We will be updating this thread as we go along. We purchased a 2011 Trail Team 4Runner last November as our next avenue for building part. This time around we will be building the 4Runner for expedition use rather than a wheeler like our FJ Cruiser. We plan to have this 4Runner built with suspension, gears, front bumper and sliders for the FJ Cruiser summit in Ouray, CO in July. We are also in the works to have the 4Runner displayed at SEMA this year as well.

Official Sponsors
Total Chaos Fabrication
Radflo Suspension Technology
Falken Tire

Our first modification was to get the 4Runner stripped down and get it painted the factory FJ55 Land Cruiser color T308 Persimmon Orange.



Stay tuned, up next we will be installing Total Chaos 2" Long Travel Kit, Radflo suspension, 4.56 gears and an ARB Air Locker next week.

Just got the 4Runner back from paint today. The paint job turned out awesome, we used a factory Toyota FJ55 Land Cruiser color called T308 Persimmon Orange! Next we are putting it on the lift for a Total Chaos 2" long travel kit, secondary shock hoops, our long travel rear suspension set up, 4.56 gears and an ARB air locker.

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Nice job it's out over on the 5th Gen forum now so expect lots of questions and comments!

The truck looks awesome in Orange! I'll be following this build closely. Excited to see what you guys have coming out for the 5th.

this build is going to rock. will be following

Definitely subbing to this one!

Subscribed. The plan is Exactly what I want to do to our 4Runner. Definitely interested!

Not a whole lot of updates so far. Still waiting on the thirds to be rebuilt with the 4.56 gears and ARB air locker and the coilovers/shocks from Radflo. I have most of our rear long travel kit put on including our prototype links that we will be releasing in the near future. The secondary shock hoops are going to need a lot of work to fit inside the fender well but we will make it happen.

Below is the Total Chaos spindle gusset that is sway bar compatible and the next picture is the Total Chaos replacement cam tabs that are much beefier than the stock ones.

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Just got in the coilovers and shocks from Radflo Suspension. Here we have the long travel coilovers, secondary remote reservoir shocks and our long travel rear shocks with remote reservoir.

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LT,

Are you building an actual long travel rig or extended travel similar to the Icon ET CO's?
If it's the latter what rear springs will be used? Also will you remove the rear swaybar or use longer links? Asking as I'm interested in a little more travel for the rear.

Thanks!

Edit:
Answered one of my questions by looking here but still curious as to the swaybar links.

Sweet sounding build! Looking forward to the updates and the results. Bold beautiful color as expected

why aren't you using your MetalTech/ICON long travel rear? Would love to hear more about that kit, what it is designed for and how it REALLY performs. Do you guys have anyone running that kit on a 5th gen runner?
Is the rear Radflo kit being added to this rig avail.? and built for the 5th gen?

We are using the long travel speced coilovers for the Total Chaos 2" Long Travel Kit, all the manufacturers make them King, Fox, Icon, Radflo and Sway Away. The extended travel coilovers that Icon offers is meant for a standard 3" lift that allows for an extra 7/8" of down travel when combined with an aftermarket UCA with a high misalignment joint.

For the rear as you pointed out we are using our progressive rate long travel springs and we had Radflo build the shocks to our specifications. We won't be using a sway bar since the shocks will more than handle the body roll even with the absence of the sway bar. Unfortunately you cannot use the factory sway bar if you want to utilize the full travel. However, there have been a few customers that have adapted Currie Anti Rock sway bars to the FJ Cruiser and have had positive feedback. We might tackle that project to provide a bolt on option since most people due carry more weight than what we typically do on our vehicles.

For the links we are in the process of having our own version of replacement links being machined at this moment. I have put the prototypes on our 4Runner and it is looking like we are going to be the full vertical travel of the axle before the links contact the axle housing ;)


We are still using the same components except with the use of Radflo shocks. Radflo had approached us about sponsoring our 4Runner so we decided to move forth with it hence why we are getting all this Radflo suspension. The rear long travel truly does work, we didn't come up with arbitrary numbers without testing them. We will offer the Radflo version of the long travel shock but we have plenty of the Icon 2.0 VS Series and 2.5" remote reservoir shocks as well for those that want a choice between the two different companies.

As far as a 4Runner running the suspension I have a customer in Guam with a 2004 V8 4Runner that is running our long travel rear and the Total Chaos 2" LT kit and he loves it. As far as I know we are the first to put it on the 5th Gen 4Runner which is going to perform the same as the 4th Gen 4Runner and the FJ Cruiser since the suspension components are all the same.

Here is some travel numbers of how the rear long travel works. This was used on a FJ Cruiser with stock links.

This is measurements with the sway bar in place.




This is measurements with no sway bar and you'll see there is an extra 4" of suspension travel.

The 4Runner suspension is all buttoned up and ready to go. We will be taking it down off the lift and start breaking in the gears. In the next week or so the front bumper will be coming off to start developing a shell bumper

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Wow!.. I really like the black roof. I have a silver 5th gen and thinking about putting a wrap on the roof now. very nice!