 The rear hatch lifts to reveal...  The rear hatch lifts to reveal generous cargo capacity. The second row seats fold forward to accommodate extra-large items. Our 33-inch Mickey Thompson spare was too big to fit under the body in the stock holder, so it goes inside. We're brainstorming about ways to build a custom internal rack that will hold the spare and our tools neatly and securely. |  If you find a 4.0 V-6 under...  If you find a 4.0 V-6 under your hood, it's a good day.Oil changes are simple; the oil filter and oil filler are accessible at arm's length.The 4.0 V-6 features four cams, four valves per cylinder, and variable valve timing. The power plant produces 236 hp and 266 lb-ft. of torque. While that's impressive on paper, it's much better when experienced via the right foot and the seat of the pants: this engine's got guts! We're running 33-inch tires and using stock axle gears; a combination that usually results in lazy acceleration. Not this time. The 'Runner is eager to run. |  As mentioned, the 4Runner...  As mentioned, the 4Runner shares its double wishbone control arms and rack-and-pinion steering with the Tacoma and the FJ Cruiser.We're using a Sway-A-Way bolt-in coilover in place of the stocker, and have removed the front sway bar for better articulation on the trail. |
 The coil-sprung, four-link...  The coil-sprung, four-link rear suspension is shared with the FJ Cruiser and benefits from the same aftermarket support. Sway-A-Way's rear coils and shocks go in place of the stock parts, and provide both lift height and superior control in the dirt. |  Since yours truly has a deep-seated...  Since yours truly has a deep-seated dislike for drums, it was nice to find a pair of sure-stopping, water-shedding discs attached to the rear axle. Four-piston calipers and vented rotors are used up front. |  There's no need to covert...  There's no need to covert to a fixed yoke rear transfer case output since the 4Runner comes that way from the factory. Most dirt enthusiasts prefer a mechanical transfer case lever instead of a dash-mounted electrical switch because a mechanical lever is simpler and more reliable. Be that as it may, the 4Runner's electrically-shifted transfer case has proven stone-reliable to date. |
 The front differential is...  The front differential is a high-pinion design, bringing greater strength and better ground clearance to the table. The Automatic Differential Disconnect system is part of a part-time 4WD system that improves component life and fuel economy. Like the electrically-shifted transfer case, the ADD has worked reliably every time we've turned the 4WD switch on the dash. |  The exhaust system's crossover...  The exhaust system's crossover tube beneath the transfer case is tucked in nicely, but could probably still use a skid plate for improved protection. The tube has an oval profile along its lowest portion to improve ground clearance. |  Mufflers aren't all that exciting...  Mufflers aren't all that exciting compared to shocks, roll cages and suspension links. The big news here is what you won't notice: sound. Thanks to a well-executed OEM exhaust system, the 4.0 V-6 is as quiet as it is powerful. |
Buildup: Round Two
Although our 4Runner had already received a round of aftermarket parts, it had been returned to stock by the time the current staff was handed the keys. This gave us a blank canvas to work with. We decided to keep this buildup mild, but still wanted as much off-road performance as possible using bolt-on parts. The 'Runner functions as a daily driver as well as a trail rig, so we needed a quick, simple transformation, and good street manners in addition to our on-trail needs. Sway-A-Way's front and rear shocks and springs added two inches of lift height, and also added bump-handling abilities unmatched by the stock suspension, which was already impressive.
Desolate Motorsports custom-fabricated a front bumper that vastly improves approach angle and flows well with the 'Runner's body lines. We're using Mickey Thompson's P285/75R16 Baja MTZ tires wrapped around Mickey Thompson 16X8 Classic II alloy wheels. We've had great success with the Classic II's in the past, but this time the wheels' backside profile didn't clear the 'Runner's four-piston front brake calipers.To fit the Classic II's, we needed a set of billet wheels spacers from Downey Off-Road. Wheel spacers aren't our favorite solution to wheel fitment problems, especially when used on the front wheels, but we can report that we've had zero troubles with the Downey wheel spacers after several thousand miles of street and dirt driving.
We'll highlight these products more extensively in future stories. This time, our goal was to show what we used to get the 4Runner ready for the dirt.
 |  The steel skidplate under...  The steel skidplate under the gas tank has done its job well and has the scratches and dents to prove it. | |