1. Introduction to Toyota Hiace 4×4 Conversion
Toyota Hiace 4×4 Conversion; Introduction Making a Toyota Hiace a 4×4 is probably the biggest modification you can do. There is so much that is involved in the process and it is very expensive, but there is no other vehicle like it. With a few delivery trucks from the car manufacturer in the factory market or used trucks, here’s how to convert it to 4WD.
Toyota Hiace 4×4 Conversion The Toyota Hiace 4WD conversion process is pretty big, but in this article, I’ll guide you through the process.
Toyota Hiace delivery truck The Hiace comes in 2 naturally-aspirated diesel engines (2.8ltr, 2.4ltr), each with an automatic or manual transmission. Think of optional descriptions such as wheelbase, windows, doors, seats, refrigeration, freezer box, factory stereo, and of course the 2 pallets that come with -20, 1280kg of the car. We offer a great truck that makes you want to convert it to 4WD. The Hiace has plenty of space, a selection of truck drives, and a front case, so I can make it for the expedition. It has spare parts that will be available on the commercial market. The motor is very strong and it is an excellent reliable repair work. There is plenty of room for free exhaust taproom planning around. Toyota’s flagship explores Australia and the 4WD allows you to go anywhere. If you have reliable power and a Toyota Hiace based gearbox on its side, you have the perfect combination for the 4WD. It’s no wonder it’s such a popular vehicle delivered by Toyota Motor Co. In the supply market, trucks are not as difficult as Land Cruiser replacement prices.
2. Benefits of Converting a Toyota Hiace to 4×4
A converted Toyota Hiace 4×4 may soon become a proud addition to your garage. Learn about all the benefits of converting a Hiace to a 4×4 too!
It is no surprise that the Toyota HiAce proves a popular platform for a 4×4 conversion. Just like a converted Ford Transit, a converted Mercedes Sprinter, or a converted Promaster Campervan, a 4×4 Toyota Hiace offers some key benefits over a standard van.
– Unrestricted travel: Maintaining a Toyota Hiace’s original load rating is trickier. When you move the drive wheels to the front, it is significantly harder to maintain the original weight rating (no matter which way you look at it). Hence, converting to 4×4 attempts to restore some of the original vehicle’s traction and stability for off-road driving with a heavy load. – Enhanced off-road capabilities: With Hiace 4×4, you can travel and handle rougher terrain, which in some cases could be life-saving. It is particularly important for campervanners wishing to explore national parks with dirt roads. – Stronger resale value: A Hiace 4×4 is a versatile vehicle – this is also beneficial when selling the vehicle down the line. If you have a standard 2WD van with the intention of traveling, camping, or touring and you post it for sale, you are taking the risk that any potential buyer might tick it off because it’s not a 4×4. However, when you convert to 4×4, your potential target group increases in turn.
3. Key Components and Parts Required for the Conversion
Toyota Hiace 4×4 Conversion; The right conversions begin with the best components, and in this section, we will go through the key components and parts needed to make your Toyota Hiace 4×4 conversion a success. Our conversion includes the replacement of the entire Hiace front subframe assembly, which carries the engine, steering, and front suspension. We offer a range of accessory support components, including transmission-into-transfer-case adaptors, drive shafts, shortened Hiace prop shafts, and diff drop brackets, drop pitman arms, elevated sway bar links, and more to complete your conversion.
Racebred Drivetrain Components: • Refurbished Toyota Hiace 4×4 subframe and front suspension kit • New customers, please complete and submit the ‘additional info’ form below to register your interest. We will be in touch to discuss and confirm your requirements.
Suspension and Lift Kits: We are still working on final specifications for various lift kit options and suspension upgrades. Though not yet ready to offer these parts, we can supply Dobinsons remote reservoir front strut/coil overs and rear shocks. Australian Made, with extended rear shackles, to suit the new and improved clearance required by Hiace 4×4 tweak.
Transfer Case and Axles: • Our conversion is specifically designed to best mate the Toyota Hiace diesel manual ZR6. Our replacement Toyota Hiace 4×4 auto front subframe assembly comes ready to accept the standard Hiace rack and pinion steering system. The steering knuckles are re-welded to improve the whole steering geometry, meaning no additional conversions are required. Efficient and trouble-free.
