Category Archives: 4×4 Tech

How to fix, maintain or modify your off road adventure truck is here. We also discuss gear and how it holds up out on an adventure.

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trail talk

Ten Things, Don’t Leave Home Without Them

airing up fj cruiser 4x4 tireAs I’m getting ready for the next off-road adventure it occurred to me there are certain things I wont go without.  Some of these are practical, some are personal but for me these things make all the difference in the world when it comes to dealing with issues I may encounter and adding to the fun.

  1. First on the list, my head!  Don’t go Freud on me here.  A big part of my preparation for even a little off-road adventure is to wrap my head around what I’m going to be doing.  I’ll review the maps, run through my mental checklists, and consider the situations I may run into.  This includes thinking about the things that could go wrong.  Since I often go out alone I know that I wont have the perfect piece of equipment for every situation and getting out of a jam is going to be up to me.  This is why I always make sure one person knows where I’m going, when I’ll be back and what to do if I’m late.  Being in the right frame of mind makes all the difference to me and helps ensure I enjoy the adventure no matter what happens out there.
  2. A big part of these off-road adventure trips is capturing and sharing the adventure with others.  I always grab the photo and video equipment including the tripod, microphones, lenses, extra batteries, chargers and video tapes.  All this equipment takes up space and it becomes a trade off with what other stuff I’ll leave at home (see #9).  But when I get a comment telling me how much someone enjoyed the story, pictures or video it brings it all home for why I do what I do.
  3. Water. Lots of water!  Way back in the day, I was out on a long hike and did not bring enough water.  The migraine and weakness of dehydration I experienced was enough to ensure I would never run out again.  I carry plenty of fat reserves around my waist to go without food for longer than I would like.  In fact a cleansing fast would do me good.  But water is an absolute must.
  4. New to the list is my iPhone.  Not that I count on cell coverage, but with all the apps. available these days I find the chance to play  Texas Holdem or listen to a few songs can be relaxing after a long day on the trail or on a lunch break.  There is even a little app that turns your iPhone into a level that can be handy when trying to make sure the rig or camera isn’t listing to one side.
  5. Of course I have my recovery gear.  This includes tree savers, snatch blocks, yank straps, shackles, shovel and hi-lift jack.  I’ve also added a new item, Maxtrax recovery system that makes for easy sand recovery.  I’ve seldom had to use the recovery gear on the trail, but I often pull it out to practice and check that all the equipment is working correctly.
  6. My tool kit is basic but has what it takes: box wrenches, sockets, pliers, box cutter, wires, fuses, crescent wrenches, screwdrivers, zip ties, duct tape, mallet and other bits. I grew up working on Baja bugs where there was nothing you couldn’t fix with a screwdriver and a big hammer.  I also count the air compressor as a mandatory tool for airing up and down as we travel between tarmac and dirt.
  7. A fold up stool…  Yes that is right a fold up stool.  My brother-in-law gave me this little gem a couple of years ago and I did not fully appreciate what a great gift it was at the time.  Every time I’m bent over airing up, peering into the front hub or checking the brakes I thank Mickey for the support!
  8. I have a bucket of fluid bottles in the back just in case something starts to leak or runs low.  Although I do a thorough pre-run check (daily on long trips) the fluids include motor, transmission and gear oil, coolant, brake, steering and windshield.
  9. Kamp KarmaIn the overnight gear department, I’ve attained a Zen like minimalist approach reducing the cooking, sleeping and living gear to what fits in a small bucket.  A bivy sack and tarp replaces the tent, a tea kettle, a small pot,that doubles as a cup, a second cup (it all fits inside itself), a compact stove that puts out enough BTU’s to contribute to global warming, a spoon, head lamp w/ extra batteries, fire starter, fuel and small repair kit.  There is also a hand full of nuts, chicken broth base and enough green tea to relax in the evening as well as get started in the morning.  The grocery list may increase on long trips, but really that is about it for an overnight adventure.
  10. I don’t always know when I’ll get to go on an off-road adventure.  Sometimes it comes down to grabbing the gear and go.  This means all the gear needs to be packed and ready…  Always ready.  All the gear is stored in a few canvas tote bags.  Each bag with its own category of gear.  The last bag is filled with the miscellaneous stuff that falls under the “just in case” title.  Here you’ll find a first aid kit, work gloves, jumper cables, wool blanket, tarp, duct tape, flash light, bungees, parachute cord, and a pair of coveralls. I dipped into this bag a number of times helping others out of a jam including jump starts and the donation of a bungee cord to keep tension on another rigs tire chains.
  11. I know I said ten things… and this is eleven…  this one is my confession of what I don’t carry that I should.  Spare parts!  It is hard to predict what is going to break but there are some basics I still have to build a kit around.  Starting this week I’m building up my parts kit to include: Axle shaft (IFS is a weak point  and no one will have one that fits…  remember the TC long travel build), belts, hoses,  nuts, bolts and …. Your ideas are welcome and encouraged.  What parts do you carry?

