Ironman Foam Cell Pro

[Dinosaur Overland]

Here is a picture with our 4Runner with Ironman stage 3 suspension, I have the 660 pound rear springs and they work great for me. I do hate that people seem to be having a problem but I can only say I love my suspension.

 

[honda250xtitan]

Follow up to my own post. Do not buy the "Performance springs" they suck. Major sag with weight under the 660lb rating. Spoke with Ironman. They are recommending I get the 3" lift springs which are for a 440lb-880lb weight rating. I did not get these originally because I do not have a constant load on my springs (factory bumper, no drawer system etc). My trailer has a 300-350lb tongue weight and I probably have 150-200lbs in the back of my truck when camping. The sag is over 3". I would have to measure again the next time I load up. My 4Runner looks like it still has factory springs in back when loaded.

The Icon heavy duty springs I had on my FJ with the same setup did not do this.

https://iconvehicledynamics.com/acc...fj-03-up-4runner-rear-3-dual-rate-spring-kit/

Ironman won't refund any money because the springs are used. The description of the "2 inch performance springs" is very misleading.

This is going to cost me a good about of money to replace them including installation. With KDSS it is way different than the simple setup on my FJ.

I don't want airbags (another thing that could fail) and I know the ride will likely be very stiff unloaded with the 3" springs. My simple free advice is do not buy either of the 2" spring options from Ironman.

Oh well...

unbolt the 2 vertical bolts that connect the sway bar to the "end links" (so 4 total if you remove both sides). those are easy easier to align then unbolting from the axle tube. the rear end isn't bad to re assemble. Front is annoying i agree lol.

 

[RedRunner_87]

Here is a picture with our 4Runner with Ironman stage 3 suspension, I have the 660 pound rear springs and they work great for me. I do hate that people seem to be having a problem but I can only say I love my suspension.

Same thing. Bummer hearing the problems people are having. I have had mine for 11k miles with no issues. That is DDing, fully loaded for week long overloading trip and general off-roading. Hopefully it is just a little bump in the road with their QC or something like that.

 

[slider76]

FCP Stage 3 after about 200 miles of commuting

I had the team over at RPM Offroad put the Stage 3 on last Tuesday. Immediately I noticed that nose dive during stops (especially "rocking") is minimized and things definitely feel tighter. I went with the stock weight springs as I only have Shrockworks sliders on right now (LFD steel crossbars too, but I imagine that weight is negligible). I feel well planted and it definitely absorbs local speed bumps better than stock suspension did.

Now just waiting for the stock tires to be ready for replacement before I size up to 275/70/17s.

No vibrations or any other issues at both freeway and local driving speeds. So far I've been very happy. We will see how things go once I size up the tires.

I should maybe mention that the shop stocks and sells Ironman products: that might make a difference as to how the install went.

 

[MAST4R]

Sure! Shoot me a PM or link. I have not looked at YouTube yet for installation ideas. Even though this is highly annoying I may wait until I add a rear bumper. That wasn't in my 2021 plans though.

unbolt the 2 vertical bolts that connect the sway bar to the "end links" (so 4 total if you remove both sides). those are easy easier to align then unbolting from the axle tube. the rear end isn't bad to re assemble. Front is annoying i agree lol.

1Louder,

I am curious about this setup in the SW in the first place.

It obviously relies on the springs to do the work. That should ensure long time between changes/rebuilds but this is the opposite of a desert performance setup.

No wonder spring rates are buried on their website and only marketing stuff shows when you look at the foam cell page. So "Comfort Load" rear is 234lb? What? Stock is 180-185. My Eibach is 202-204.

With a cheap Icon 2.0 or Fox 2.0 or even just Eibach's own shock and Eibach 1.0 lift, the 4Runner will come off any ledge or big rock with no issues at all when loaded with about 200lb in the rear.

So if for Ironman 234lb is comfort, then are the shocks full of marshmallows? I know the Eibach on stock shocks is super comfy, I have run that on Kamikaze, Boxcar, and Elephant Hill, and all the way to Montana plus many dirt roads there, but I also know control was not suitable for more than an experiment. I am sure the IM is better than that, of course, but looks like the same idea.

