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  • The 90 series suspension upgrade guide

    Here's a collection of suspension options available to 90 series Prado owners.
    - If you have general questions please post them in a relevant thread (not here), or create a new thread.
    - If you'd like to provide input into this thread, or question any specific contents of this thread, please send me a PM, or reply here if appropriate.

    DISCLAIMER:

    - You are responsible for checking the legalities of your modifications in your state/territory/country.
    Last edited by glen_ep; 09-04-2015, 01:01 AM.
    glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

  • #2
    Re: The 90 series suspension upgrade guide

    Made into sticky to keep it at the top.

    Please only post firm information, links to info or DIY threads and sites in this thread.

    Post any questions in the linked/relevant threads or start a new one if none exists.

    Questions or general comments will NOT be accepted in this thread. It's an information guide only.

    Mick
    Last edited by MickL; 29-08-2011, 09:32 PM.
    [CENTER][B][I][SIZE=1][COLOR=blue]1KZ-TE Turbo Diesel, 5 speed manual, 3.5 inch lift, 265/70/17 Mickey Thompson MTZ, D-Tronic chip, Boost controller, mandrel exhaust, dump pipe, modified intake, ARB steel bar, Magnum winch, Safari snorkel, rear drawers, half cargo barrier, dual batteries, Uniden UHF, Sat Nav, reverse camera, Magellan XL , Tjm bash plates, ARB alloy roof rack, rear telescopic work light and numerous other modifications!!!
    Now with 3BAR MAP sensor & 18PSI Boost![/COLOR][/SIZE][/I][/B][/CENTER]

    Comment


    • #3
      Re: The 90 series suspension upgrade guide

      also for a 3" lift, allpro offroad in the usa supplies a coil over for the front that is adjustable from 0" to 3" lift, but due to a slightly diffrent design upper control arms do not need to be replaced, although it will hold alignment better if the upper control arms are replaced

      link here:
      http://www.allprooffroad.com/9602frontsuspension/299

      they also supply a 3/4 inch diff drop

      http://www.allprooffroad.com/9602fro...n/9602diffdrop

      for the rear 80 series standard front coils and standard rear shocks will lift the rear 3" although it will require bump stops to be extended my 10 mm

      adjustable panhead rods for the 3rd gen 4runner will fit as suspension and chassis are the same
      1997 3.4 V6 Rv. mods; 1 1/2 inch bodylift, 285/75/R16 cooper STTs, 16x8 sunraysia style black steel rims '0' offset, 2 inch heavy duty springs, bilstein shocks (80 series rear), GME remote mounted UHF.

      Comment


      • #4
        Re: The 90 series suspension upgrade guide

        hey there Glen, was looking at the sonoran steel webpage, looks like they do a kit for the 3rd gen 4Runner that should fit and comes with everything you need to go anywhere up 3.5 inches of lift....(also can choose between rear shocks to suit just offroad or to suit load carrying aswell )

        im getting one of them,
        1997 3.4 V6 Rv. mods; 1 1/2 inch bodylift, 285/75/R16 cooper STTs, 16x8 sunraysia style black steel rims '0' offset, 2 inch heavy duty springs, bilstein shocks (80 series rear), GME remote mounted UHF.

        Comment


        • #5
          TYRE SIZES AND MODIFICATION REQUIREMENTS


          STANDARD SIZES:

          30" on RV6
          Tyres: 215/80/16 (29.5")
          Rim: 16x7 +30 offset

          31" on GXL
          Tyres: 265/70R16 (30.6")
          Rim: 16x7 +15 offset



          UPGRADE SIZES:


          32" in 265/75R16 - (most popular)


          2" suspension lift

          PRO: Simple, effective, affordable, insurable.
          CON: Not extreme enough for some of us.

          + Front Coils and Struts - Various brands available (Bilstein, Dobinsons, OME, Ironman, EFS, KYB, Tough Dog, etc)
          + Rear Coils and Shocks - Various brands available (Bilstein, Dobinsons, OME, Ironman, EFS, KYB, Tough Dog, etc)
          + Tyres: 265/75R16 (31.6") will fit without rubbing.
          + Rims: Original GXL are fine (+15), alternatively aftermarket 0 (zero) offset rims are ideal for tyre placement under GXL wheel arches, but some rubbing may occur under extreme articulation.
          + ~Extended sway bar connects recommended but not required.



