2002 Tundra

[Patrolman]

This isn't going to be a build thread as so much of a "maintenance" thread. Recently picked up a 2002 Tundra Xtra cab (suicide doors). 4.7L V8 and automatic transmission. It was a fleet truck for a construction company from brand new, so 278k of relatively hard use. Fortunately the interior is in very good shape, all the original body panels so no accidents. Ran and drove it home, passed emissions, but needed attention to the maintenance the company put off as they were getting ready to sell it.

This is going to be my new work truck (hailing parts, towing the car trailer, and home improvement junk). Will also be our rig for taking the camper on trips.

Pics are from the ad listing.

[Hypoid]

That is a nice looking truck Jeff!

[Java]

The early Tundras and Sequoias last forever, looks like a great truck! :thumb: Has it had the timing belt done?

[Patrolman]

For being a "construction company" truck, it is in very good shape.

The guy from the company who sold the truck had no records, so I will doing the timing belt and changing all the fluids. Already put new drums and shoes on the rear since they were worn out. Ordered the parts for the front disc brake upgrade. Will bleed the brakes with fresh fluid so brakes should be basically all new.

Here is the rest of the TDL:

1) front headlight replacement due to bad fading
2) install larger tranny cooler
3) brake controller
4) replace cracked exhaust manifold
5) radiator
6) fan belt
7) replacement wheels/tires (done)
8) sliders (you never know when you might need them!)
9) front hitch mount

[Patrolman]

So I have found some interesting things about this truck. Since it was a fleet truck, I believe it may have been custom ordered.

The upgrades:
- LSD
- Tow package (transmission cooler, hitch, wiring)
- upgraded sunvisors
- 4.7L V8
- 4wd
- power locks
- power mirrors
- power windows

The downgrades:
- stock steel wheels
- no ABS
- split bench seat

Anyways, when I looked at the options list available, it seems that it got some bare bones stuff, with some options such as the LSD. I figure it was probably custom ordered this way. Makes it a bit of an oddball.

[Patrolman]

One of my maintenance items was spark plugs. The truck had just basic standard plugs in it. The first 2 came out with a bit of a struggle. Since it has aluminum heads, I really didn't want to damage them. The other 6 plugs seemed pretty frozen into the heads. Put some spray lube into the spark plug holes and let them soak for about 30 mins. Came out quite a bit easier, with less concern about damage. The good news is that each plug had no obvious signs of any issues such as oil, carbon, fuel, etc. I was quite surprised to find that all of them had basically no center electrode remaining, and the gap was more than 2x the recommended. It was certainly due for plugs. Pretty surprised that it passed the e-test as well as it did.

[Patrolman]

I swapped on some different wheels/tires, and the rear drums basically fell off the truck. The brakes on the truck were just about worthless when I bought it. The parking brake didn't work at all, so I figured the shoes were out of adjustment. When I pulled the drums off, I noticed the shoes were worn hard on one end, and not much on the other end, so they were due for replacement. The drums were at the end of their spec as well, so time for replacement. Truck stops much better that before, but I think there is still room for improvement in the braking. Also replaced 2 rear wheel studs that were stripped. New lugnuts all around too.

[Patrolman]

The headlights were really yellowed, so I picked up a set of Eagle Eyes replacements for $40 shipped. Much better, but again, I think there is room for improvement. The bulbs that came with the lenses are pretty yellow and not as bright as expected. I will likely upgrade the bulbs at some point.

[Patrolman]

The most recent project has been the front brakes. The 2000-2002 had smaller calipers and pads. This apparently resulted in overheating the pads and rotors which would warp the rotors. I could tell the front rotors were warped when I test drove the truck. Decided to upgrade to the 2003+ larger calipers (used) and new pads with brand new rotors. The pads were worn out, so good opportunity to complete maintenance and an upgrade. Fairly easy job, and the fluid needed bled anyways, so good opportunity to take care of that at the same time. The upgrade either requires trimming a tiny amount of the dust shield or replacing the dust shield with the 2003+ version.