And 650lb being the minimum front spring rate simply means the front shocks are very weak. I find the 6112 weak, so I run them on 650lb springs. How weak these need to be for 650 to be the baseline?

Looks like a setup optimized for maximum durability at the expense of performance.

Very interesting idea and many here say they love it so that's great, but does not tempt me here in AZ.

 

[1Louder]

1Louder,

I am curious about this setup in the SW in the first place.

It obviously relies on the springs to do the work. That should ensure long time between changes/rebuilds but this is the opposite of a desert performance setup.

Very interesting idea and many here say they love it so that's great, but does not tempt me here in AZ.

Well, you can get a smoother ride with an Icon Stage XXXXXXX, OME, King, Fox, I dunno. You can also enjoy pulling them off every 1-2 years to have them rebuilt. NO THANKS!

My basic OME Setup on my old FJ lasted over 130,000 miles. 7 years' worth of fun without having to replace them. Although about 6 months before I sold it I did buy some non-adjustable reservoir shocks with heavy-duty Icon springs.

I agree everything is a trade-off. KDSS is great on the road. I have not found any negatives offroad to date. With that said for me at least, it takes DIY replacements out of the question. That was a conscious choice that I decided to make when I bought the 4Runner

 

[ssRoRo]

Picking lift option

Looking at the foam cell kits. Deciding between stage 2 and 3 for my 4th gen with 33"s. My LCAs are frozen and suspension is worn so was going to cut out the LCAs and do a full suspension upgrade. Going with the performance kit for weight, but any input on the lift size option? Will 3" on both front and rear keep the vehicle with only a slight forward rake? or mostly level? Just wondering how the vehicles are sitting. Was also considering a 2.5" front and 2" rear but worried it might settle weird. Any input helps, the tech just said do a stage 3 with 3" all around, but said they don't know how the vehicle would sit after. I also don't want to go 3" and be stressing out my CVs.

 

[RedRunner_87]

Looking at the foam cell kits. Deciding between stage 2 and 3 for my 4th gen with 33"s. My LCAs are frozen and suspension is worn so was going to cut out the LCAs and do a full suspension upgrade. Going with the performance kit for weight, but any input on the lift size option? Will 3" on both front and rear keep the vehicle with only a slight forward rake? or mostly level? Just wondering how the vehicles are sitting. Was also considering a 2.5" front and 2" rear but worried it might settle weird. Any input helps, the tech just said do a stage 3 with 3" all around, but said they don't know how the vehicle would sit after. I also don't want to go 3" and be stressing out my CVs.

I did a 3" all the way around and I still have the factory rake just at 3" higher.

 

[tammak]

Huge thank you to all that came before me here and shared feedback.

I opted to convert from my spacer lift to a suspension lift and despite at-cost pricing for Kings and lots of Bilstein love, I opted for Ironman 4x4 given the value for my use case.

Use Case: Adventures-only 2016 Limited in/around Colorado with summer wheeling, winter ski trips, and Costco runs

Weight Notes: Constant fixed load of !420lbs for SSO Full Roof Rack, Full RCI skids (all of them) with aluminum options where available, RCI flat sliders with kickout, hidden winch mount + winch...and rarely +150lbs for Tepui RTT or a 16' dual console fishing boat.

Previous Setup: Went with a Daystar spacer lift on XREAS and loved the lift AND the company's service -- one of the best experiences out of any company I have ever reached out to. This setup addressed the nose diving from hard braking, gave some good height, but did limit suspension travel when offroad. I wish I did this on day one, not year three. I opted to do a diff drop as well (by Revtek)...jury is out on this but didn't seem to hurt and improved CV angles.

