The Platform
Project Fuji marks my third venture into overland builds, but this time with a different approach. Instead of starting with a stock vehicle and undertaking a complete modification from scratch, I opted for a pre-built vehicle. My goal is to refine it to perfectly match my specific needs, and in some cases, even reverse certain modifications. This new project is centered around a Toyota FJ Cruiser, a platform known for its robust off-road capabilities and iconic design.
The Story Begins
My history with the FJ Cruiser actually dates back to December 2012. A friend and I decided to take our vehicles, his Ford Ranger and my Subaru STI, into the snow-covered Gifford Pinchot National Forest for a winter camping trip. Our adventure was short-lived as both of us ended up stuck in ditches at different points. However, amidst the snowy mishaps, a particular moment stood out. A lone black Toyota FJ Cruiser, equipped with a winch, came to the rescue of the Ford Ranger. The driver skillfully used a snatch block and a nearby tree to winch the Ranger out of the ditch. This was my first impactful encounter with the FJ Cruiser, leaving a lasting impression of its capability. My second memorable experience with an FJ Cruiser occurred in February 2019 during a snow wheeling trip with a group. One participant brought a straight-axle swapped FJ riding on massive 40″ Goodyear MTR tires. This machine was an absolute beast and opened my eyes to the extreme potential of the FJ Cruiser platform.
2007 Toyota FJ Cruiser
Why the FJ Cruiser?
Similar to the Jeep Cherokee XJ, the Toyota FJ Cruiser platform, which is based on the esteemed Land Cruiser Prado, boasts a rich heritage and a passionate community. Toyota’s legacy in the off-road world is undeniably legendary on a global scale. Any discussion about off-road adventures inevitably includes considering Toyota’s significant contributions—from the original 4×4 Hilux/pickup to the renowned Land Cruiser series, and the contemporary 4Runner, Tacoma, and Tundra models. For this overland build, the Toyota FJ Cruiser was a natural choice.
I could delve into numerous aspects of the FJ Cruiser, such as its retro styling reminiscent of the classic FJ40, its durable body-on-frame construction, the factory-installed electronic rear-locking differential, and the famously reliable 1GR-FE V6 engine, among others. However, my primary reasons for selecting the FJ Cruiser for Project Fuji boil down to these key factors:
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Durability: The FJ Cruiser’s drivetrain—including the engine, transmission, transfer case, driveshafts, differentials, and axles—demonstrates exceptional resilience, even under substantial modifications and demanding conditions. Reports of breakages are typically linked to extreme driving scenarios, highlighting the inherent robustness of these components. While frame rust is a known concern, proactive maintenance can effectively mitigate this issue, ensuring long-term durability.
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Comfort: The Toyota FJ Cruiser provides a surprisingly comfortable ride, both on paved roads and challenging off-road trails. Toyota’s proven independent front suspension and solid rear axle configuration strikes a balance between on-road drivability and off-road capability. The FJ Cruiser further enhances comfort with a high-mounted, double wishbone, stabilized front suspension paired with a 4-link rear suspension featuring a stabilized lateral rod and coil springs—eliminating leaf springs for a smoother ride. It also features 4-piston front disc brakes and 2-piston rear disc brakes for reliable stopping power. The V6 engine delivers an optimal blend of power and gearing – providing ample performance without being excessive. Minimal interior noise and light, responsive steering that still provides road feedback contribute to overall driving comfort. The balanced engineering of the FJ Cruiser package is truly exceptional, making it a comfortable platform for long overland journeys.
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Capability: The combination of a 6-speed manual transmission, a 2-speed transfer case, an electronic rear locking differential, and Toyota’s A-TRAC system, along with generous suspension travel, provides the FJ Cruiser with outstanding off-road capability. This setup allows for smooth and controlled crawling over a wide range of obstacles, making it a highly capable vehicle for tackling challenging terrain.
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Parts Accessibility and Cross-Platform Compatibility: The Toyota FJ Cruiser shares numerous components with other popular Toyota models such as the 120-series Land Cruiser Prado, Tacoma, 4Runner, Tundra, and Hilux. This extensive parts sharing translates to unmatched availability of both replacement and maintenance parts across the globe. This global parts network is a significant advantage, especially for overland travel in remote locations, setting the FJ Cruiser apart from many other vehicle manufacturers.
2007 Toyota FJ Cruiser
Existing Modifications
The FJ Cruiser I acquired already had a substantial list of modifications performed by the previous owner at a shop in Oregon, specializing in off-road enhancements. These existing modifications provided a solid foundation for my Project Fuji build:
- 4.88 Gears: Optimized for off-road performance and larger tires.
- Stage 2 Clutch: Upgraded for increased torque capacity, beneficial for off-road driving and handling larger tires.
- 6 Inch Lift with Fabtech Front Differential Drop, Fabtech Struts, and Total Chaos Upper Control Arms: A significant suspension lift for increased ground clearance and off-road capability, utilizing quality components from Fabtech and Total Chaos.
- Rear Differential Armor: Provides crucial protection to the rear differential from rocks and trail debris.
- Resz Front and Rear Bumpers: Heavy-duty aftermarket bumpers for improved approach and departure angles and enhanced protection.
- Warn 8k Winch: An essential recovery tool for self-recovery and assisting other vehicles.
- CB Radio: For off-road communication with fellow travelers.
- Pioneer Touchscreen Head Unit: An upgraded infotainment system with modern features.
- TRD Shift Knob: A sporty touch to the interior.
- TRD Exhaust: Potentially for enhanced sound and mild performance gains.
- Aftermarket Subwoofer: Improved audio system with enhanced bass.
- HID Headlights with LED Halo: Brighter headlights for improved nighttime visibility and a distinctive look.
- 18″ ProComp Wheels wrapped in 35″ BFGoodrich KO2 tires + a 35″ KM2 spare: Aggressive off-road tires and wheels, providing excellent traction.
- Viair Air Compressor and Tank (mounted behind rear bumper): On-board air system for tire inflation and other pneumatic needs.
- Shovel and Axe Mounts: For carrying essential recovery and camping tools.
- Rock Sliders (not attached): Side protection for off-road trails, requiring installation.
Considering it was a rust-free 2007 Toyota FJ Cruiser with a 6-speed manual transmission and 109k miles, priced under $20,000, and exhibiting no wobbles or shakes, it seemed like a worthwhile starting point. However, to better suit my specific overland travel requirements, a few adjustments were necessary:
- Re-mounted and re-wired the air compressor and tank inside the rear hatch on the driver’s side: Relocating for better protection and accessibility.
- Replaced the OEM roof rack with Prinsu modular rack: Upgrading to a more versatile and robust modular roof rack system.
- 16″ Method Race wheels 701 matte black: Downsizing wheel diameter for improved tire sidewall and off-road performance, while opting for durable Method Race wheels.
- BFGoodrich All-terrain T/A KO3 LT315/75R16/E tires: Switching to the latest generation of BFGoodrich all-terrain tires in a 35-inch size for enhanced all-terrain performance.
- Subthump flush mounted subwoofer box on passenger side: Relocating the subwoofer for better space utilization and a cleaner installation.
More details and photos coming soon!
