Total Chaos +2 Long Travel on 4th Gen 4Runner

[T4Rfun]

http://i271.photobucket.com/albums/jj128/cp92620/IMG_8117.jpg

Well the team at Total Chaos Fabrication http://www.chaosfab.com/ (http://"http://www.chaosfab.com/") has done it again. The new IFS +2" Long Travel suspension Kit, as well as a new rear kit for the 4th Gen 4Runner is available, and I've been running it now for a few weeks. I want to thank Nicole, Kurt, Jeremy and the rest of the Total Chaos team. A friend recommended I talk to them about the build on my 06 Sport V8 4x4. I wanted something more then just UCA's and coilover, but I didn't want to go with the full long travel kit with my 4x4. I wanted articulation, more travel, strength and quality. The front travel is now at approximately 12" and we added almost 2" of travel in the back.

My project concept is to build an expedition 4Runner capable of handling pretty much anything a trail might throw at me. When I talked with TC, I learned of their development of this new front suspension kit and the new rear links were too good to pass up as well. The full package is impressive. To take full advantage of the TC kit, I worked with TC and the good folks at King Shock Technology http://www.kingshocks.com (http://"http://www.kingshocks.com") to spec and build the complete suspension system I wanted, and believe me they didn't disappoint. Needless to stay, I owe my friend a little extra gift in his stocking for the introduction, Total Chaos and King have a very happy customer, I can't stop grinning from ear to ear, and the 4Runner community has another "serious" quality option for suspension.

If you haven't had the opportunity to check out any of the TC products in person, do it. The overall quality is amazing and the welds are mechanical art! The TC team is a group of some of the most passionate and honest people I've worked with on this project. Brian at King is another Ace, and he deserves credit as well. I’m happy to answer any questions I can, but be sure to go direct to the source as well, these people love to talk Toyota.

I hoped to be able to get more of the project build done before posting pictures, but I'll post more information on the other components involved in my project in other threads, or maybe I'll start a project thread. Some of the other modifications include, Shrockworks front bumper and sliders, PIAA lights, Warn winch, Budbuilt "Stainless Steel" skids...yes they are custom and yes they are Stainless Steel (more on that later) National Luna Dual Battery kit, Oil Filter relocation kit, Eezi-Awn Series 3 Roof Tent, Roof Rack, and more... don't want to pimp everything here.

The pictures here are with my BFG A/T 265/70-17. This week, I am mounting Goodyear MTR's 275/70-17. I will then make the final step to MTR 285/70-17 in January/February when we are able to settle necessary trim or fender modifications to get the clearance needed to run 285's without having to limit up-travel.

Tire test:
- 265/70-17 BFG A/T - fits no problem

- 275/70-17 Goodyear MTR - Ideal tire size if stock fenders are retained “minor fender trimming required”

- 285/70-17 Goodyear MTR - would have to limit up travel with stock fenders - Fiberglass recommended

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http://i271.photobucket.com/albums/jj128/cp92620/IMG_8116.jpg

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Here are some of the specs…


Front Install:
- TCS#86002 Total Chaos 2” wider long travel kit
- TC Weld On Spindle Gussets
- 4340 extended 4wd axles
- King Coil Over: 8” x 2.5” W/Res., 18”x 700lb coil spring


http://i271.photobucket.com/albums/jj128/cp92620/86002_kit-1.jpg
The Total Chaos 2” wider long travel kit


http://i271.photobucket.com/albums/jj128/cp92620/FJ_Front_Coil.jpg


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http://i271.photobucket.com/albums/jj128/cp92620/IMG_8105.jpg

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I also added the weld on spindle gussets. Check these out, and then crawl under and look at your spindles without gussets… run, don’t walk to TC and get these.



http://i271.photobucket.com/albums/jj128/cp92620/59698-s.jpg

http://i271.photobucket.com/albums/jj128/cp92620/DSC00993-1.jpg

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Rear Install:
- TCS#86400 Total Chaos adjustable rear links:
-Upper links
-Lower links
-Panhard bar

- ICON Vehicle Dynamics rear coils
- King 2.5” smooth body W/Res., res. mounts included




http://i271.photobucket.com/albums/jj128/cp92620/IMG_7944-1.jpg

http://i271.photobucket.com/albums/jj128/cp92620/86400.jpg

http://i271.photobucket.com/albums/jj128/cp92620/2inchprerunnoncoilL-1.jpg

[Good Times]

Lookin sexy Chris! Good to see another great 4runner build!

Btw did you get a chance to drive up to BB last weekend? I know that was on your itinerary but wasn't sure since I didn't hear from ya with some pix :)

O btw, welcome aboard!

If you've got trail run photos, make sure to post it in the "event report" section! ppl drool over those pix!

[T4Rfun]

Btw did you get a chance to drive up to BB last weekend? I know that was on your itinerary but wasn't sure since I didn't hear from ya with some pix :)


We did Go up, but didn't get to do much wheeling or testing. There was 3-4 feet of fresh sticky powder on the trails and with my A/T and no lockers, it wasn't good. The only real testing I was able to do was with my snatch strap. :rofl: I pulled out a CJ5, a Mall Queen Chevy 4x4 and what I think was a F150 stuffed into a snow bank. It got so bad I just left my strap attached the rest of the weekend.

I took ever opportunity to test the new suspension and I'm impressed. I was interested as well as to how it would perform on the road up, since we removed both the front and rear sway bars. Of course there is some lean in, but very controlled and easily acceptable. Going from the xreas with swaybars to this new suspension package took a little getting used to, but after a short while I was impressed with it's street handling as well. Since this is my daily driver, it needs to have some road manners.