Ironman 4x4 Setup: Foam Cell Pro, Stage 3 with Front (prebuilt) 2.5" / Performance Springs and Rear 2" Performance Load Springs

Alignment: Just had a solid shop in Denver for an alignment and bumper to bumper check to ensure my DIY install went well...all came back okay. They suggested against Heim joints for the adjustable rear sway links due to noise...but it came with the kit and I don't have a problem with the noise. Here are my specs:

OEM UCA & XREAS (old dealer alignment)

• Left-Front: Camber @ 0.5*, Caster @ 1.9*, Toe @ 0.46*
• Left-Rear: Camber @ -0.3*, Toe @ -0.08*
• Right-Front: Camber @ 0.6*, Caster @ 2.2*, Toe @ 0.5*
• Right-Rear: Camber @ -0.3*, Toe @ 0.08*
• Total Toe @ 0.96*, Steer Ahead -0.02*

OEM UCA with Daystar 2.5" Front/Rear Spacers on XREAS

• Left-Front: Camber @ 0*, Caster @ 2.8*, Toe @ 0.04*
• Left-Rear: Camber @ -0.3*, Toe @ -0.1*
• Right-Front: Camber @ 0.1*, Caster @ 2.7*, Toe @ 0.05*
• Right-Rear: Camber @ -0.3*, Toe @ 0.08*
• Total Toe @ 0.09*, Steer Ahead 0*

Ironmen UCA with 2.5/2" FCP Stage 3 Lift

• Left-Front: Camber @ 0*, Caster @ 3.4*, Toe @ 0.09*
• Left-Rear: Camber @ -0.4*, Toe @ -0.35*
• Right-Front: Camber @ 0*, Caster @ 3.6*, Toe @ 0.08*
• Right-Rear: Camber @ -0.3*, Toe @ 0.32*
• Total Toe @ 0.17*, Steer Ahead 0*

Actual Lift Height

• XREAS Stock - Dont have them
• XREAS + Daystar - May have them, will look
• Ironman (+250lbs for mods pre sliders, winch): Left-Front @ 23.5", Right-Front @ 23.4375", Left-Rear @ 24.5", Right-Rear: 24.75"
• Ironman (+440lbs for all mods): Left-Front @ 22.87", Right-Front @ 23", Left-Rear @ 24.38", Right-Rear: 24.6"

Thoughts So Far

• I am running FN F(X) Pro 17" wheels with Falken Wildpeak AT3/W LT(E) 265/70-17.
• When I purchased, Ironman had limited stock but I spoke with their customer service team and after going over my specs, seemed to be the right pick. Great team there!
• My RTT and 16' fishing boat use cases are rare and I feel airbags are the better option for me versus a much stiffer spring. It isn't tough or expensive to swap front or rear springs now that XREAS is gone should I change my mind.
• I am glad I waited to see if I needed the usual Toyota lean spacer...my current numbers are close enough but I did buy the adjustment wrench just in case (for the fronts).
• My 4Runner is no longer a daily driver. So if not on a Costco trip, she is off road or making a run to go skiing...so the truck-like ride is good. For what XREAS was, it's a superior on-road experience to any SUV/truck suspension I have driven in IF smaller/medium spacers are added to the wrong. The braking nose dive wasn't great, but cornering was unmatched.
• As with nearly every product I have purchased, instructions are hit or miss. Ironman would be mid-pack. They have a good install video on a GX for the stage 2 lift and there are a handful of install guides like Trail4Runner out there. With a bit of Googling, I found the correct panhard and rear sway link adjustments which were most elusive.
• I think I lost a set screw and will email Ironman...I don't expect any issues but also have no worry...they are extremely responsive and knowledgeable compared to some of the other manufacturers I have come across for Toyota and Chevy.
• I am at day 7 with 120ish miles on the clock...time will tell how things settle.
• I plan to add airbags after a RTT trip and a short boat tow to see if I really need them or can live with some sag.

Happy to answer any questions folks have, especially if you are doing the Stage 3 setup and need some pointers.

question:i have a 2016 4RN 2wd limited, wanted to level out with small lift do weekend adventures beach, mountains, light off road travel on lots of red dirt and gravel i recently purchased ironman's stage 2, 2.5" suspension kit Front Springs:
2.5" Lift Performance Load (0-110LBS Additional Payload)
Rear Springs:
2" Lift Performance Load (0-660LBS Additional Payload)
my question is i believe i have x-reas and will have to remove them to install the other , any advice ??? I have stock 245/60r20 and would like to go a little bigger with better terrain tire part of why I opted for the lift and i just dont like the low front ride, as well soft dirt and mud with what i have now there is no grip and spin... kind of a noobie any info will help and i have read lots as well as asked questions but cannot find exact thread for install on type and any issues with install or maybe a suggestions instead of .. thinking of cancel order since they are backorder anyway...