This is my top ten and for me it works.  I don’t expect that it will work with anyone else but I hope it will encourage you to think about what you need to be prepared and enjoy your adventures.  Leave your recommendations and help everyone including me build a better kit.

cv axle insides
how to maintenance

IFS Axle Disassembly (Old School)

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I don’t always disassemble an IFS half shaft…  But when I do I use kinetic energy. The world’s most interesting Land Cruiser Guy.

It does not happen often, but when you need to rebuild your font axle, its good to know how it all comes apart. Recently Metal Tech upgraded our front end, which involved rebuilding the front axles with longer shafts. While we where there, Mark Hawley demonstrated how to disassemble the front axles. The typical IFS method involves duct tape and a chop saw followed by cutting and throwing away the shaft. Instead of cutting, Mark went old school, calling on trick from the cruiser guys that uses a little kinetic energy release the shaft from the CVC.

For the price of some pipe or tubing you have laying around save yourself the cost of replacing the shaft or rounding up a chop saw.

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trail talk

Bill Burke Is Coming To Town

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It is not everyday that you get the opportunity to learn from the best in off-road. And when you have that opportunity by all means take it.

Bill Burke is an internationally recognized 4×4 trainer who teaches back country driving techniques, winching and extrication methods, vehicle preparation and maintenance, land navigation and woods’ skills. And with every outing comes additional training on environmental awareness and trail etiquette.

Among his accreditation, Bill is a permitted outfitter guide through the U.S. Forest Service and Bureau of Land Management. Bill also travels the globe to consult and to lead back country expeditions, and serves as a technical consultant in the areas of 4-wheeling expertise and environmental concerns to various businesses, the media, 4-wheel drive manufacturers, dealerships and government organizations.

Bill is going to be in the Northwest to conduct a number of classes in the Portland and Seattle areas. Several clubs and groups including the North West FJ Cruisers Club and Northwest Overland Society are already making reservations for their members.

We have our reservation.  Now is the time to make contact with one of the clubs or Bill Burke’s Off-Road Driving to secure your place in one of his up coming classes in the Northwest.  Everyone who has ever taken Bill’s training class, many have taken it multiple times, say it is one of the best training sessions they ever took.

Hope to see you at a training session and if you can’t make the training check out some of Bill’s videos and other training materials.

toyota fj cruiser front long travel suspension flex
How To Modification Info

Too Much Wheel Travel, Is There Such A Thing?

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As the saying goes “you can never be too thin or too rich”.  We’d add, your rig can never have too much wheel travel on an off-road adventure.  To that end we finally took the plunge and threw out the stock independent front suspension (IFS) and replaced it with Total Chaos’ 2″ long travel kit…

Now, we could go into a write up with pictures, witty descriptions and clever verbal banter that you have come to expect from us, but than you would not have incentive to read the article we shipped of to “4WD Toyota Owner”…  Hopefully this video will hold you over… if you’re really jonesing for a story you can always check the archives.

