There are two accomplish to retrofitting a branch Toyota electric locker to your third-gen 4Runner: one, addition out and installing the appropriate cogwheel and axle; and two, base the e-locker so you can use it with the blow of a on.
We wrote about the abundant automated genitalia in the aboriginal bisected of this storyline, in “Biopsy of a Toyota e-Locker Swap: Allotment 1” [http://www.off-road.com/trucks-4×4/tech/biopsy-of-a-toyota-elocker-swap-54205.html]. It’s the bisected of this action that involves the arbor and differential, acquirements how to differentiate (hah, animosity humor) which genitalia fit what, again award and adhering the adamantine genitalia to your truck. The wiring, which comes next, is the adamantine allotment (another comedy on words there) – what connects to what, what admiral what when, and which what is right.
Planning for Base the E-Locker: EssentialsSo, your arbor and cogwheel are afraid by the chase with care, and it’s time to get that e-locker below ascendancy – push-on ascendancy from the cab; instant-on ascendancy (almost instant; it takes a few moments to engage); trail-ready ascendancy that lets your 4Runner be bound aback it’s bouldered and affable aback it’s not.
Method #1: Call it “get ‘r done” or “straightforward”: you aren’t afraid about befitting your barter autogenous attractive altogether stock, or you’re all about the function. In the end, you can ascendancy the branch e-locker with as little as one about-face and six or seven wires.
Method #2: This is OEM-correct appearance – the branch e-locker controller, birr indicator, abundant of the branch harnesses and plugs from your donor agent (or the dealership), application as abounding OEM parts, hangers and connectors as possible. All of the capital pieces are attainable from the dealership (though we tend to acquisition the junkyard/salvage/Craig’s List acquaintance added acceptable and below expensive).
Starting with the home-built wiring, we begin this action to be appealing involved, so we’re activity to focus on that method, and access the OE-based base in addition article.
There are assorted choices to accomplish application the bootleg e-locker control: relays; blow switches; base routing; indicator lights (indicating what?); resistors to apathetic the motor; use of the OEM accouter and plugs. You accept options, and you can set up these controls as you please.
We chose to use OE genitalia for several analytical connectivity chores, and aftermarket/non-stock $.25 aback they simplified the action or helped abstain invasive mods. This counterbalanced Toyota’s about well-designed (though sometimes complicated) branch genitalia adjoin anatomic artlessness that steered us appear adapted or aftermarket parts.
12-volt power: we debated breadth to affix the ability for the e-locker. Association accept done it through radio power, altered fuses in the berth alliance box, or affairs ability from the berth block affairs (the alone advantage we don’t like – too random). We went aback to our allegorical aesthetics – simple – and acclimated a 10-amp Add-A-Fuse with the 10-amp agitation ambit in the berth agglutinate panel. The Add-A-Fuse was tolerable because we were base one device, not a host of things, so it would be a committed fuse. They’re not pretty, but they assignment with branch ability (no vampire clips), are attainable to affix and attainable to replace.
OE base harnesses: the one that connects to the e-locker (the “e-locker bundle” – #1) and the accouter that connects to #1, runs over the ammunition tank, into the berth and should accommodate the anatomy pass-through adolescent (the “e-locker array extension” – #2). Both are dealership/junkyard/donor barter parts.
Partial OE harness: #3, the “e-locker anatomy connector,” links #2 to the capital berth base central the truck, a the point breadth the #2 enters the berth below the driver’s rear seat. It’s possible, but not reasonable, to abstract #3’s connectors and associated affairs from the capital anatomy accouter whole; instead, apprehend to cut #3 out as aing to the capital accouter as possible, accepting the bung and at atomic a bottom of the affairs aback you do.
Control switches: one for the e-locker, and one as its analeptic (as a assurance cutoff). You can accumulate things and use athletic aftermarket switches, or wire relays into failing switches. We were perusing the switches at OTRATTW (Over the River and Through the Woods) [http://www.otrattw.net/home.php] and, to our pleasure, begin a austere dual-pole/dual-throw (DPDT) advantage (with bifold absolute indicators) that could handle the accepted that would be beatific to the e-locker, so we didn’t charge relays at all. This, accompanying with a afire single-pole/single-throw (SPST) that we had in the garadtch, meant we had afire indicators at anniversary switch.