3.1. Drivetrain Components
Drivetrain components are those that are anything that keeps the car moving, and that aren’t part of the engine or the wheels. These are an essential part of the 4×4 conversion Hiace, as you need to be able to actually drive and propel your vehicle after the alterations have been made! There are, however, many different types and varieties of parts that could be considered to be drivetrain components for a Hiace 4×4 conversion.
At its most basic, however, the two areas of focus for drivetrain components in a Hiace are the transmission and the transfer case, as these parts draw their power from the engine, and are crucial in transferring that energy, as well as controlling and directing the car’s speed.
Transmission: The transmission is the component of the drivetrain that takes the power generated by the engine and gets it to the wheels. It sits directly under the car’s engine (and above other drivetrain components), and modifies the input of the engine to give the driver greater control over the vehicle’s speed and torque.
Transfer case: A transfer case is a part of the 4×4 that makes it all-wheel drive (AWD), as it sends power to both the front axle and the rear axle. This part projects the power being generated by the engine into the front and rear driveshafts, and gives the driver control over how much power is delivered to the wheel on each shaft, which is particularly useful if one set of tires is seeking to travel at a different speed than the other set.
3.2. Suspension and Lift Kits
The second step to a Toyota Hiace 4×4 conversion is to upgrade the suspension, generally in combination with a lift kit. These get a bit complicated, and the world of suspension and what works and what doesn’t also changes over time as people discover weaknesses. The basic idea stays the same though. The Toyota Hiace is a passenger vehicle, and as such, is made with a comfortable ride in mind. This leads to a car-like suspension, and to achieve about a 9-seater van ride height, there isn’t much clearance under the van at all, where a proper 4×4 setup will need ample room below to accommodate long spring travel. This is not to be underestimated. Even these 4×4 factory Hiaces with air suspensions are actually designed to be not far from the ground for its 4×4 capabilities.
Lift Kits and Points: A standard 4×4 suspension lift of 40mm to 50mm, paired with all-terrain tyres is generally the cheapest conversion package available and works really well for those who are on a tight budget. Generally only need to lift 50mm as the factory 4×4 models have no more than 190mm – 200mm from midpoint under the vehicle to the ground, given the small standard tyres which are getting replaced anyway. Consider lifting only about 10mm in the rear, noting that: Over-lifting the rear can lead to over-correction issues, such as severe understeer in certain conditions. Resisting too much weight transfer to the front with a huge rear lift can really affect handling and ride comfort. Fits under the (statutory) limits of a minor modification. A comprehensive guide to Toyota Hiace 4×4 conversion conversions will need to include more information about lift kits soon.
3.3. Transfer Case and Axles
Transfer Case
A transfer case is basically when two gearboxes are placed together in the transmission. One is driven by the engine (input), and the second one drives the front and rear propeller shafts at the same time (outputs) using the planetary gears.
In 4WD, we have the power coming from the engine being split by the transfer case to the front and rear axles. The ratio of that power can also be changed twice as well on the Hiace via the 4×2/4×4 selector lever inside the cabin.
Axles
The 4×4 conversion for the Toyota Hiace requires the addition of a front axle to be driven by the transfer case. This is also the case if the vehicle is fitted with auto-locking hubs or manual locking hubs. The front differential on the Hiace is connected to the front axles and has planetary gears in it just like a transfer case. This is how the engine-driven power is transmitted to the propeller shafts and into the front differential to turn the front axles and wheels. However, when a front differential is engaged, the wheels will always turn. To avoid this steering issue, a differential with disconnected axle/wheel hubs is chosen, which is most common in factory 4×4’s. In the Hiace conversion, the axles are driven full time, but for road user preferences, a vacuum-operated front axle hub disconnection unit is fitted to stop the axle shafts moving when the front transfer case is not engaged in the “4×4” position.
The rear differential on the Hiace is driven from one of the front planets in the transfer case. With the transfer case in “4×4” high or “4×4” low, the setting of a high or low range ratio turns that planet gear, which twirls the other planet gears and then forces the rear axle to turn. This is the reason why the center diff is removed from inside the transfer case.