 

[generald]

question:i have a 2016 4RN 2wd limited, wanted to level out with small lift do weekend adventures beach, mountains, light off road travel on lots of red dirt and gravel i recently purchased ironman's stage 2, 2.5" suspension kit Front Springs:
2.5" Lift Performance Load (0-110LBS Additional Payload)
Rear Springs:
2" Lift Performance Load (0-660LBS Additional Payload)
my question is i believe i have x-reas and will have to remove them to install the other , any advice ??? I have stock 245/60r20 and would like to go a little bigger with better terrain tire part of why I opted for the lift and i just dont like the low front ride, as well soft dirt and mud with what i have now there is no grip and spin... kind of a noobie any info will help and i have read lots as well as asked questions but cannot find exact thread for install on type and any issues with install or maybe a suggestions instead of .. thinking of cancel order since they are backorder anyway...

Sounds like you have the right setup. This will reduce rake a bit but also give you some height for larger tires (with a simple push mod to the front wheel lines). The Ironman Youtube channel has install guides or Trail4Runner (Ironman 4X4 Foam Cell Pro 2/3” Lift Kit Stage 2: 5th Gen 4Runner Install) has a good step by step.

As long as you purchased them pre-assembled, should take you a day with some helping hands and only a few basic tools and an extended socket set.

Check out the guide above and happy to answer any follow ups.

 

[Terratrooper]

Hello, I'm considering the Ironman Foamcell kit. Was thinking of doing the 2" so I didn't have to do UCAs and a differential drop. Your truck looks great! What size lift did you buy from ironman and what size tires are on the SR5 wheels. I just put new 275s on my SR5 wheels and I like how they look. Thanks!

 

[RedRunner_87]

Hello, I'm considering the Ironman Foamcell kit. Was thinking of doing the 2" so I didn't have to do UCAs and a differential drop. Your truck looks great! What size lift did you buy from ironman and what size tires are on the SR5 wheels. I just put new 275s on my SR5 wheels and I like how they look. Thanks!

I am running 255/80(33x10) on my SR5 wheels. I didnt do the diff drop on my 3" kit.

 

[fmPro]

GREEN25 Discount code through 3.17.21

Hi, all. Thanks for the excellent details, install links, etc. I places order and the code GREEN25 (Through 3.17.21) got me $599 off on Pro Performance Stage 2 kit. $1799 delivered is a smoking deal and free TREDs boards included. Was looking at Icon Stage 2 and this seems very comparable kit for less.

 

[RedRunner_87]

Hi, all. Thanks for the excellent details, install links, etc. I places order and the code GREEN25 (Through 3.17.21) got me $599 off on Pro Performance Stage 2 kit. $1799 delivered is a smoking deal and free TREDs boards included. Was looking at Icon Stage 2 and this seems very comparable kit for less.

I am glad they are continuing with their killer deals. I have their green TREDs too, haven't used them yet lol

 

[Decipher]

I missed the 25% off code by a few days. Any chance we’ll extend this??? [emoji1695]


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[Tuco S.]

I missed the 25% off code by a few days. Any chance we’ll extend this???

If you sign-up for email updates on their website, they'll let you know when the next sale will hit. My guess would be somewhere around Memorial Day or 4th of July.

 

[Decipher]

If you sign-up for email updates on their website, they'll let you know when the next sale will hit. My guess would be somewhere around Memorial Day or 4th of July.

Thanks! I’ll do that.


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[JoppyJay]

The coupon code SPRING15 takes 15 percent off an order until April 15.

Think that’ll be as good as it gets or is there a chance another 25 percent off sale is coming up soon?

 

[4RNEWBIE]

Spring25

25%

 

[RedRunner_87]

Spring25

25%

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