[Patrolman]

In anticipation of installing a larger trans cooler, I wanted to make more room on the driver side in front of the radiator. The horn was in the way, but it was held on by a single bolt. There is a bolt on the back of the horn, and it can be spun on the bracket. By spinning it, there is room to mount it closer to the headlight. There is a bolt that makes for it to mount easily. The wiring still plugs in without stretching it. The horn now barely clears the grille when the hood shuts. Allows for a full 12x12 inch area to mount a cooler though.

[Patrolman]

Saturday morning project was to install the front hitch receiver. Removed the "shield" and the wing trim all as one unit. There are 6 bolt holes, 4 of which are the factory tow hook holes. There are 2 additional holes that need to be drilled and have new bolts/nuts installed. I got the hitch mounted, and the 4 main bolts installed. Didn't get the 2 holes drilled. Will get that done soon and reassemble the shield for more pics. The receiver has a 9,000lb winch capacity and 500lb tongue weight. Should do everything that I ask of it!

Here is where I bought the hitch (best price I could find - $121.79 with free shipping):
https://www.streetsideauto.com/p/draw-tite-front-mount-receiver-65031/?utm_source=GoogleShopping&utm_medium=GoogleShopping&utm_campaign=GoogleShopping&gclid=CjwKCAiAiJPkBRAuEiwAEDXZZSAjUE2VCD4WhtDqY0iR c3JRsJIyPPXqn5iDkTUJwMxNLS4sTDEw4hoCWzAQAvD_BwE

Here is a link to an install video:
https://www.etrailer.com/tv-Hitch-install-2005-Toyota-Tundra.aspx

[Patrolman]

My timing belt parts arrived Saturday, so the afternoon consisted of the tear down. Worked right up until dark and got the new water pump installed and the new belt in place. Lots of little things to wrap up to finish the project. It was DEFINITELY time for a belt. I had no records for the truck, so I was nervous about it. There was a tremendous amount of cracks in the belt, so very glad that I didn't put it off.

I purchased the total Aisin kit from Amazon for $138.78:
https://www.amazon.com/gp/product/B00725CM34/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

Didn't include the tensioner so I bought this on Amazon for $35.78:
https://www.amazon.com/gp/product/B001CIAQ3A/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1

The parts include the pump/seal, belt, idler, tensioner pulley and rubber seals. I also plan to install a new serpentine belt, radiator hoses, and Toyota coolant.

[Java]

I've been looking at Sequoias of the same generation and I'd prefer to get one like yours that needs the timing belt service done so I get to do it and inspect / replace so much. Good job buying Aisin parts, that truck will run forever. :thumb:

[Patrolman]

Just wrapped it up and got the engine to start for a couple seconds. Starts and runs great. No leftover bolts which is always a good thing. No coolant in it yet as I intend to drain the block and put on new radiator hoses.

Now that I know how to do it, it is probably a 5-6 hour job. Getting the belt lined up correctly was a bit of a hassle. The marks were a bit deceiving. I am glad that I did the work myself. Know it is done right and I also know exactly when/what was done. I tried to buy the best parts that I could without going to Toyota. :)

[Patrolman]

I've been looking at Sequoias of the same generation

If you are serious about them, try to get a 2003+. They will have the larger front brakes. I had to buy calipers and upgrade mine. Those calipers are in high demand since the larger calipers are upgrades for the early Tundra, early Sequoia, 4Runner and I believe Tacoma.

[Jim]

Hey Jeff, I found the maintenance log for your white truck!!!!

The first page has the date it was put into service!

ALL OF THE OTHER PAGES ARE BLANK.

Now you know.

[Patrolman]

Thanks Jim.

Since this was a corporate truck for a large corporation, they did their own service. They said there were no maintenance records because of that. I am now believing that there were no maintenance records due to no maintenance being done. :)

What I am realizing is that they did some maintenance, but as the time was approaching to sell the truck, they just stopped doing anything other than oil changes. Slowly replacing one thing at a time. Figure eventually I will have a brand new truck.

[Patrolman]

I've been looking at Sequoias of the same generation

Learned something new yesterday. Even though my 2002 has a "tow package" it apparently isn't set up to have a brake controller. 2003 was the first year the Tundra could have a brake controller without running new wiring to the rear. Unsure if the Sequoia is the same.

https://www.tundrasolutions.com/forums/1gen-tundra/130025-brake-controller-wiring-harness-2000-2002-a/