Hey Folks, Time to do the Build thread..

@scrappyjackalope on IG for build pics as we go.. updates here from time to time..

Ok, history on 4runner.... Bought from a 73 year old Little old lady original owner from down in Ventura. This thing is clean and I intend to keep that way
250k miles but to me seems like a 60k mile 4runner. The stack of receipts she gave me when I bought must add up to about $100k ..haha

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As far as the way it sits this moment it is 100% stock suspension with some 33x10.5x15 bfg's. 4.88's with a eaton/harrop electric locker in rear. All new suspension components cv's etc.. I took out the ADD and added some new Aisin locking hubs.

Now for the plans..
Custom built by me 62" dana 44 with a eaton elocker
at first a low as possible leaf spring sas with the end goal of a 4wu 3 link front.
For now OME 1.5" coils in the rear but
63" chevy rears later with a chance of a 4wu 3 or 4 link rear..

Marlin Built 150/r151f hybrid transmission
23 spline marlin 4.7 gears
Custom rear bumper
Custom front bumper
toyotafiberglass.com front fenders
some sort of fabbed rear axle housing at about 63 to 64" eventually. Just gonna use some spacers to even it a bit for now.

But the biggest thing I am looking forward too is the 1UZ.. I have put a lot of time considering lot of different motor swaps from the Cummins B2.8 to the 3.4, LS, SBF, SBC heck even a turbo k24 or 2jz.. but everything keeps me coming back to the 1UZ.. killed motor and it is hard to compare to the v8 sound.. for as wide as it is it fits pretty well and there is a ton of support for all things 1UZ swap.

So anyways feel free to follow along. I will get busy with the long travel this week but more than likely won't finish up till the week of the 4th of July. Hopefully I will have it driving to the pacific mountain cruisers swap meet on the 9th in Petaluma..

 

That is a super clean looking 2nd gen! Excited to see the LT setup, it's on my longer list of things to do still arguing with myself with the LT vs SAS.

 

I was in the same boat. I was contemplating a 3 link front solid axle. Got close to biting the bullet but in the end wanted to do something I hadn't done before with the long travel. Might start the tear down tonight. We will see

 

Took some measurements of ride height and what not. I have gotten conflicting info on how much lift it gives you so figure no better way to know for sure.. Before pics Below

 

Fenders have been a big consideration too. I have found one set I really like from toyotafiberglass.com that I think I will be ordering. Cleanest look IMO. Pic is from YouTube channel desktoglory

 

Did a little more tonight.

I got the factory down travel stop cut off, finished trimming the old shock mount area off. Notched for UCA down travel.

Also played with the bushings supplied for the UCA's All I can say for sure is they have things a off on the UCA bores, bushings and spacers (way too tight the way they supply them when torqued properly, even for a new set up) and honestly their UCA is not square on the 2 bores as far as being inline with each other(see pic) Heck this honestly is kind a big issue in my book. I will call them on Tuesday..
Wonder if they don't have it bolted down well enough in a solid jig when they weld or they pull from jig before it cools? I think the bushings will eat most of it up but 2 things happen when like this. One it will create paracitic drag or resistance to smooth movement, and 2 it will wear bushings prematurely. Either way for the absolute premium price you pay for this kit so far there have been lots of things not so premium. Both shock hoops are not bent square between both bends(see pic), all the notches in tubes for the frame pieces had to be fixed. Instructions are not instructions, Just medicore drawings at best. Other things as well. I am not just trying to bag on Total Chaos but I want to be honest with folks who are about to plunk $6k down on a "Premium" long travel kit

And last but not least the hardest thing by far with doing this job was cutting the inner fenders. Not hard as in physically diffcult but mentally difficult since this 4runner is so perfect. But it is done now

Also started figuring shock hoop hanger placement.. no welding yet but more than likely will start tomorrow.

 

Ok so I went out and checked the other UCA and it is as bad but in another direction so that tells me the bore center of the arms being offset are not by design but rather poor jigging or procedures during manufacturing

Off center

Lower arm looking better aligned, checking initially with machinist straight edge.

Off center

Side by side of both arms, note how they are off center in different directions. Cross shaft is straight as a arrow and bushing was rotated to eliminate is as the cause of being offcenter.


I can not see any reason why you would not want anything other than a perfect centered arm pivot point anyways but figured I better cover all my bases before I call them. I even rotated the cross shaft and it is dead nuts straight. Then I thought I better pull the polyurethane bushing and rotate it to eliminate the chance it is off, but all stayed the same when I rotated the bushing 180*

Went ahead and starting looking at the lower arms and they seem to be better at least according the machinest straight edge. A closer look coming soon

 

Back on the road! Super happy with ride height and stance. I added OME 1.5" rear coils and 1.75" rear wheel spacer to get the track width close to the front.