          33" in 285/75R16 or 255/85R16


          * via "tubbing" aka cutting/enlarging of wheel arches

          PRO: Large tyres + high clearance, very low center of gravity
          CON: None if DIY. Cost if paying a professional.

          + Any 2" lift as described above.
          + Tubbing ~$2,000+ AUD
          + Tyres: 285/75R16 (32.8") or 255/85R16 (33.1")


          * via 2" suspension lift and 1-2" body lift

          PRO: Simple, effective, affordable, insurable, raises body and main tank from potential damage.
          CON: Chassis and aux tank are still low as per suspension lift

          + Front Coils and Struts - Various brands (as above)
          + Rear Coils and Shocks - Various brands (as above)
          + Rear handbrake cable bracket - Custom relocation bracket for cable
          + Body Lift (requires several mods - to be detailed separately)
          + Tyres:
          ....285/75R16 (32.8") on stock +15 offset rims - causes rubbing (perform wheel flare mods/cutting).
          ....285/75R16 (32.8") on 0 offset rims brings tyres close to GXL arches - causes rubbing (perform wheel flare mods/cutting).
          ....255/85R16 (33.1") on stock +15 offset rims - no rubbing!.
          ....255/85R16 (33.1") on -13 offset rims brings tyres close to GXL arches - causes rubbing (perform wheel flare mods/cutting).
          + Other - Front wheel arch/body seam mods (tyre dependant, as above)
          + ~Extended sway bar connects recommended but not required.


          * via 2.5-3" suspension lift

          PRO: Arguably the most capable option.
          CON: The most complicated to setup and perfect, the most expensive and the least reliable. All components, CV's, bushings, ball joints will be under greater stress than any other options, so will fail prematurely.

          + Front Coils and Struts - Stay with 2" 90 series struts, but note some can flex further than others. Coils - too many possibilities to list here. Depending on your weight (engine, bar, winch, batteries) you may be able to use the most HD 2" 90 coils available. For heavier rigs look at 120/150 series coils (lifted ones, but they're already much firmer so don't get the most HD ones) - having access to specifications is really quite important to get the right results. Spacers can also be used but consideration must be made for topping out and damaging the shocks.
          + Front UCA (upper control arm) - to avoid UCA binding with tyres and/or coils.
          + Front diff drop 1.5" - to slightly reduce CV angles
          + Rear coils - LC80 standard FRONT coils (original sagged ones). If using aftermarket standard height coils instead, expect height to be anywhere from 3.5-5" !
          + Rear shocks - LC80 0-2" REAR shocks. LC100/105 rear shocks can also be used, but note their upper pin is thicker (stronger ) and you'll need to use the 90's lower bushings, 100/105's upper bushings.
          + Rear brake line extension - extend single center hose
          + Rear handbrake cable bracket - Custom relocation bracket for cable
          + Rear handbrake cable extension - extend cable or modify handbrake leaver
          + Rear bump stops - extended bump stops to avoid topping out the shocks
          + Tyres:
          ....285/75R16 (32.8") on stock +15 offset rims - causes rubbing (perform wheel flare mods/cutting).
          ....285/75R16 (32.8") on 0 offset rims brings tyres close to GXL arches - causes rubbing (perform wheel flare mods/cutting).
          ....255/85R16 (33.1") on stock +15 offset rims - no rubbing!.
          ....255/85R16 (33.1") on -13 offset rims brings tyres close to GXL arches - causes rubbing (perform wheel flare mods/cutting).
          + Other - Front wheel arch/body seam mods
          + ~Extended sway bar connects recommended but not required.



          35"


          * via 4-6" lift aka "drop lift" kit

          PRO: Can instantly fit large tyres and provides a very large appearance. Rear suspension can be designed for extreme flex.
          CON: Cost. Structural changes are irreversible. No added clearance is gained under the front diff, due to added cross member.

          + 4-6" lift kit using a 2-4" front diff drop via lowered front cross member, eg, http://www.caloffroad.com.au/product...ifspre2005.htm
          + Rear brake line extension - extend single center hose
          + Rear handbrake cable bracket - Custom relocation bracket for cable
          + Rear handbrake cable extension - extend cable or modify handbrake leaver
          + Rear bump stops - extended bump stops to avoid topping out the shocks
          + Tyres: 33-35"


          * via "tubbing" aka professional enlarging of wheel arches

          PRO: Large tyres + high clearance, very low center of gravity
          CON: Cost

          + Any 2-3" lift as described above.
          + Tubbing ~$2,000+ AUD
          + Optional - arctic style flares
          + Tyres: 33-35"
          Last edited by glen_ep; 02-05-2016, 11:57 AM.
          glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

          Comment


          • #6
            EXAMPLES
            If you have something different, please send your specs to me via PM, and I'll add them here.


