I just changed out my front suspension with the bilstein 5100's and Moog 4runner springs (81088). The install took me 6hrs and I think it should have only taken about 3. It was a pain to get the lower control arm pushed down far enough to get the new struts into place. Besides that, I had to remove the sway bars from the arms, unless I shouldn't have done that?. And it was just about impossible to get them back in place. I've turned a wrench or two in my time and this kicked my ass. That sway bar is no joke. Just wanted to give anyone a heads up who has the KDSS system, it's not as easy as removing regular brackets and re-installing.
good lord, KDSS sway is no joke during strut install
- Thread starter gx470
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sorry about that, i was too stressed to do pics. But I read up more and found an article that mention lifting/supporting the kdss drivers side with a jack. I didn't do that because I left the skid plate on and didn't realize this. I went ahead and redid the install today to move the bilsteins to the 1.75" lift instead of the .85". I was afraid to tackle it again but did it with no issues today in 2hrs instead of the 6hrs the other day.
JohnJMonroe
New member
There is a definite technique to it.
Here is how I tackle it:
1) I safety wire the hydraulic ram up in place so it doesn't get out of position when I remove the bar.
2) loosen the brackets that attach the sway bar to the hydraulic ram and the mount, but don't let the bolts come all the way out of the bracket. You just want to let them loose so the bar can rotate and move.
3) disconnect both lower control arm brackets that hold the sway bar on to the LCA.
4) do what you need to do with the lower control arms.
5) to reinstall, start with the passenger side lower control arm bracket. Get it started, but don't tighten it. This can be a *****. I used two jacks. One under the LCA, one under the bar. The more the drivers side of the bar can move around, the easier this is. Use a screw driver to align the bracket to the LCA using the two holes at the top of the bracket.
6) Get a ratchet tie down strap. Hook it to the drivers side of the sway bar and somewhere on the frame to pull it towards the lower control arm. Use the ratchet strap to pull it where you need it to be. Also use a jack to adjust the bar and the LCA into place.
7) Attach the drivers side sway bar bracket to the LCA. Get it started and snug it, but don't tighten it yet.
8) Tighten the sway bar to the hydraulic ram and its mount on the passenger side. Torque them back down. Then torque the passengers and drivers side LCA bracket.
9) Remove the ratchet tie down strap and safety wire from the hydraulic ram.
Of course this is all harder when you've installed a lift and now the lower control arms are in a different position.
Here is how I tackle it:
1) I safety wire the hydraulic ram up in place so it doesn't get out of position when I remove the bar.
2) loosen the brackets that attach the sway bar to the hydraulic ram and the mount, but don't let the bolts come all the way out of the bracket. You just want to let them loose so the bar can rotate and move.
3) disconnect both lower control arm brackets that hold the sway bar on to the LCA.
4) do what you need to do with the lower control arms.
5) to reinstall, start with the passenger side lower control arm bracket. Get it started, but don't tighten it. This can be a *****. I used two jacks. One under the LCA, one under the bar. The more the drivers side of the bar can move around, the easier this is. Use a screw driver to align the bracket to the LCA using the two holes at the top of the bracket.
6) Get a ratchet tie down strap. Hook it to the drivers side of the sway bar and somewhere on the frame to pull it towards the lower control arm. Use the ratchet strap to pull it where you need it to be. Also use a jack to adjust the bar and the LCA into place.
7) Attach the drivers side sway bar bracket to the LCA. Get it started and snug it, but don't tighten it yet.
8) Tighten the sway bar to the hydraulic ram and its mount on the passenger side. Torque them back down. Then torque the passengers and drivers side LCA bracket.
9) Remove the ratchet tie down strap and safety wire from the hydraulic ram.
Of course this is all harder when you've installed a lift and now the lower control arms are in a different position.
helocat
New member
First KDSS I did was the same deal. However the next 20+ it was much easier knowing how to set the system into a service mode.
You open up the shutter valves for the KDSS system on the pump on the drivers side of the frame.
Remove the steel guard for the pump system.
On the back of the system are two valves you open 1.5 turns but no more. This will put the system in bypass so you can hand cycle the KDSS. Once you are done set the truck on level ground then close the two valves. This also resets the ride height for the KDSS system.
Ironman 4x4 has a nice PDF located here on this:
Prado 120/150 & 4Runner N280 - KDSS Instructions - Ironman 4x4
Mark
You open up the shutter valves for the KDSS system on the pump on the drivers side of the frame.
Remove the steel guard for the pump system.
On the back of the system are two valves you open 1.5 turns but no more. This will put the system in bypass so you can hand cycle the KDSS. Once you are done set the truck on level ground then close the two valves. This also resets the ride height for the KDSS system.
Ironman 4x4 has a nice PDF located here on this:
Prado 120/150 & 4Runner N280 - KDSS Instructions - Ironman 4x4
Mark
So apparently the shutter valve allen bolts are missing from my KDSS system! WTF? No service mode for me. Mine is a 2005 GX470 but should be the same as a 4th Gen. How is it possible I have no shutter valve bolts?? They are empty!
I struggled like crazy to get the driver's side shock in today. I'm tackling the passenger side tomorrow, but now I'm VERY concerned about the KDSS in my truck, and wonder if it's even functioning?
From what I understand they are supposed to be below the center section of the block between to two tanks up inside the rusty looking area in the video I made here this afternoon.
https://youtu.be/vSkAxh2Lh8E
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