Overland Warehouse Suspension Kits

[Overland Warehouse]

We get a lot of enquiries about our suspension systems, and thought it may be a good idea to give people background on them.

We have a lot of experience with various suspension systems on the 4Runners after driving and wheeling with them for many years, on almost every type of terrain and with various levels of modification to the vehicles. In the end we decided to build our own systems, as we saw a need in the market.

We partnered with Radflo Suspension Technology to develop our own unique systems. We have designed and tested these systems over a long period of time and with a number of our customers to come up with our (OW) valving and specific designs. Radflo provided input and manufactures the shocks for our suspensions, as well as some assemblies like the coilovers, and we also have different suppliers for other components, such as coilsprings for some applications.

In our experience it works best to match both the front and back, as well as the coils and shocks to the specific application it will be used for. We have worked with many customers to design specific systems to their needs, but we have found that the majority of customers are extremely happy with our pre designed kits. In either case we are happy to work and weigh option to see what will work best for a customer, so feel free to contact us with any questions.

We have various applications and will give some details for each, so people can understand the purpose of each better. See our website section on suspensions for each kit here:

Overland Warehouse Suspensions

 

[Overland Warehouse]

4th Gen 2.5 Heavy duty kits

4th Gen 2.5 Heavy duty kits

The 2.5 kits were designed for people looking to build up a very capable rig and potentially add some heavy accessories like bumpers, skids, etc. The 2.5 kits were set up to provide excellent control offroad for rigs carrying extra weight, while maintaining good on road manners and ride quality. Although the kit was designed for heavier vehicles a number of customers have found it very pleasant to use on road with a stock weight vehicle. The best way to describe the on road ride on a stock truck is that small road irregularities tend to be felt in the cabin more than the stock suspension, but large potholes, bumps, etc get soaked up much better than the stock suspension. Also even with the increased ride height customers find nose dive and body roll much better than the stock suspension.

The 2.5 uses beefy rebuildable and custom valveable high end shocks on both the front and the back. We matched the shocks on both axles to give consistent ride and endurance capabilities. The high end 2.5 shocks also will take a lot to get overworked, and it uses an internal reservoir floating piston assembly to separate gas and fluid for optimum performance.

On the front adjustable coilovers we used beefy 700lb/in coils, which is more than the typical aftermarket coilover assembly. We did this to help the front suspension carry the extra weight of aftermarket bumpers and winches much more easily without the need to preload the coil excessively. They still provide good on road manners with a stock weight vehicle, and only firms up once cranked down (which works nicely when you add the extra weight of a bumper, etc). These coilovers use a notched collar and hook wrenches, which we found superior to the pin style setup used on many other aftermarket coilovers (far less wear on the collar and much easier to adjust). The coilovers are adjustable from around 1-3.5” of lift (on stock weight truck it is closer to a minimum of 2-2.5” of front lift minimum).

On the rear we decided to add a few extras as well. Since most 4th Gens tend to rub a little when fully flexed out with 33” or larger tires, we decided to add bumpstop spacers to minimize that rubbing. This also gave us extra room to put a longer shock assembly in, for our extended length shocks in the back. The added benefit of the longer and bigger body is that we have a bit more fluid and cooling capacity, as the rear of these vehicles (especially when loaded) works the shocks harder than the front. Additionally we provide a brake line relocator that allows the customer to enjoy the extra length, without having to open and bleed the brake line system, as would be needed with longer brake lines. So in the end it has a bit more travel, droop flex, cooling capacity while keeping the tire form rubbing the fender, etc. We matched these shocks with high grade rear coils, that can carry much more additional weight than stock, while maintaining great on road ride and manners. The rear kit provides around 2.5” of rear lift, dependent on the vehicle (as they all seem to vary).

 

[Overland Warehouse]

4th Gen 2.0 Medium duty kits

4th Gen 2.0 Medium duty kits

As time went buy we had various requests for a more economical suspension solution aimed more at people having a daily driver that occasionally goes offroad, and don’t really plan to build a massive trail rig. In order to satisfy this need we developed the 2.0 kits.

The 2.0 kits were designed for people looking to modify their daily driver to be trail capable. The 2.0 kits were set up to provide great on road ride, while maintaining great off road control and capability. Although the kit was designed for stock weight vehicles it is still capable of carrying the extra weight of accessories, but won’t do it as well as the 2.5 kits – specifically when it comes to control offroad). As with the 2.5 kits, the best way to describe the 2.0 kits on road ride on a stock truck is that small road irregularities tend to be felt in the cabin more than the stock suspension, but large potholes, bumps, etc get soaked up much better than the stock suspension, although on the 2.0 kit the on road manners will be even better than on the 2.5 kits when it comes to the small bumps. Again even with the increased ride height customers find nose dive and body roll much better than the stock suspension.

The 2.0 uses rebuildable and custom valveable high end shocks on both the front and the back. We matched the shocks on both axles to give consistent ride and endurance capabilities. The high end 2.0 shocks uses an internal reservoir floating piston assembly to separate gas and fluid for optimum performance.

On the front adjustable coilovers we used more standard 650lb/in coils, which are found on most aftermarket coilovers. These coilovers use a notched collar and hook wrenches, which we found superior to the pin style setup used on many other aftermarket coilovers (far less wear on the collar and much easier to adjust). The coilovers are adjustable from around 0-3.5” of lift.

