When I need to replace components on the 4Runner in the name of maintenance I am always on the lookout for an upgrade. Recently faced with refreshing the front-end of the truck, I took the opportunity to move from my existing front suspension setup to new, Dakar-proven Total Chaos Fabrication suspension components up front.
You could say I “bought the farm” here, installing everything that Total Chaos makes for the front of the 4Runner:
- Race Lower Control Arms (8500R-10FJ) – These replaced my tired lower control arms that had dry, cracked bushings and leaking ball joints. The Race lower control arms feature fully-boxed construction along with a strong uni-ball joint (versus a ball joint), and a secondary shock mount that allows me to continue to run my secondary bypass shocks.
- Long Travel Secondary Shock Hoop (86600) – The second piece of the dual-shock puzzle. These hoops work both on the stock length “race” setup and on the +2” and +3.5” long travel setups and provide the upper mounting location for the secondary shock. They bolt to the shock tower up top and weld to the frame.
- Uni-Ball Upper Control Arms (96504) – I was previously running Camburg upper control arms, and decided to swap them out to Total Chaos for more compatibility with the rest of the setup and to get another degree or 2 of caster adjustment out of my alignment.
- Other – While I was at it, I also installed new inner tie rods (the outers were done 5K miles ago). Bypass shocks – while I was able to use my existing Icon bypass shocks with the new setup, I did have to send them in to be reconfigured slightly to bolt up. Coilovers – since they were coming out anyways, I replaced the worn out spherical bushings in my Icon front coilovers. Gussets – I had previously installed the full complement of Total Chaos Guessets (Spindle, Cam Tab, Shock Tower).
The Install: I’m not going to give a how-to, as the install is lengthy and I didn’t attempt it on my own. Instead, I enlisted Pete and crew at Main Line Overland to do the install, which they completed over a couple of days last week. The mix of mocking up, welding, mocking up again, adjusting and servicing shocks, painting, and tightening it all up was a marathon effort!
Pete from Main Line Overland mocking up the new components
First Impressions: The combination of all of the new parts working together is a dramatic improvement vs. my old, tired setup. Steering is precise and heavy-on-center (how I like it) and the front end feels solid and responsive on the road and some of the vibration and wandering under braking has been eliminated, likely thanks to the new spherical bushings and urethane bushings throughout the front end.
I have not had a chance to log some miles on the dirt, but expect the setup is going to perform just as good as it looks! If I can’t get it out before, the Mid-Atlantic Overland Festival will be the maiden dirt voyage.
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