            Original GXL
            Front Suspension: Originals
            Rear Suspension: Originals
            Tyres: Original 265/70R16 (30.6")
            Load: Unknown (various sources)
            Age of suspension: Many years
            Rim-to-Flare measurements:
            - Front: 730 ~ 745 ~ 753 mm
            - Rear: 725 ~ 740 ~ 755 mm
            Articulation measurements: Unknown


            2" suspension - OME medium - 6 months
            Front Suspension: OME 2881 coils with 90004 struts
            Rear Suspension: OME 2890 coils with 60028 shocks
            Tyres: 265/75R16 Mickey Thompson MTZ
            Load: Steel bull bar. Third row seats removed. Toolbag in the rear.
            Age of suspension: Maybe 6 months
            Rim-to-Flare measurements:
            - Front right/left: 776 / 776 mm
            - Rear right/left: 794 / 798 mm
            Articulation measurements:
            - Front left droop / right compressed: 820 / 677 mm = Front travel: 143 mm (~5.5")
            - Rear right droop / left compressed: 1026 / 572 mm = Rear travel: 454 mm (~18")
            Owner's mod page: http://www.pradopoint.com/showthread...ting-broken-in


            2" suspension - OME heavy
            Front Suspension: OME 882 coils with OME N91S struts, Sonoran Steel front diff drop
            Rear Suspension: OME 892X coils with N86 shocks
            Tyres: Originals
            Load: Front winch with minor bar work. Third row seats removed.
            Age of suspension: 1 month (expect further sag)
            Rim-to-Flare measurements:
            - Front (left / right / avg): 808 / 805 / 806 mm
            - Rear (left / right / avg): 820 / 811 / 815 mm
            Articulation measurements:
            - Front (extended / compressed): 890 / 690 mm = Front travel: 200 mm (7.9") * Not confirmed, but with this kind of figure, the sway bar was probably removed.
            - Rear (extended / compressed): 990 / 670 mm = Rear travel: 320 mm (12.6")
            Owners's mod page: http://www.pradopoint.com/showthread...t-installation


            2-3" suspension
            Front suspension: Coilovers by Icon Vehicle Dynamics (previously Donahoe Racing), Total Chaos Upper A-Arm, Sonoran Steel tapered diff drop, sway-bar disconnected
            Rear suspension: Pedders H/D springs, 2.5 coil spacers, 3rds Productions adjustable Panhard Rod, Rancho RS5000 shocks, Sonoran Steel handbrake relocation bracket, Sonoran Steel Progressive Bump Stops
            Tyres: 285/75R16 ProComp XTerrain
            Load: Unknown
            Age of suspension: Unknown
            Rim-to-Flare measurements: Unknown
            Articulation measurements:
            - Front droop / compressed: 895 / 625 mm = 270 mm (10.5") *sway-bar disconnected
            - Rear droop / compressed: 1020 / 615 mm = 405 mm (16")
            Last edited by glen_ep; 09-04-2015, 10:45 PM.
            glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

            Comment


            • #7
              PART LINKS


              BODY LIFT:

              - aluminium full kits in sizes 1", 1.5", 2", 2.5" and 3" from http://www.ebay.com.au/usr/glen_ep2 (contact me via PP, FB or email for discounts)
              - plastic kits in sizes 1" and 2" from http://www.luxlifts.com.au/toyota/to...rado-90-series (steering spacer not included)
              - glen_ep's steering spacers in 1", 1.5", 2", 2.5" and 3" http://www.ebay.com.au/usr/glen_ep2 (contact me for discount)
              - 1.5" aluminium full kit from UK http://www.milneroffroad.com/toyota-...it-1-12-inch-0



              FRONT DIFF DROP (minor drop to improve CV angle):

              - glen_ep's 1" tapered diff drop (contact me via PP, FB or email for discounts):
              http://www.ebay.com.au/usr/glen_ep2

              - Total Chaos 1" diff drop:
              http://www.chaosfab.com/96-02-4Runne...cessories.html

