FOR SALE — $55,000 1985 Toyota Hilux YN67 Extra Cab. Ground-up engineered, road-legal in NSW. Well over $130,000 invested. Engineering certificate and all compliance documents included.

Contact: alloffroadau@gmail.com

Three years. Well over $130,000. One engineer involved from the first day. The Hilux is done — and I'm selling it.

My priorities have changed. I don't have the time to drive it the way it deserves, and I don't have the space to keep it. There's no mechanical issue and no backstory. It's a truck that needs someone who will actually use it.

Here's exactly what it is and what went into it.

1985 Toyota Hilux YN67 Extra Cab rock crawler — road-legal NSW build

The Build

The base is a 1985 Hilux YN67 Extra Cab. The engine and gearbox are from a 2000 Hilux — a 2.7L 3RZ-FE petrol with a 5-speed manual. Proven, reliable, and straightforward to service.

Everything under it is different.

Both diffs are replaced with Jeep JK G2 housings — significantly stronger and wider than anything Toyota fitted. Both run ARB Air Lockers with 4.88 gearing. The front runs a high pinion setup. All axles are Nitro Gear 35-spline chromoly throughout. The transfer case is a two-speed Atlas with 4.3:1 low-range gearing. Combined with the 4.88 diffs and the Atlas's ability to run front-only, rear-only, or both independently, the crawl ratio flexibility is beyond anything running a standard transfer case.

Steering is PSC hydro-assisted — a 1.5-inch cylinder assist ram off a Toyota Land Cruiser 80 Series power steering box, with 4130 chromoly solid bar links (38mm lower, 34mm upper) and Dodge Ram tie-rod ends. It steers with zero effort lock to lock.

Suspension runs N70 front and N80 rear leaf spring packs with fabricated slide boxes front and rear. Not a shackle conversion — slide boxes deliver 250mm of travel versus 120–130mm from a standard shackle. The mechanism uses an oil-impregnated Delrin bush. No maintenance required. Paired with Rancho adjustable shocks at 15 inches of travel and Tough Dog springs, the truck is composed on rock and predictable at speed.

Driveshafts front and rear are chromoly. Rock sliders are 50x50 box section, 4mm wall, bolted through 16mm plates welded directly to the chassis.

The entire car was rebalanced from scratch. Everything heavy was moved to the rear — fuel tank, spare tyre, dual ARB air compressors, batteries, and winch. This was an engineering decision, not packaging. It works.

Engineering and Compliance

Hilux YN67 chassis and suspension detail — JK G2 diff housings and slide box suspension

An engineer was involved from day one. Compliance was designed into the build from the start — not added at the end.

The vehicle went to Canberra for full testing with 800 kg of load on the back: swerve tests, brake tests, and a brake plate test at 98 km/h. The brake plate test measures brake force on every wheel individually, both with and without the booster connected, against RMS parameters. The Hilux didn't pass first attempt. It now runs a dual diaphragm Toyota Land Cruiser 80 Series brake booster, a 1-inch 80 Series master cylinder, and 330mm Jeep JK front rotors. It then passed.

Since completion there have been no modifications. The truck has been inspected by Highway Patrol. No issues. The full engineering certificate and brake test results travel with the car.

The Gear

Electrical — Two 130Ah DCS lithium batteries centre-mounted in the rear tray, charged by an M2K high output alternator on custom-fabricated brackets. All secondary wiring done by a professional auto electrician. The system handles dual ARB compressors, a 12,000 lb winch, and a Lazer light bar running simultaneously without issue.

Winch — Sherpa 12,000 lb rear-mounted unit with 28m rope running via tube to the front. Rear-mounting keeps the front approach angle clean and puts weight where it belongs. The Sherpa runs a genuine All-Bright solenoid and a 6.6hp motor. Already used in the field. No issues.

Lights — Lazer Linear 24-Elite. Slimline, exceptional output, fits the minimal front bumper without compromise.

Comms — GME XRS-390 IP67 UHF radio. Waterproof, commercial-grade.

Roof rack — Custom fabricated.

Tyres and rims — BFGoodrich KM3 37-inch mud terrains on Dirty Life THEORY 9305 17x9 rims. ADR-compliant, correct offset for the G2 housings.

Rear tray — Custom-fabricated by the builder and his son. Pan-braked, folded, swaged for rigidity, raptor coated. Two weeks of work to get the packaging right.

Interior — Recaro Specialist L driver's seat. Momo steering wheel. Clutch booster fitted to take the weight out of the heavy-duty clutch pedal.

Flares — The rear Trail Mod Jeep flares are required for road-legal driving on public roads and are fitted as standard. Off the tracks they can be removed and stored in the back of the car in under 15 minutes. Same goes for the front flares — they unbolt cleanly and pack away. You're not committed to running them on the tracks if you don't want to.

Hilux YN67 custom rear tray, Sherpa winch mount and ARB dual compressor setup

Registration

Currently on NSW Classic Vehicle Scheme — modified historic rego at around $50 a year. The rego does not transfer with the car; it's tied to club membership and the buyer arranges their own.

If you'd rather run standard rego, hand over the engineering papers and register it like any other car. The hard work is done.

The Price

$55,000.

You're not buying the body. You're buying two and a half years of professional fabrication, a full engineering certificate, a compliance process that most modified 4WDs in this country have never been through, and a parts list that cost well over $130,000 to put together.

To my knowledge this is the only road-legal Hilux on 37-inch tyres engineered in NSW. It is unlikely another will be built like this.

Watch the full build video above before you call.

Contact: alloffroadau@gmail.com

See it in Action

Every video below was filmed after the build was completed. This is what the truck actually does on real NSW tracks — Watagans, Killingworth, Newnes Plateau, Wheeny Creek, Mt Airly to Genowlan Point. Watch a few before you call.