Parts to Get from Your Donor Agent (or Toyota)From the donor rig that gave us our e-locker, we acquired the #1 “e-locker bundle” accouter that connects to the animosity and contains the OEM animosity breather, and the #2 addendum – the “e-locker array extension.” These two harnesses are the capital ones to get if you’re arena forth at home. Note: there are aftermarket kits for this action that can be had with a accouter that alcove from about-face to pig, like the one offered by 12-Volt Guy [http://www.12voltguy.com/], but they’re not as affected as what we developed, and they amount more.
With accouter #1 and 2 and the appropriate switch, you’ve got abundant to accomplish this activity go with about no added expense. However, if you’re able to get the fractional #3 harness, you can use it as an ideal constituent connection. #3 is not essential, though, and any Molex or water-resistant six or eight-pin adapter will do the job. In fact, our aboriginal absorbed was to reclaim some able OE-Toyota plugs from a second-gen 4Runner that we cut up years ago, but aback the buyer of the donor third-gen let us accept as abundant of the autogenous accouter as we wanted, it became a non-issue. We now had the branch plugs and affairs all the way from the e-locker to the cabin, and that’s homebrew y.
Routing and Modifications of the OE HarnessesRepurposing branch base agency you’ll charge to abuse it. The #1 accouter doesn’t charge anything. Because Toyota has been accepted to change genitalia and designations amid through a assembly run, accomplish abiding to analyze the affairs in that #1 harness: the two affairs that ability the actuator motor (green and green-red, of a hardly added barometer than the added affairs in the harness); two affairs that ascendancy the locking position-limiter angle in the animosity (green-blue/black and green-yellow, admitting there are acclaimed cases breadth this green-yellow is aloof green; both are lighter barometer than the motor-power wires); the blue-yellow wire for the locker-on indicator; and the two white-black arena affairs (from the position-limiter angle and the locker-on indicator). These are the affairs that matter.
The over-tank addendum (#2 harness) is altered than the #1 accouter in a few ways. It’s got ABS brake-sender affairs in it (white, black, red and green). We disco’d these affairs on the animosity end and pulled them out of the bung on the anatomy end so they’re out of the way, but larboard them in the accouter in case article bottomward there needs to be powered at a after date. Also, there were some wire blush changes from #1: the green-yellow wire (if it’s not already aloof green) is blooming in #2; the blue-yellow wire becomes yellow-blue; also, the two arena affairs breach into a abstracted plug. As far as we’ve figured, all four-wheel drive third-gen 4Runners accept a bung in the capital berth accouter that will affix with the ground-only bung in accouter #2, admitting we had to change one of the pins in the #2 arena bung to adjust with the capital berth accouter plug. At this point, you’ve got bristles affairs larboard in the #2 accouter to affix to your e-locker switch.
With #3 (the in-body harness, with which we got about two anxiety of wire), we accepted alignment of anniversary wire’s assignment and blush (the above as #2, thankfully) and anchored five-foot lengths of abandoned automotive wire to each. We accept the charge to abstain affairs stuff, but try to use wire colors that accomplish faculty so you don’t afield backfire your headquarters.
Important: with the #3 accouter now antic seven-foot leads, we could bung into #2 below the driver’s rear bench (where the body-to-undercarriage elastic anchorage resides) and ability the centermost animate breadth we planned to install the multi-purpose OTRATTW ascendancy switch. We are additionally able to cull these affairs from the centermost animate and reroute them, after cutting, to the driver’s left-foot bang animate aback we accompany the factory-style e-locker base (which uses that breadth to abode the rear-diff processor and added than a few junctions).
Techniques and Ought-TosYour columnist can do a lot of things, but soldering has not been amidst them until this project. The architect aing aperture (whom I seek out to get awe-inspiring wiring-theory answers) took a few account to advise me some of the art that is able soldering, and it makes base a agent abundant more… sure. I’m aloof a beginner, but this is what I learned, and it helped.
-It’s not about the heat; it’s about the preparation. Actuality aing on the temperature makes soldering easier, but prepping the apparatus and affairs makes things click. Apple-pie the iron, tin the adamant (get a little adhesive on the adamant to draw the adhesive through the wire), tin the wire.
– Tinning: accepting adhesive on the allotment to be soldered, or on the tip of the iron.
– Keep the tip of the adamant apple-pie with animate absolute or ablaze sandpaper.
– Adhesive conducts electricity.
– Regular adhesive doesn’t like aluminum.
– Electrical adhesive is not the above as automated solder.
– Some solders accept alteration in them – it helps them band with the metal. The blazon of alteration is called as the “core,” such as “rosin-core” solder, because it’s in the solder.
– Rosin-core adhesive is accomplished for best electrical soldering – acid-core is not.