We will tell you, this set up allows you to dial in more lift for bigger tires or add droop for more travel.  Since we spend more time bombing down dirt roads than crawling over boulders and rock we choose to utilize all of the 11.5 inches of travel dialing in more droop to keep the rig riding fast and smooth over miles of washboards.

So how does it ride you ask… you know you were thinking that. The ride is incredible.  We had a chance to take it off road a little bit and the ride unbelievable…  and those pothole filled back roads are not match for this setup.  Even without the sway bar, the rig corners like it is on rails with very little body roll.  No it doesn’t handle like a Porsche, but you can’t take a Porsche where angle fear to tread.

fj cruiser knuckle gusset installed
gear review

Knuckle Buckle Buster (say that fast 3 times)

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removing fj cruiser steering knuckleTurns out there is a weak spot in the FJ Cruiser’s front knuckles that can give out under the right circumstances.  Now those circumstances can be found on off-road adventures and include speed, suspension extension and brute force, all in the right combination…

Since we look for places that set up situations where all those circumstances come together, we thought we would see about reinforcing the knuckle spindle.  We found that Total Chaos now offers a weld on 1/8” laser cut spindle gusset intended to reinforce the spindles where they bend. These gussets can be installed with aftermarket upper control arms (UCA) but are not compatible with stock upper control arms. Just another reason for a UCA upgrade.

grinding prep fj cruiser knuckleThe gussets also dictate that you run without a sway bar.  On the road the sway bar helps eliminate body roll and keep the wheels planted on the ground at high speeds or in emergency maneuvers.  Off-road the sway bar can limit the amount of flex your rig is capable as it tries to balance out the movement.  We are running Sway-A-Way coil overs upfront and use the rig as for daily driving.  Luckily the SAWs are plenty capable of preventing body roll on their own and removing the sway bar should not impact on-road performance.  If you’re running a daily driver with other coil overs, test drive your rig without a sway bar before committing to permanent removal.

We headed down to Metal Tech, to have the guys help us out with this mod.  Mark and LT really know Toyota’s and have performed several of these mods, including one on their own shop FJ after bending a spindle during a hard day of wheeling.

LT welding on fj cruiser knuckle gussetThe first thing the guys did was pull apart the rig, removing the sway bar, breaks, hubs, seals, lines, and sensors in order to pull off the knuckle.  Be gentle with the ABS sensor that plugs into the front of the knuckle, you don’t want to set off all the angry dash lights when you bolt it all back up.  Also before you start be sure to have new seals and hub covers on hand since they will take a beating during the disassemble process and are hardly worth spending the time needed to clean and repair.

With the knuckle off it is time to apply heat.  The TC gussets weld directly to the knuckle up the length of it to the UCA mount point.  That means there is a some prep needed to ensure you get good contact and alignment between the knuckle and gusset.  With a little grinding, LT quickly cleaned up the knuckle and than on to the welding table.  Sparks, fire, metal…  It just doesn’t get much cooler than this.  (You can see, LT left the stock UCA attached in order to hold the knuckle up off the table and make working around the corners a little easier.)fj cruiser knuckle gusset

After giving the metal a chance to cool down it was time to pull out the one universal tool every wheeling back yard or pro mechanic must have.  Rattle Can paint!  You have to love that can of Rustolium sitting on the shelf that keeps little spots looking good and stays off the rust as we through the rig into all the nasty stuff that convert perfectly good steel into weak brittle bits.

With all the fab work done, it was time to button it all up and reassemble the suspension.  That means the new UCAs go into place along with bolting on the hubs and seals, tie rods, brakes, lines and of course bleeding the break lines.  The shield that holds the ABS sensor cable out of the way will take a little grinding to ensure it fits up against the knuckle and gusset.  After getting it all put back together it was a quick run to the hot rod shop down the road for an alignment and the hole thing was done in no time.  With all the experience the guys at Metal Tech have, this mod was easy.

