4th Gen 4Runner E-locker Retrofit is Finally Happening!

Apr 13, 2020 | By admin

With the Coronavirus quarantine in full effect, I have found myself not needing a car so much anymore. So, I figured I would take this opportunity to get down and dirty with my 4th Gen 4Runner e-locker swap…FINALLY!

Those of you that may have somewhat followed along, I bought this axle about a year and a half ago. Yes, It’s been that long. I also decided that I will not regear right now for the simple fact that it’s not in the budget and I really don’t mind the current feel on 33s. As my tires wear down, and I’m in the market for new rubber, 35s may be in the question, and at that point, I may have the funds to regear from East Coast Gear Supply.

In the week leading up to it, I did a lot of prep. I took apart the diff actuator to make sure it was still in good shape. Inside, it was actually in great shape. But the aluminum housing was corroded and the little bolts holding it together were so stuck I had to drill them out and re-tap the holes.

Unfortunately, I’m terrible at drilling out bolts and made a terrible hack job on the aluminum. Yes, I even used a center punch! Ugh… Fortunately, I was able to put enough threads in it to get the case snugged back up.

Rather than use an o-ring, I decided to use gasket maker. Since the case was corroded, I felt as though this would provide the best seal.

After properly indexing (VERY IMPORTANT TO ENSURE PROPER ENGAGEMENT) the actuator and reassembling it, I moved onto the third member.

First I repainted the housing with some rust converter and then Eastwood extreme chassis paint. It turned out pretty good if I must say so myself.

I also decided to swap out the diff studs for 10.9 rated button head bolts. For the e-locker, you’ll need (7) 35mm M8x1.25 bolts and (2) 40mm M8x1.25 bolts. I used Fastenal.com to order them. I reused the factory studs for the actuator. Since the stud nuts are only torqued to 18lbs/ft, just crank the button heads down pretty good and they shouldn’t back out when you torque the nuts. This was definitely a tedious process.