4WD Toyota Coaster Build up @ ExplorOz Blogs

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Toyota Coaster

4WD Toyota Coaster Build up

Feb 11, 2010 at 15:31

Life TourBoy, Bundaberg

Why build one Toyota make one you ask?

the factory Awd Coasters are mainly in the icy areas of Japan and production is to around 20 per year. Apart them being a grey they may have rust from salting of the roads.

The 2 problems that I can see are that don’t have much clearance and a lower than side door entry. The problem in my view is the independent and portal hubs from the cruiser. The mega cruiser was imported to Australia either so I hate to break anything and to get parts that month.

The case is that of a dyna and can be time or part time 4wd and has low but isn’t connected so you can’t low unless you have linkages up.

I was going to make one for myself I failed to find a suitable 2nd one to purchase. During many to many fellow EO members I that finding an ex tour that is regularly serviced and put the heavy vehicle pit every 6 was the go as it wouldn’t have been off (2WD) and generally would be in better condition than any ex 4WD bus that had been flogged to anyway.

I have since had many from others interested in one as the last one was built approx 8 ago and now no one does it. So I will be building a few if is interested.

So I hunted around and this

2wd coaster

I have to use NPS300 Izuzu diffs as are still in production and are readily as are spares. The previously built usually had ford Dana 70 but these are becomming scarse and

The transfer case I decided on is a proof cast iron driven New Process 205 from a F truck. These are cheap to and are virtually indestructable behind a big V8, so the old 1HZ won’t kill it. A lot of Oka’s use transfer case. The early used a Rockwell transfer but they are expensive and are noisy on the .

I am intending to keep the Toyota and gearbox with transmission and mount the transfer case from the gearbox via a small shaft.

I will be using the Toyota Parabolic rear springs and mounting the rear under the springs.

The front will also leaf springs as the earlier with coils suffered some issues and most converted back to leaves. is everything. I am trialling a set of Mitubishi front springs to start as I want it to ride well, if are too soft I will add another

Here is a pic of the rear diff in

Rear diff

The front is up but not installed yet and then will be the case and shafts. Hopefully I be able to reuse as many toyota bits as possible and am putting in a brand new radiator at the time as it was tired anyway.

Ok is an update, the front is basically in a few adjustments to be made before all up. The air cleaner assembly will need to be relocated to the passenger to allow for the steering arm to have room. This will fitting the snorkle easier

The exhaust will have to be past the transfer case as was a muffler right where the case will be fitted.

Another update.

Diffs are in and height adjusted to suit, case is in, linkages and lever are made, brakes are hooked up and changed, shock mounts are to be made this week to use shocks.

Driveshafts have been and are going to be made modifying 2 of the and the front will have a new shaft made up. Only is the driveshaft mob are going on holidays for 2 d’oh.

Steering will be this week, replacing the arm that has welded tie rods for a made arm utilising 2 x screw in tie rods for easier maintenance and years down the track.

thinking about air cleaner box and won’t decide on a final until the steering arm is sorted I may even use a bull bar mounted donaldson type filter.


Toyota Coaster

The steering box will to be replaced with a Hino unit as the coaster although very similar to the hino works the opposite way. At the the vehicle is steerable but to turn the wheel to the right makes the bus go A bit freaky when reversing and I doubt that Qld Transport like it that way. lol I want to go down the route of an box and more linkages which make for more serviceable down the track so a new box it will be. will make it one shaft the steering box to the link on the diff.

A polished alloy bullbar be grafted to the front this

Still can’t set up the air cleaner the new steering box is sorted out.

shaft bloke still on until the 15 March.

I made a of mods to the transfer case to make it a bit smoother as the NP205’s are to shift at the best of time. The of the divorced transfer case hang down a bit low for rock and so I may put in either a Mitsubishi or Isuzu with cable or vacuum next time instead of but it works OK anyway just a thing and the NP205 is generally than the jap units.

Still to get new shocks to replace the toyota and a new set of tyres rather than the riding MRF’s. and also when the air cleaner is sorted

New radiator is in and grass guard to the bottom for protection.

On the rear as I’m going with wheels, the inner stud the wheel on as normal but we’ve the inside of the wheel nut to enable it to be on back to front and fit over the of the inner wheel stud so it also locks the inner in place. Just a piece of thing and it has the advantage that if wants to put on duals in the future, all you to do is take off the outer nut, it around and put it on as you normally would dual wheels.


The new truck power box is being fitted, the driveshaft is back from holidays and will have them today, that only the bullbar, air cleaner assembley, a set of new shocks and some better MRF tyres Modification plate, HV and rego.

UPDATE. 26/3

we were all set for an end for the conversion today and to the coaster home.

The bullbar on, the snorkle was manufactured and fitted, new air assembly installed, power filled up, new radiator topped up, bottle re-installed, steering arm slightly to avoid rubbing on the on full left lock and she was up for the first time in nearly 2 We then flexed the suspension on a ramp and all is good nothing is anything else and I think this thing will close to 1m of wheel travel.

Then I took it for a drive and the case that I bought is so back in the workshop she went. I my supplier and he said no worries it back and we will send out So maybe the end of next week and $. I had even organised a pit inspection for afternoon. oh well. The bump for the front hadn’t turned up so they can be done next too. It seems to ride well and the brakes feel than the originals.

too much for our short ramp

Toyota Coaster
Toyota Coaster


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