On the rear we use matched 2.0 rear shocks to match the performance and ride of the front 2.0 coilovers. We matched these shocks with high grade rear coils, that can carry much more additional weight than stock, while maintaining great on road ride and manners. The rear kit provides around 2.5” of rear lift, dependent on the vehicle (as they all seem to vary).

 

[Overland Warehouse]

5th Gen 2.5 Heavy duty kits

5th Gen 2.5 Heavy duty kits

The 2.5 kits were designed for people looking to build up a very capable rig and potentially add some heavy accessories like bumpers, skids, etc. The 2.5 kits were set up to provide excellent control offroad for rigs carrying extra weight, while maintaining good on road manners and ride quality. Although the kit was designed for heavier vehicles a number of customers have found it very pleasant to use on road with a stock weight vehicle. The best way to describe the on road ride on a stock truck is that small road irregularities tend to be felt in the cabin more than the stock suspension, but large potholes, bumps, etc get soaked up much better than the stock suspension. Also even with the increased ride height customers find nose dive and body roll much better than the stock suspension. These kits were based of the great success we had with the 4th Gen kits, with the required updates to best suite the 5th Gen changes.

The 2.5 uses beefy rebuildable and custom valveable high end shocks on both the front and the back. We matched the shocks on both axles to give consistent ride and endurance capabilities. The high end 2.5 shocks also will take a lot to get overworked, and it uses an internal reservoir floating piston assembly to separate gas and fluid for optimum performance.

On the front adjustable coilovers we used beefy 700lb/in coils, which is more than the typical aftermarket coilover assembly. We did this to help the front suspension carry the extra weight of aftermarket bumpers and winches much more easily without the need to preload the coil excessively. They still provide good on road manners with a stock weight vehicle, and only firms up once cranked down (which works nicely when you add the extra weight of a bumper, etc). These coilovers use a notched collar and hook wrenches, which we found superior to the pin style setup used on many other aftermarket coilovers (far less wear on the collar and much easier to adjust). The coilovers are adjustable from around 1-3.5” of lift (on stock weight truck it is closer to a minimum of 2-2.5” of front lift minimum).

On the rear we use matched 2.5 rear shocks to match the performance and ride of the front 2.0 coilovers. We matched these shocks with high grade rear coils, that can carry much more additional weight than stock, while maintaining great on road ride and manners. The rear kit provides around 2-2.5” of rear lift, dependent on the vehicle (as they all seem to vary).
Since some 5th Gen 4Runners are fitted with the KDSS swaybar system, we took care to not place excessive stress on the KDSS hydraulic pistons with extended travel shocks. This is done to help prevent premature wear on the KDSS system. If customers with NON KDSS systems would like to fit the extended length rear 2.5 kit, as found on the 4th Gen, they will need to contact us to discuss their needs. Also note that the kits need to be ordered for either KDSS or non KDSS systems.

 

[Overland Warehouse]

5th Gen 2.0 Medium duty kits

5th Gen 2.0 Medium duty kits

This is a more economical suspension solution aimed more at people having a daily driver that occasionally goes offroad, and don’t really plan to build a massive trail rig. In order to satisfy this need we developed the 2.0 kits. These kits were based of the great success we had with the 4th Gen kits, with the required updates to best suite the 5th Gen changes where needed.

The 2.0 kits were designed for people looking to modify their daily driver to be trail capable. The 2.0 kits were set up to provide great on road ride, while maintaining great off road control and capability. Although the kit was designed for stock weight vehicles it is still capable of carrying the extra weight of accessories, but won’t do it as well as the 2.5 kits – specifically when it comes to control offroad). As with the 2.5 kits, the best way to describe the 2.0 kits on road ride on a stock truck is that small road irregularities tend to be felt in the cabin more than the stock suspension, but large potholes, bumps, etc get soaked up much better than the stock suspension, although on the 2.0 kit the on road manners will be even better than on the 2.5 kits when it comes to the small bumps. Again even with the increased ride height customers find nose dive and body roll much better than the stock suspension.

The 2.0 uses rebuildable and custom valveable high end shocks on both the front and the back. We matched the shocks on both axles to give consistent ride and endurance capabilities. The high end 2.0 shocks uses an internal reservoir floating piston assembly to separate gas and fluid for optimum performance.

On the front adjustable coilovers we used more standard 650lb/in coils, which are found on most aftermarket coilovers. These coilovers use a notched collar and hook wrenches, which we found superior to the pin style setup used on many other aftermarket coilovers (far less wear on the collar and much easier to adjust). The coilovers are adjustable from around 0-3.5” of lift.

On the rear we use matched 2.0 rear shocks to match the performance and ride of the front 2.0 coilovers. We matched these shocks with high grade rear coils, that can carry much more additional weight than stock, while maintaining great on road ride and manners. The rear kit provides around 2-2.5” of rear lift, dependent on the vehicle (as they all seem to vary).

Since some 5th Gen 4Runners are fitted with the KDSS swaybar system, we took care to not place excessive stress on the KDSS hydraulic pistons with extended travel shocks. This is done to help prevent premature wear on the KDSS system. Also note that the kits need to be ordered for either KDSS or non KDSS systems.

 

[Overland Warehouse]

In additon to the full suspension kits we also sell the front and rear kit seperately on the website.

We also have a remanufacturing program where customer can order remanufactered suspensions, swap it out and send the old core units back to us. Details available on request.

Please contact as at info [at] overlandwarehouse.com for any questions.