4. Step-by-Step Conversion Process
Conversion process
We strip the rear area of the van, removing bumpers, fuel tank, and inside trim. We sandblast the rear chassis, cleaning it back to shiny bare steel. We paint the chassis with inorganic zinc epoxy heatproof paint. For reasons that are beyond the scope of this guide, we install a shortened HDJ rear propshaft. The rear diff is installed and set up. From here on, every upgrade goes from the rear (pulling things forward). We install the 2″ lift kit, brake proportioning valve, wheel cylinders (from the top of the 4×4 master cylinder), handbrake cables, new pipes, a full brake overhaul, gear-shift modifications on the gearbox, and more. We mounted the 2-speed gear lever and a throttle cable from the Hiace accelerator pedal to the DSL pump. The front wings and headlights, inner guards, grill, wiring, and the rest are repaired to the new van standard.
These steps are a basic roadmap of the steps we follow to convert the Toyota Hiace. The actual steps are far more detailed and intricate, and every step has a myriad of potential options. Every vehicle is different. Every conversion is different. Every customer is different. Every set of needs is different. That’s why people come to us.
Joining the rear driveline (diff) with the gearbox is a classic conversion problem. If the welding is not done correctly, it is putting great forces into the welds in the wrong direction and can quite easily break the welds, even under a van that hasn’t seen dirt.
4.1. Preparing the Vehicle
Toyota Hiace 4×4 Conversion; Converting a Toyota HiAce to 4×4 is not a small undertaking, and the bigger backlogs that the HiAce’s gain in preparing for a 4×4 installation need to be addressed upfront. Before you are willing to look at the lean back and place the project physically, there are many things to consider. The most critical aspect of the project is to see how much needs to be done to get the backlogs of the BDG engineering conversion team to the stage where they can start 4×4 installation. The low roof mine with a wheelbase is 2575 millimeters while the short wheel is 3210 millimeters, so the difference is 635 millimeters between the two models. This measurement provides you with a ton of the information you’ll need when you’re checking the HiAce vehicle.
If the vehicle is on the hoist once you have taken the rough hi body from the rear suspension, and in the front, you will clear what needs to be done. Some examples will be this: the form car, and the design changes, and the supply of the standard engine for the car manufacturer. Knowing that the HiAce’s have not changed since 2003 but the shape of the body has the ability to change, customers turning up for a 4×4 installation decided it would be a better idea if a complete front end were to be installed. This led to an upgrade to a newer front end, which requires some significant bodywork and modifications like front nose and radiator support and Aluminum outer skin heater box and just as well as some Minibus with the seat tracks. The first-generation converted HiAce, from 1977 through to 1985, never sold in Australia due to the run of the Australian distributor. The only place these 4×4’s are in Japan and New Zealand. Keep this in mind if you have imported one of these models as in today’s market parts are not available.
4.2. Installing Drivetrain Components Toyota Hiace 4×4 Conversion
1. Lift up the back of the engine and install the girders to a suitable position. Two lengths of wood are placed between the floor and engine for tightening. 2. Put the transfer case and connecting shaft on the chassis according to the position of the engine and then mark the position of the hole at the end of the transfer case’s output shaft, and enlarge the hole of the chassis accordingly to weld the appropriate iron block. 3. Clean all the metal blocks and steel connecting shafts and apply the rust-proof paint. Install the transfer case bottom cover first, and then install the gear-shift shaft. 4. Adjust the alignment of the two short connecting shafts, install the bearing in the shaft, and check the length of the intermediate support bearing. 5. Due to the existence of a large amount of power transmission shaft differences between domestic Hiace and this Domestic Hiace version powertrain. 6. It is feasible that this version/axle center dimension is the same as the domestic Hiace in the Japan market and directly replaced by.