But now for the not so good, it handles on road like garbage! Toe is good(1/8"toe in) and it has plenty of postive +caster(not sure of degree yet) which from my experience are the 2 biggies for on road handling. But heck I haven't played much with IFS. Basically, it tracks straight but on turn in it just kind of takes off and you find yourself in a constant battle with steering inputs. These uni balls are EXTREMELY stiff. Like crazy stiff, I read they will break in but holy smokes I won't be surprised if these are playing a big role in the onroad manners





Also at this ride height it is 2" higher than stock. I can't imagine wanting to be much higher either with these long travel arms for ride height. So the folks saying you get 3.5 to 4" lift over stock are smoking something That being said as far as ride height I am super pleased, I wanted low. Matter a fact before I put in the rear springs this morning, I took it to Petaluma swap meet yesterday at completely stock height

 

Well folks a lot has happened since the last update. In the previous post installing the total chaos long travel I made light of some issues with the design and construction of the kit.

As nice as it appeared by the nice powder coat and great welds some very serious problems were found in UCA construction and their bushing design. Also for anyone considering uniballs they have a lengthy break in process that I could not keep driving on the rode responsibly. Anyways long story short Total Chaos refunded my money and I sent back their kit.

I am super disappointed and spent many many hours trying to get everything right to make this kit work like you would think a long travel suspension should but it is too flawed. If you want a suspension that rides like a couple of 2x4"s for springs and is dangerous to drive until who knows when the uniballs break in go for it..
this what she looks like right now




But on to the good news....

I have since decided to go back to the route I am most familiar with over the years.. Solid Axle Swap

I just picked up a Dana 44 that I am going to narrow down to 62". I will set it up with a eaton elocker as well and 4.88s. So anyways you will get to see me build this axle.



At first I am going leaf springs but the end goal is to go with a 4wheelunderground 3 link kit. I have been talking with them and really look forward to their kit.

Also although my 22re runs great and is fresh I had the chance to get with Jim at 22re performance for his 2.5 build and will be putting this in o ce i get the axle under it

 

Oh man I'm super upset to hear that about the long travel setup. I hadn't heard much about uni-ball break in what is the issue with driving them? Would changing the springs on your coilovers helped the ride at all?

Excited to see what you do with the SAS since I see myself eventually ending up doing one of these two options in the future but if I go SAS I would REALLY prefer to have a 4link + coil setup in the front rather that leafs even though the leafs are much simpler. Like you I DD my truck and replaced an older XJ with the 4Runner because I got tired of how the XJ abused me driving down the road haha.

 

I actually had put 500lb springs and a shim on the large bushing sleeve and got it riding decent. But there were many big issues with their kit. MANY.

I will be going with a 4wheelunderground 3 link in the not to distant future actually. This will get me going right now with leaves..

 

Completely agree with your statement that for 6k you'd expect a well sorted kit and from everything you see I would 100% expect that. Upsetting that was not your experience.

 

Here are a few more updates.. cut the housing, pressed out the balljoints, blasted everything. Going 62". Gives you 2 stock length axles and toyota spring pad width. Cut 4" on long and 1.5" on short..

😀

All blasted and the passenger ready to mill.

Cleaned up housing some with wire wheel

Cleaned up

C's blasted and almost ready to press out old tubes

 

Whoa! Super cool!

 

I am pretty surprised you had issues. I found a used set and removed it from a Toyota Pickup, installed it on my 4runner and it rides so much better than my stock IFS setup. It has performed beyond my expectations. The bushings are squeaky and I don't like that, and I can't get perfect alignment but it's good enough and tracks straight on hwy.

So, you said that it is not riding right, any details? Did Total Chaos try to blame your installation or they just said ok return no problem?

Your truck looks really nice with the LT setup

 

I sure did love the look of it installed too 😀

in the above posts though you can see a few of the issues pictured with the warped upper control arms, Also on the large upper control arm bushing they are using a completely wrong application as, I am sure once worn out it will start to cycle better. There were a lot of issues I spelled out in emails to them and they did not argue and said sendnit back... I feel bad trashing them publicly though..

 

They have a good reputation, they will be fine

I imagine someone just didn't put the parts together well.

 

Hopefully their newer vehicle products are a much better design. The 86 to 95 kit is extremely lacking and I feel bad for folks who have no idea and just love the look over everything else.. The 86 to 95 kit is more like something a kid in his garage would build not a $6k high performance kit.. I did like their lower boxed arm though. Had no issues with that. Also I will never own anything with a uniball again 😀

 

Hey Folks, Time for a update

Been working on finishing up the Dana 44 build. A good way into the SAS as well. Hopefully I will have it on tires by the weekend.

 

Parts me toyota to dana 44 flange

A little 4340 to keep you smiling..

Low profile hanger

On the axle.. halfway there

Getting close