              - Sonoran Steel, 1" tapered diff drop:
              http://www.sonoransteel.com/

              - Toytec 1" diff drop:
              http://www.toyteclifts.com/index.php...=130&Itemid=72

              - All-Pro's 3/4":
              https://www.allprooffroad.com/9602frontsuspension/280



              FRONT DIFF DROP (full cross member drop for 4-6" lifts):

              - Fab Tech product a 6" Tacoma kit which may work
              http://www.fabtechmotorsports.com/TO...SYSTEMS-c1274/

              - Tuff Country produce 5" and 6" Tacoma kits which may work
              http://www.tuffcountry.com/lift-kits/toyota/tacoma/



              FRONT UPPER CONTROL ARMS:

              - Light Racing with large BALL JOINT and camber/caster adjustments, PT #LR25460 for 95-04 Tacoma and 96-02 4Runner:
              http://www.spcperformance.com/
              http://www.sonoransteel.com/
              http://eastsidecustomtruck.com/
              http://www.toyteclifts.com/ * Toytec delivers internationally via www.bongous.com

              - Total Chaos with 1" Uni-Ball PT# 96500:
              Australian local distributer: Wizard Performance in NSW * Unconfirmed!
              http://www.wheelersoffroad.com/
              http://www.chaosfab.com/

              - Camburg with 1" uniball:
              http://www.wheelersoffroad.com/
              PDF Information Sheet from http://www.camburg.com/
              PDF Information Sheet from http://www.camburg.com/

              - All-Pro with 1" uniball:
              https://www.allprooffroad.com/9504fr...sion/9504aarms



              FRONT *ADJUSTABLE* COILOVERS:

              - All-Pro/Bilstein combo and Fox Racing Shox:
              http://www.allprooffroad.com/9602frontsuspension

              - Icon Vehicle Dynamics (previously Donahoe Racing)
              http://www.iconvehicledynamics.com
              http://www.wheelersoffroad.com/
              http://www.trdparts4u.com/ - OR - http://www.trdparts4u.com/

              - Light Racing LR-Max, 0-3.5" lift, shock width of 2.5", part #25310 (suitability is uncertain)
              http://performance-curve.com/toyota4...coilovers.aspx
              http://www.polyperformance.com/

              - Sway-A-Way, 0-3" lift, shock width of 2" or 2.5", parts #52000-108-9 or #56000-108-9
              http://www.swayaway.com/VehicleMake_4.php
              [urlhttp://www.wheelersoffroad.com/9602donahoe4runner.htm[/url]
              http://www.offroadwarehouse.com/
              http://www.offroadwarehouse.com/

              - Toytec/Bilstein combo (up to 3.5"):
              http://toyteclifts.3dcartstores.com/...2-4R_p_42.html



              REAR ARMS & PANHARD:

              - glen_ep's super heavy duty rear control arms (contact me via PP, FB or email for discounts). Upper is listed, other arms made on order:
              http://www.ebay.com.au/usr/glen_ep2

              - Total Chaos Extreme Rear Links: Panhard, 2x upper and 2x lower, all adjustable with Heim joints
              http://www.chaosfab.com/96-02-4Runne...cessories.html

              - Toytec complete rear adjustable DOM link kit
              http://toyteclifts.3dcartstores.com/...Kit_p_140.html

              - Sonoran adjustable panhard:
              http://www.sonoransteel.com/index.php?m ... cPath=1_11



              Extended Sway Bar Links


              - glen_ep's Aussie made sway bar disconnects (contact me via PP, FB or email for discounts).
              http://www.ebay.com.au/usr/glen_ep2

              - 30mm longer from Wholesale Suspension in Western Sydney. Part numbers LP95FRONT and LP95REAR.
              Contact: www.wholesalesuspension.com.au
              Photos: photo 1 and photo 2



              EXTENDED BUMP STOPS:

              - glen_ep's 1" rear bump stop spacer (contact me via PP, FB or email for discounts):
              http://www.ebay.com.au/usr/glen_ep2

              - Sonoran Steel:
              http://www.sonoransteel.com



              HAND BRAKE BRACKET:

              - Sonoran:
              http://www.sonoransteel.com



              LSPV bracket (Load Sensing Proportion Valve):

              http://toyteclifts.3dcartstores.com/...Kit_p_134.html



              Long Travel kits:

              http://toyteclifts.3dcartstores.com/...r-_p_1021.html



              Heavy Duty CV axles:

              http://toyteclifts.3dcartstores.com/...les_p_185.html
              Last edited by glen_ep; 24-07-2016, 06:51 PM.
              glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