I really didn't get much in the way of pics. I didn't want to end up with parking lot or driveway pictures. I'll be going up again in a few weeks. :clap:

[Scuba]

Im so jealous
:thumbup:



:bling:

[T4Rfun]

Im so jealous
:thumbup:

Thanks Scuba. I've been lurking, learning and planning for over a year, and most of that time was spent being jealous of one rig or another on this and a few other sites I frequent. I appreciate the comment. There is still a lot to do, but I'm happy that I'm finally getting started and pleased with these first steps.

[strykersd]

Looks good, I'm not going to lie I'm jealous too. So you went up to Big Bear this weekend? I was up there Saturday and Sunday also, I tried to do a little snow wheeling, but being open/open I didn't get too far. I should have my rear locker in within a few weeks and we should get a group together for a snow run!

[T4Rfun]

Looks good, I'm not going to lie I'm jealous too. So you went up to Big Bear this weekend? I was up there Saturday and Sunday also, I tried to do a little snow wheeling, but being open/open I didn't get too far. I should have my rear locker in within a few weeks and we should get a group together for a snow run!


Thanks. This has been in planning for a long time. I still have some work to do on this and of course need some place to test, so BB is good with me. Shoot me a PM or start a planning thread and I'm in.

[Scuba]

Snow run x2 Stryker !!!
I'd be down !!

[warrior3313]

How much does this Kit Cost? I am really interested in putting this in this summer. Need to start saving now.

[T4Rfun]

How much does this Kit Cost? I am really interested in putting this in this summer. Need to start saving now.


Warrior, the costs below are for the complete Total Chaos kit including the extended axles (to retain 4 wheel drive) and King shocks. There are other shock options with this kit, but in my opinion King is the best, so that was my choice. You certainly pay for the quality, but again in my opinion, you get what you pay for.

* Retail cost on the Total Chaos Front IFS Mid-Travel kit itself is (TCF# 86002) = $2750.00.
* Extended Axles = $575.00 (set)
* The Total Chaos rear kit 5 pieces uppers, Lowers and the pan (TCF# 86400) = $1289.00
* Icon Dynamics Rear Coils (used Icon T4R/FJC Coils - good choice for my projects planned additional weight in the rear) = $250 (set)
* King Coilover 2.5" x 8" with 16"x700lb coil = $1350 (set)
* King Rear Remote Reservoir Smooth Body Shocks (FJC & 4Runner) = $750 (set)

[warrior3313]

Do i Need really need the Rear kit? I was thinking of doing something different in the rear? So for the front by its self is 2750.00 and it comes with everything or i need to extend the axels at 575 too.

[T4Rfun]

Do i Need really need the Rear kit? I was thinking of doing something different in the rear? So for the front by its self is 2750.00 and it comes with everything or i need to extend the axles at 575 too.


You don't have to run the rear kit as I did. I only did it to complete the package and to compliment what was done on the front. There are other options of course. I like the strength, they are trail adjustable, easily serviceable, and since I planned to do some upgrade in the future anyway, I did it all together. I do believe that each component compliments the next and therefore gives the overall suspension it's best performance.

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From TC website...
Factory Toyota rear rubber bushings bind when your suspension cycles and can limit wheel travel and articualtion. TC upper, lower and pan hard bar links are built using 1 ¼” x .375 chromoly tubing. Designed to be trail adjustable, these links are tapped on one end and utilize a 7/8” heim for maximum articulation and tune ability. TC supplies all necessary hardware and hi- misalignment spacers required to install this bolt on conversion. The opposite ends of the upper and lower links include gusseted pivots that feature zerk fittings and use replaceable urethane bushings and an inner sleeve that eliminate any pivot resistance. TC allows you to lubricate these urethane pivots through factory access holes on the chassis for convenient maintenance. Lower links incorporate emergency brake line tabs needed to reinstall the factory lines. The TOTAL CHAOS pan hard bar is tapped on both ends and is fully adjustable utilizing ¾” heims to offer maximum adjustability and strength.
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The front at $2750 includes everything pictured in the original post kit. It does not include the extended axles, the coilover shocks or the steering spindle gusset (again and option). So the front would look like this...

* Retail cost on the Total Chaos Front IFS Mid-Travel kit itself is (TCF# 86002) = $2750.00
* Extended Axles = $575.00 (set)
* King Coilover 2.5" x 8" with 16"x700lb coil = $1350 (set)
* Weld on Spindle Gussets are about $43 for the set

[T4Rfun]

Wheel the crud out of it and enjoy!! :thumbup:


Thanks NorCalBorn. I plan to do just that. It looks like I'll be running some local trails (all easy stuff) tomorrow just to do a little testing and because I need to get dirty again, :clap: then over the next few weeks back to the build. No BB trip until the 10th.

[T4Rfun]

Total Chaos has the 4Runner kit posted on their site now for those that are interested, check it out. http://www.chaosfab.com/what.html You'll find it in the "what's new" section and also of course in the suspension for the 4th Gen 4Runner.

I've had a few chances now to run this on the trail and I am blown away. The ride is amazing and it takes big hits without any complaint and remains well under control. The combination of the Total Chaos kit and the King shocks is worth the investment. Of course I have to buy my wife a new dinning room table to offset the expense and keep the peace, but oh well. I think she might need a new hutch to go with that table...I need air lockers. :rofl: