy for the awhile, at least till this “DRY is fully underway.
Probably more to go on the list, but it is starting to bloody scare me now ......
She is a 1997 Toyota Prado GLX 3.4 V6 Petrol with 197000 kms on her, of which I have done about 25,000 of in the 3 years I’ve had her.
I have my Prado in the shed in bits, undergoing some much needed upgrades and service work.
Some pics of the work so far
http://s1275.beta.photobucket.com/us...ado%20Overhaul
I was to busy doing the work to take more
I will take a few more and post however
I have so far completed the following;
The 2-inch lift with new Iron Man springs and 40mm foam shocks, also fitted the Firestone airbags in the rear springs.
All new, Fulcrum super pro bushes front and rear, new upper and lower ball joints, new rack ends and tie rods, both front CV’s overhauled to premium quality units, new CV oil seals fitted in the font diff.
Replaced the front sway bay link rods as the passenger side one had snapped.
Replaced the oil in the Front and rear diff, along with the transfer case.
Painted the front-end components, wishbones, front sway bay, steering rack, steering knuckles and front hub units etc with zinc primer and black epoxy paint.
Other miscellaneous painting, ie under battery.
Painted the chassis and cross members with zinc primer, black chassis paint and then sprayed with stone guard, just a little bit of the rear to go.
Did a service on the Auto, drained the oil from the Auto, remove the pan, cleaned the filter (Toyota says clean, not replace) and magnets. Did a flush via the cooling lines to get the old oil out of the torque converter.
Fitted a new auxiliary oil cooler and plumbed it all up.
New cam belt, idler and tensioner fitted.
Inspected the water pump, bearing felt OK, and no sign of leakage, so I didn’t replace it.
Overhauled and adjusted the clutch in the fan, was very little silicon oil in it when I opened it up. Refilled with 2 x 18mm Toyota 10,000 cSt Silicone oil.
New belts and hoses fitted.
Radiator and engine chemically flushed and rinsed through several times.
Cleaned the Idle and MAS sensors.
Engine oil and filter change.
New Air cleaner fitted.
New Fuel Filter.
Greased prop shafts and ball joints.
I am Currently in the middle of painting and then overhauling the front brake callipers, along with the fitting of the snorkel and the removal of the power antenna motor unit, so I can get the busted bits of the old mast out.
I will be stone guarding the inside of the inner guards while I have the plastic covers off.
I can then get the front feet back on her and get the back end up on the stands again and do the overhaul and painting of the Rear Calipers and complete the stone guard on the rear of the chassis.
Then I can get it in for the wheel alignment.
YEAH.
Still have the following to get done.
Remove clean and test the fuel injectors.
Inspect/replace the knock sensor wires.
Do the valve clearances.
Fit extended breathers to the diffs, transfer case and gearbox, this requires the removal of the centre console etc.
Replace the 3 busted air vents in the dash.
Kick out old windscreen, clean and repaint mounting sill areas. Refit new screen.
Make roof console and fit new C/B radio and antenna.
Fit new in-dash radio, have a great one on flea Bay for $500, with reverse camera input, mine works but CD is a bit dodgy.
Fit and wire up the reversing camera.
Make and Fit duel battery Tray and wiring fuses etc for 2nd battery.
Run Power wires to back end from the 2nd battery, one for cig plug, and heavier wire for Anderson type plug.
Remove the seats and rest of the carpet so I can complete the clean up and touching up the interior floor pan paint, has a few little bits of rust staining starting.
Get the driver’s side refurbished, RH edge is soft and lacks support for butt and leg.
Fit the passenger side window monsoon cover.
Remove the stuffed window tinting and replace with new film, RH 2nd and 3rd seat windows are very bad, kids pulled the film off.
Make the HD roof rack bars. Thinking of going for a roof top tent and awning set up. Make the front basket and over bonnet removable extension.
Wire up the LED sidelights.
Make the rear storage module fridge slide (drop type slide would be good), draws, cargo barrier, water storage and pump system.
Replace the busted read door trim with a fold out table system.
Make reversing light mount off the spare wheel carrier, and wire up new reversing light.
Fit and wire up the new LED light bar.
Get in behind the dash and clean out the A/C evaporator.
Make and fit recovery point’s front and rear.
Look at fitting some better under body bash plates, ie Bush skins, Brown Davis or Iron Man. Iron man includes the gearbox and is $430 delivered off EBay, need to see what they cost in Cairns. Bushskinz and others look like they are only front part under engine, no gearbox protection, which I need being an Auto. Found Iron man cheaper by googling it
Remove door trims, inspect door interiors and spray with fish oil or stone guard.
Suss out fitting the new A/C Condenser, mine is on the way out, the alloy fins disintegrate if you touch them, and getting the system re-gassed, new filter dryer etc.
Might see if I can borrow some gear from my mates dad who is a fridge tech, save a bloody lot of $$$ if I could !
I have the ARC license but no gear at home to do it.
Suss out headlight upgrade, hear the X100 are a good upgrade, as HID upgrades are not legal due to the requirement that they be fitted with washers and wipers.
Sus out making a winch mount behind the alloy bull bar, and fitting a winch. Maybe just get a hand winch for now off E Bay. Buy recovery gear.
Should see me busy for the awhile, at least till this “DRY is fully underway.
Probably more to go on the list, but it is starting to bloody scare me now ......
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