While we’re at it, if you don’t apperceive base basics like how to apprehend a base diagram, what a arena or broadcast is, and how to analysis for current, this isn’t the job for you until you do a little learning. Take one of those association academy auto-wiring courses (fun!), or at absorb a few account account about the rules of not afire your barter to the arena like a snot-nosed rookie.
12-Volts of E-Locker Control: Article Borrowed, Article InnovatedWe affective 12-volt ability from the driver’s ancillary in-cabin agglutinate animate at the 10amp “Gauge” agglutinate with an Add-A-Fuse. Like adumbrated earlier, we’re accomplishing this one simple and effective. There are a lot of means to get power, but we capital to acquisition a antecedent that was accessible, absolute and repeatable (and not a vampire blow – the antecedent buyer of this barter appears to accept had a long-running activity with a vampire-clip retailer).
We put a master/energizer/cutoff about-face (a afire SPST toggle able of hoisting some weight) inline with the ability cable from the agglutinate animate to accommodate an added band of assurance for the e-locker. One of the few downsides of authoritative the Toyota e-locker after the OE computer is that you anticipate its safeties, and no one wants to bang on the locker at 80 mph… With the master-power switch, we bargain the likelihood of afield activating the locker.
If you’re activity nifty, you can absorb the branch “RR DIFF LOCK” about-face as the analeptic about-face in abode of our bargain afire toggle. Admitting we advised the “RR” pushon to not be able of administration the pass-through accepted all-important to actuate the e-locker (unlike the afire toggle we used), you can wire the RR DIFF LOCK about-face to ascendancy a broadcast that again carries the weight, with the benefit of it actuality wireable into the birr lights.
The capital about-face we acclimated – a able-bodied DPDT assemblage bogus by Carling in Mexico (no Chinese knockoffs for us) – is awash by the above OTRATTW. These are the guys who retail switchgear with absorbing and advisory covers. We chose a applied characterization –“Rear Locker” – but you can opt for “Ninja Suppression Mode” or “Prius Attack Lights” if you prefer. Jim at OTRATTW spec’d a able-bodied 12-volt, 20-amp DPDT on-on about-face that could handle the accepted appropriate to about-face the e-locker on and off, which fabricated a broadcast unnecessary, and the about-face had the lighting to accurate both power-on and locker-on independently.
Pay absorption to the pin numbers on a switch. They’re usually constant from one architect to another, so the #1 or the #5 pin on one schematic analogs to breadth things go on another. Application those pin numbers, we can additionally bigger allegorize breadth e-locker affairs go. Per our adjustment (see the schematic for added information), we active the capital about-face as follows: 12-volt ability to the #1, 6, 8 and 9 pins (switch power, diff-engage, diff-disengage, diff-locked indicator), locker motorvation goes to pins #2 and 5 (green/red at #2 and blooming at #5), the locker angle position about-face connects to pins #3 and 4 (green at #3 and green/black at #4), pin #7 meets the diff-locked about-face (blue/yellow wire) and pin #10 area the switch-power indicator.
Because 12-volt ability was appropriate at several pins in the capital switch, we fabricated a jumper accouter that would affix alloyed 12-volt ability to the four power-hungry pins: “switch power” (which will bout the cachet of the analeptic switch), “diff-engage” and ‘”diff-disengage” for the e-locker, and “diff locked” that passes through the assurance sensor in the e-locker.
Details to ConsiderA affection acclimated by several acute guys with e-locker base affairs was a resistor (one advocacy was for a five-ohm, 40-watt unit) on the green-wire ancillary of the e-locker actuator, what’s capital purpose is to apathetic bottomward the motor. Because the affection was not included in all of the base sketches, we chose not to – no acumen you can’t agreement with one yourself.
If the afire OTRATTW about-face turns out to not be ablaze abundant for use in a sunny, ablaze cockpit, we’ll run an LED to the birr in a position that’s added conspicuous, or application into the OE birr indicator for the rear locker. Having the ablaze in the centermost animate wasn’t ideal from the angle of a altogether abiding interior, but it simplified a cogent footfall in the action (wiring that abstracted locker-on indicator).
If you’re analytic for e-locker harnesses (the #1 and #2 harness), there’re two altered bung styles – accomplish abiding castigation matches the diff-housing connector. 12-Volt Guy has some acceptable photos to advice you differentiate bung types.
Do yourself a favor, and abstraction the base diagram in this adventure and online (just chase “Toyota e-locker wiring”). This one is our creation, with some account of our own aing by those adopted from several e-locker base affairs created by association in the Toyota off-roading community.
The 12-Volt Guy12voltguy.com
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