              Comment


              • #8
                reserved
                Last edited by glen_ep; 09-04-2015, 10:45 PM.
                glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

                Comment


                • #9
                  Want to make your Prado a high speed racer? Here's a long travel solution from Total Chaos - but you won't ever get it engineered for road worthy in Australia!

                  http://www.chaosfab.com/96-02-4Runne...Kit-96000.html



                  A couple things to consider:
                  - It's only a front end solution, so you'll need to find a suitable rear axle which is 7" wider than stock. Ideas anyone?
                  - Standard Prado CV axles are too short, so you will have to purchase their modified Tundra CV axles.
                  - 7" wider track means your tyres will be sticking completely outside your body/flares!
                  Last edited by glen_ep; 09-04-2015, 09:51 PM.
                  glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

                  Comment


                  • #10
                    Total Chaos has developed a brand new product to improve the rear articulation and reduce damage to mounts. Looks brilliant!

                    96450 Chromoly Adjustable Rear Links - 96-02 4Runner


                    TOTAL CHAOS offers a complete chromoly rear link system for the 96-02 4-Runner that provides an additional 1.5” of wheel travel. Factory Toyota rear rubber bushings bind when your suspension cycles and can limit wheel travel and articualtion. TC upper, lower and pan hard bar links are built using 1 ” x .375 chromoly tubing. Designed to be trail adjustable, these links are tapped on one end and utilize a 7/8” heim for maximum articulation and tune ability. TC supplies all necessary hardware and hi- misalignment spacers required to install this bolt on conversion. The opposite ends of the upper and lower links include gusseted pivots that feature zerk fittings and use replaceable urethane bushings and an inner sleeve that eliminate any pivot resistance. TC allows you to lubricate these urethane pivots through factory access holes on the chassis for convenient maintenance. Lower links incorporate emergency brake line tabs needed to reinstall the factory lines. The TOTAL CHAOS pan hard bar is tapped on both ends and is fully adjustable utilizing ” heims to offer maximum adjustability and strength. This package can be purchased individually. It reuses factory hardware and each link is shipped pre set to a factory replacement spec length.

                    http://www.chaosfab.com/96-02-4Runne...cessories.html
                    Last edited by glen_ep; 27-10-2015, 09:41 AM.
                    glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

                    Comment


                    • #11
                      See my build up thread for what's involved in modifying the front body seam and both front/rear flares:

                      http://www.pradopoint.com/showthread...oken-in/page12
                      Last edited by glen_ep; 14-12-2011, 06:14 AM.
                      glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

                      Comment


                      • #12
                        you have put alot of effort into this, good job!
                        75 Series Cruiser No More
                        Replaced with a G6E Turbo
                        95 Series Prado [url]http://www.pradopoint.com/showthread.php?19936-Beast2h-s-Prado[/url]

                        Comment


                        • #13
                          Isthere a listing somewhere of what extended sway bar links I can use for three inch lift?
                          1997 Vx Grande green/silver
                          Mods done and mods to come ! Search for my build

                          Comment


                          • #14
                            I wish I knew an answer to that! I did find some guy in USA making/selling some, but they were quite backyard-ish. If insurance/crash inspectors saw them...eeesh. If you find something, please let us know!

                            Oh, our original front connections are longer than the rear, so could potentially be used on the rear. However, the bolt size is different.
                            glen_ep - engineered, 4" lift, 33" 255/85R16, lockers, 4.88 ratios www.pradopoint.com.au/showthread.php?17237 www.youtube.com/user/glenep www.fb.com/groups/ToyotaPrado90

                            Comment


                            • #15
                              The 2nd gen 4Runner (1990-1995) rear sway bar links are way longer; even longer than our front sway bar links.

                              I buy ones from ebay. I have 80 series front coils in the rear of my Prado. For my opinion, a must do.

                              Cheers
                              Prado RZJ90. OME 881 coils Nitrocharger Sport shocks front, 80 Series front coils & rear 80 series Tokico shocks rear, 255/85R16 Cooper Discoverer ST, Viper rocksliders, parking brake cable rear axle bracket, extended rear brake line, extended diff breathers, headers, engine perfomance mods, soon LR upper control arms, ARB rear locker in the future.

                              Comment

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