So how was the handling on the road without a sway bar?  With Sway-A-Way coil overs, I did not notice a change in handling.  That was even after taking the twisty back roads from Newberg to Portland, the hole time testing how fast I could comfortably go into and out of the turns.

toyota mass air flow sensor removal
how to maintenance

How To Clean A Mass Air Flow Sensor

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Toyota mass air flow MAF sensorToday’s sophisticated computer controlled fuel injected engines squeeze a significant amount of horse power out of each combustion chamber.  In order to achieve their maximum output, they need precise input.  That precision involves 14.7 parts air for every 1 part fuel or 14.7:1.

In order to know the correct amount of fuel to pump, the engine must know how much air is coming  in.  Air flow is not a constant. As the rig drives down the trail, through the hot and cold as well as humid or dry conditions air volumes change. Enter the Mass Air Flow (MAF ) sensor. The technical jargon behind the acronym MAF involves a constant voltage passed over two heated wires placed into the airflow.  As the air flows across the the wires, they cool down creating a positive temperature coefficient (PTC).  In other words by measuring the drop in temperature of the wires (or increase in current passing through them) the engine’s computer can calculate the airflow.  To ensure a correct reading the engine’s computer takes into account temperature and humidity as well.

Eventually, dirt and oily film can cook on the wire creating a thin insulating layer of muck.  Periodically, there’s a cleaning cycle where the wires are heated to a very high temperature to burn off deposits. If the deposits remain and engine’s computer sees an air mass value out of range, it sets an error code…  and the dash board lights up like a Christmas tree.

2007 toyota fj cruiser engine bayManufacturers of MAF sensors recommend replacing the sensor, after all they are in the business of selling them.  If you have a few garage tools and about twenty minutes you can clean the MAF sensor, which may solve the issue, if the wires are mucky between cleaning cycles.

Removing the FJ Cruiser’s MAF sensor for a visual inspection and cleaning is a simple procedure.  The first step is to remove the plastic engine cover, by loosening the two nuts up front and lifting the cover off it’s hinge.

mass air flow maf location fj cruiserOnce cover is removed, the MAF is exposed in the front of the secondary air flow box.  Carefully, unhook the wire harness connecting the MAF to the engine’s computer.  To remove the wire harness, depress the clip and give a snug pull on the sides of the connector.  Do not pull on the wires.  If the connector refuses to release its grip, try holding the clip down while sliding a screw driver between the connector and MAF, gently prying  the two apart, careful not to apply too much force (remember plastic exposed to heat, over time can become brittle).

With the harness disconnected, remove the two screws holding the MAF in place and lift the sensor out of the the air flow box.  You can cover the opening with a shop towel to prevent any dirt, bugs or stray bird poop from falling in while you clean the sensor.

With the MAF sensor removed inspect the hot wires for muck.  In order to clean the hot wires we picked up “contact cleaner” from Radio Shack and following the directions, really read the directions… sprayed the hot wires with cleaner.

The contact cleaner we used drys in about 10 minutes and does not leave a film.  After the cleaner has done it’s job, slide the MAF back into place.  You will hear a click as it seats past the O ring on the sensor’s collar.  Screw it into place, connect the wire harness and reattach the engine cover.  Your done.

If you have an Intelligent Tester, you can ensure the mass air flow sensor is operating within spec following the Toyota mass air flow check service bulletin.  We simply made sure the dash board lights didn’t go into hyper-drive when we started the rig and let it warm up.

voodoo blue fj cruiser driving through snow 4x4 trail
trail talk

Snowpocalypse Weather Watch

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FJ cruiser in snowKnowing what you’re getting into on an off-road adventure and planning for the weather is a big part of finishing an off-road adventure safely.  Currently the Northwest is experiencing cold, snow and ice that is a little more than usual.  Before we go out on a trail run we usually check with the National Oceanic and Atmospheric Administration (NOAA).