6. Time and Performance 7. Install two rear suspension leaf springs and drive system bends to connect them. The main leaf spring of the rear suspension leaf spring has an arc plate fixed on the front of the middle wire, and the spring bushing is installed in the middle of the connecting wire on the arc plate. The main spring wire passes through the connecting seat of the front suspension rod and runs it closely to the front seat of the chassis. The rear part of the main spring leaf is connected to the rear part of the chassis through the front seat. The stabilizer connection seat is welded under the front and rear of the chassis respectively. Both of them are paired with an anti-roll bar, and the sway bar uses a double head rubber strip.
4.3. Upgrading Suspension and Lift Kits Toyota Hiace 4×4 Conversion
A standard Toyota Hiace 2WD van is not capable of your average tours and adventuring trails off the grid. The bigger wheels and ground clearance that a Hiace 4×4 offers have given it an advantage over other non-offroad vans. As for upgrading a 4×4 standard commercial vehicle to suit a variety of passenger services, it is substantial for offroad services.
For conversion, the front half of the 4×4 vehicle remains stock with the same characteristics and dimensions. Drive, suspension, axles, and the like are not subjected to modification. However, the rear half has 4×4 spider kit bolts for top armor fabrication while welding it with 3 crossers under the body. This allows mounting of the passengers’ luggage box. Also, the original suspension on the rear remains unchanged. The upgrade has to be performed according to the classes of springs used and the 4×4 kit newly installed according to the proposed ZVT-GO 16.7.3 requirement. This also requires the zonal mining motor vehicle permit so that the vehicle can be operated only within the mining lease area or premise.
The split air conditioner had made rear luggage fabrication costly, and it cost 90 thousand rupees for installation. The front A/C is not hindered and works as a passenger compartment A/C as usual.
This is the most loved and excited task to be performed. Firstly, cut the LSPV connecting rod. Keep the plastic cover on while filling it with grease on the pushing chamber. The rear RH wheel assembly has to be removed. Rear spring shackle bolts have to be removed and attached to the RG members, and then apply the hydraulic jack under the SG and check the whole detachment of the rear springs. Remove the rear wheel RH side nuts. Apply the appropriate sized rod and hit the bolt repeatedly to shear the bolt from the suspension.
Fitting a 4×4 kit is a 15 feet basement, so lift the RG with the hydraulic jack so that the wheels and the RG are in the air. Remove the hydraulic jack. Loosen the RH leaf spring a bit, and ensure not to remove it fully. Just the bolts could be loosened. The bolts on top of the RG are not loosened. Loosen the Lower Ball joint bolts and with the jack’s help, loosen the nut from the ball joint and remove the jack. Apply the hydraulic jack under the horn of the RG assembly and remove the stabilizer link from the lower RG assembly.
5. Maintenance and Upkeep of a Converted Toyota Hiace 4×4
5. Maintenance and Upkeep of a Converted Toyota Hiace 4×4
The world of Toyota Hiace 4×4 vans is a tricky one, and while vans can be maintained, it has to be understood that running a 4WD Hiace means maintenance above and beyond that of 2WD vehicles. Preventative maintenance is the key to success for any car, and the world of a converted 4×4 Toyota Hiace van is no exception. In this chapter, we present our views and thoughts on the upkeep practices and a quick spruce up of your Hiace between trips.
When the conversion of any Toyota Hiace commences, most conversions are furnished with a donor vehicle front half: every part and panel is removed, and each piece is cleaned, inspected, and refurbished. With the long hours and substantial cost involved in refurbishing donor parts, owners trust that their vehicle will last well into the future. And it will, if it is maintained well and used as the manufacturer originally intended. For new Hiace owners, if presented with a vehicle that has seen a little wear and tear and running gear that is out of warranty, there are also measures that require upkeep and maintenance to ensure vehicle longevity into the future as well. The information provided in this chapter presents our thoughts and what we know about maintenance in a Toyota Hiace 4×4 outside of the new vehicle warranty period.
The Luxury of New Parts Installation of a 4×4 conversion into a new Hiace enables such parts as the leaf springs, shackle mounts, fixed pinion drop, and fixed radius arms, etc. to be fitted with new Hiace parts as well. In this regard, owners can continue running their Hiace as a factory Hiace inside the warranty period, maintain their logbook servicing, and keep the U680 Hiace Suspension in new condition all in one, rendering a revised view on the information that follows.