My installation of Ironman Foam Cell Pro (FCP) Front strut w/ Stock springs and KDSS Bushings.
Prep:
A)Remove front skid plates/shroud (first 2)
B)Build out shock: Stock height is 2 1/16 inches of thread showing on bottom (8.5 inches from center of bottom mount to bottom of spring). Set screws in place on both keeper rings and keeper rings should turn freely on shock threads, spring spacer ring and associated rubber bushing ring in place. Pull shock piston up and put washer and bottom rubber bushing on. Watch Ironman’s video on building strut for hints.
https://www.youtube.com/watch?v=UrKvX-rHGdo Lube the strut threads with lube of choice.
C)Mark bottom of alignment cams (4 each side) with sharpie.
Steps:
1)Chock Wheels
2)Loosen Lug Nuts
3)Raise all 4 corners and use jack stands to secure vehicle in air. All tires need to be off ground.
4)Remove KDSS shield(12mm) and Mark bottom of KDSS valve bolts. Unscrew bolts 2 turns.
5)Remove 8 bolts holding KDSS sway bar in and let hang on vehicle.
6)Support Lower Control Arm with Jack (Tight is right!) Loosen/remove bottom ball joint bolts.
7)Remove center strut bolt (NOTE: the shock should NOT move down when loosening) Top flats are secured using vice grip or crescent wrench or whatever.
8)Lower jack arm that is holding Lower Control Arm slowly (strut spring pressure released)
9)Remove lower shock bolt
10)Enlist help to leverage Lower Control Arm down while you wiggle strut with or without spring out of vehicle.
11)Keep spring orientated as original (Ground Flat up). Remove old strut from spring and replace with new strut. Remember to pry old bottom bushing from stock perch. Use Ironman video on building the FCP strut for guidance. CRITICAL NOTE: The shocks are not pressurized. This creates difficulties when inserting the shock into place as ANY PRESSURE on the shock piston rod will bugger up attempts to get the shaft to properly extend through the top perch hole. It is such a PIA that I moved the spring retaining rings to the bottom of the strut in order to get the shock piston rod through the top perch with enough space to get the top bushing, washer and nut on. Screw down the top nut till it won’t turn no mo. Then adjust the spring so it is orientated correctly on top move the bottom spring retainer up against the spring and properly orientate it. Have friend put pressure down on lower LCA to get bottom of shock to line up properly, place bolt through lower shock mount along with spacing washer (if desired). Snug lower nut on bottom shock bolt. Turn the first locking ring up to hold the spring retainer in place. Have friend put pressure on LCA to generate space to raise bottom spring retainer. Continue to raise locking ring to desired height using Ironman’s dedicated tool and or Hex wrench. Bring Lower locking ring up and use friction to lock in place. Measure thread showing from bottom locking ring so you can match the other side later.
12)Place jack under LCA. Orient the bottom ball joints so the bolts will insert and engage with associated holes. Raise jack and compress strut and strut spring. Snug bolts up and torque to spec.
13)Repeat on other side.
KDSS Stabilizer bar w/ Dr. KDSS rings
https://www.youtube.com/watch?v=lO7H_WqiMQU&t=8s
1)Make note of orientation of existing tabs on bushings.
2) Remove front KDSS bar. At each bushing location, remove old bushing and replace with new in same orientation as old.
3)Use floor jack to raise bar into rough location. Wrestle one end mount into place using Hammer, screwdriver, vice grips and various effective cursing. On the end bushings there is a dedicated spot on the bushing to lever bushing hole up. Repeat on other side. Next added was the KDSS piston and finally the fixed stabilizer bar. Ample screwdriver pressure was used to align this last bushing up. Floor jack pressure was used to raise bar in place. See Dr. Kdss video for alignment of bushings on bar.
Finish work:
1)Put tires back on.
2)Safely lower vehicle and torque Lug nuts to spec.
3)Tighten KDSS valve bolts (2 turns)
4)Replace KDSS shield.
5)Check ride height and tighten available set screws.
6)Replace lower skid plates.
Aftermath:
Imbibe spirit of choice, asprin as needed, at least 30 min in hot tub and massage of affected body parts.
Prior front end squeak/moan is now GONE.
4 Runner now Handles like it did when new. I.e. it corners flat, no swinging back and forth etc.
Ride height is the same (no complaints from my wife).
Buy friend who loaned heated space to work in their garage a bottle of the proper liquid
Modify signature on forum and write up event.
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2016 TEP, KDSS, ALPRO Apex Sliders, Focal IS690TOY, Old Red's Accessory Meter Display Mod
, Rear Differential Breather Mod, Radium Fuel Surge Tank, URD Supercharger
, Ironman FCP shocks