NOAA can tell you what to expect just about anywhere in the nation and have a number of good educational resources to go along with all their maps and data.  And when the weather gets really bad, they put out special reports to explain exactly what your in for.  NOAA’s NW region put out this December 20-21 weather advisory.

Snow and extreme weather can add to the fun of an off-road adventure creating an additional challenge to an otherwise easy trail.  It can also turn a fun trip into a ugly mess if you’re not prepared for what mother nature throws at you. Be prepared before you go out and check with NOAA and stay safe.

fj cruisers on rubicon trail
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Everyone Was A Noob Once

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Brian “Woody” Swearingen and Last Great Road TripOver the last couple of years I’ve had an opportunity to wheel with a number of experienced guys who have forgotten more than most will ever know.  And because of those opportunities my abilities have improved.  But I am still working on the basics.

When we started this off-road adventure idea I would read and talk to anyone who would take the time to chat, then go out on easy logging roads to test what I learned.  Luckily I found a number of people willing to teach the new guy (the really great overlanders, are eager to help others).

Although the Toyota FJ Cruiser has a lot of technology such as A-TRAC and E-Locker to help you out, it is important to get comfortable with the right approach to an obstacle in the first place and know which technology best fits the situation.  You will also want to learn the low tech items including building a sand anchor or safely operating a Hi-Lift jack.

When I looked through some of the archives, I came across a few resources that stand out as belonging on everyone’s reading list:

And when you’re ready for the complete manual on all things overland adventure, be sure to read “Planning and Leading An Overland Expedition“.

If like me, you struggle with dyslexia and reading quickly looses entertainment value, check out the videos from Bill Burke, Getting UNStuck and Getting PREpared.

This reading list will not substitute for practice, but it will provide you with a solid understanding and a strong foundation.  To really go further and get the most from your 4×4 experience, consider joining a local 4×4 organization such as the NW FJ Cruiser Club or Rising Sun Four Wheel Drive Club of Colorado. A club will provide an opportunity to wheel on trails where members can teach you the finer points of picking a line as well as demonstrate moving over, through and around obstacles on the trail.

We were all noobs once and every time I get together with experts to chat I’m reminded of just how much I still have to learn.  If you’re starting out, read everything you can, join a club, find a mentor and hang in there.  Before long a newbie will be knocking on your door asking for a little advice.

fj cruiser kn air filter
gear review

Long-term Report – K&N Cold Air Intake

We all get excited by our new mods and tell everyone we know how its the best (fill in product name here) on the market and we explain all the reason we choose product X. But over time does that glowing praise fad, or are you still pleased with your purchase? This report follows a year of use in all sorts of off-road adventure conditions, and reflects our real world experience with the K&N CAI for the the Toyota FJ Cruiser.

We replace the Toyota FJ Cruiser’s stock air intake with a K&N cold air intake (CAI) about 30,000 miles ago.  The decision to make this mod was based on the horse power gain claims and our desire to beat the dust and debris associated with the dirt and gravel roads of expedition travel.  We picked up the K&N model 63-9030 cold air intake for the Toyota 4.0L engine.

K&N states “our 63 Series Intake Kits or AirCharger® Intakes are built for many different vehicles and represent a dramatic improvement over a K&N O/E replacement filter alone. These intakes use only non-metallic rotationally molded tubes that can reduce intake air temperature and decrease intake sound over a metal tube. Restriction can exist BETWEEN an air filter and the engine reducing the benefit of a K&N Air Filter. The weakest link in the airflow ‘chain’ robs a vehicle of its natural horsepower. Often that weak point is the factory air path leading to the Engine. K&N Air Intake Kits virtually eliminate air path restriction by replacing the air filter and the entire air path to the engine. The aerodynamically engineered tube drives a massive amount of air into an engine, which translates into POWER.”

According to K&N we should have seen a horse power increase of 11.95hp @ 4785rpm (K&N intake kits dynojet research).  And while our rig was not put on a Dyno to validate the increase we felt a gain and certainly heard the throaty sound of air rushing in.

The installation is simple for anyone who has changed their own oil or replaced a stock air filter.  The kit came with all the parts and easy to follow instructions. The bigger, and I do mean bigger, air filter is washable and reusable allowing you to save money on filter replacements and increase air flow.

K&N states “All filters are constructed with ultra-strong molded pliable rubber flanges which absorb vibration and allow for secure attachment” and this is where we saw a major problem.  The weight of the air filter hanging off the intake mount combined with the vibration of the rig as we cruised over washboard back roads (200 to 500 miles a day of washboard gravel and dirt at speeds of 40 – 55 mph) caused the filter to rub against the rigs body. This rubbing caused the filter to wear a hole through its wire mess and polished off the rig’s paint and primer below.  At one point the filter vibrated completely off the intake tube despite a adjustable screw-down band clamp that came with the CAI.  We did manage to correct this problem with some zip ties that secure the intake tube to the heat shield, adding support for the filter and lowering the amount of vibration cause the heavy filter.

The other drawback we found is that although the K&N CAI comes with an air guard designed to shield it from the hot engine bay, it is less than an ideal fit.  Unlike TRD’s CAI which encloses the air filter and draw cool air from the outside, K&N’s is much more open with hot air flowing in from around, underneath and above the shield.

Bottom line, would we do it again…  No!  Although the K&N CAI works well enough, the lack of air control and the filters desire to jump off the intake tube led us to remove this K&N CAI.

All high flow air filters trade some filtration capability for more air flow.  They try to solve it with oil spray or other dust attraction.  The oil sprayed onto this type of filter has been blamed for muck on the MAF (mass airflow) sensor so use it sparingly according to directions.    For now we will go back to the original stock configuration.  For us the additional horse power claim from added air flow was not worth the trade off of filtration and added headaches.

yellow sun fusion fj cruiser rock crawling
gear review

Don’t Take My Word For It

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sun fusion fj cruiser yellowIf you read this website and well you must or you wouldn’t be here….  You know I believe the Toyota FJ Cruiser is a great rig for the type of off-road adventures we do.  We take the rig on off-road adventures, across Alaska tundra, through Baja desert, over tough Rubicon 4×4 trails and explore just about any two track that looks interesting. And while I will tell you it is a great rig, who am I!

Well don’t take my word on it, turns out we have some other opinions to share and it is not the thousands of other FJ Cruiser owners… We’re all biased.  No, this best rating comes from US News & World Report.  They just came out with their list of best truck, cars, hybrids, and toasters.  Ok I’m kidding about the toasters, I think the Hamilton Beach True Toaster is the best.  In the category of Midsize Crossovers/SUVs US News & World Reports picked the Toyota FJ Cruiser number one.  In their words “Despite the fact that it’s a bona fide truck-based SUV, the Toyota FJ Cruiser provides a surprisingly comfortable highway ride. Add to that a cool, retro-looking exterior and its ability to double as a rugged off-roader and daily driver, and you’ve got a good value — even if fuel economy isn’t the greatest.”  And the Toyota FJ Cruiser’s quirky looks, it gets a 9.2 (excellent) score for it’s Exterior from US News & World Reports.

If that is not enough, The Washington Times reports on the Insurance Institute for Highway Safety, finds that the FJ Cruiser earned a Good ratings and has become a Top Safety Pick.  This rating is of course on the new 2009 rig but you check Insurance Institute for Highway Safety web site for Top Safety Picks from earlier years.  I’ll save you the click through…  2007-2009 received a Good rating.  And for these guys a rating of Good, is as good as it gets.  While your looking around on the Insurance Institute’s site check out all the cool info on safety, crash test and status reports.