We all want a 4-wheel drive vehicle that can do everything well. Some would say this is impossible, but unless you need a purpose-built rig for just one type of terrain, there are quite a few candidates to choose from. I recently purchased a stock ‘96 Toyota 4Runner to be my all purpose vehicle for traveling, desert race chasing, camping, trail wheeling, surfing, and getting the groceries.

It became pretty evident that the only dirt Toyota anticipated this SUV to see was that of a light trail or dirt road. I wanted larger tires with minimal lift to gain ground clearance, increase suspension travel and significantly improve its performance both on the street and the trail. It seemed like a tall order without major modification and a wad of cash, but read on, the answer is easier than you think.

In most cases in order to improve our truck’s off-road capabilities the on-road handling has to suffer. In the past you really only had two choices, either install a stiff riding “lift-kit” or break out a box of sawz-all blades.

[pic Project FUNrunner: The grocery getter before the storm]

Well, times have changed and there are a few truly talented companies that can build a suspension system to improve the entire character of your rig. Leading the charge in the battle for the perfect real world suspension system are the master fabricators at Total Chaos Fabrication. The pros at Total Chaos are developing state of the art suspension systems to improve all areas of your truck/SUV. Their long-travel suspension kit was the perfect solution for our 4-Runner. The Total Chaos long travel kit includes longer fully boxed upper and lower tubular A-arms, upper Uni-balls, polyurethane bushings, extended braided stainless steel brake lines, longer steering tie rods, and adjustable limit straps.

Also shown are the Sway-A-Way shocks (not included in the kit)

Unlike most aftermarket upgrades that require trip after trip to the hardware store, Total Chaos includes all the bits and pieces you will need right down to the last bolt and washer. Since there are many choices in spring rates and shocks, you will have to make the choice when it comes to shocks, and coils. You will also have to source your own longer front inner axles or order them in the kit from Total Chaos. TC supply’s step-by-step instructions that are almost perfect, so I’ll spare you the details and stick to the high-lights. For shocks I opted for the race proven quality of Sway-A-Way. Their new line of shocks are manufactured with the best materials and coatings available. Whether it’s bashing rocks, sand blasting through the desert or dealing with corrosion from the ocean, these shocks are built to take it. Total Chaos offers a valuable secondary shock hoop upgrade for those that plan on using their prerunner for heavy desert bombing and high-speed wheeling. My budget was limited to only adding an additional pair of 2 1⁄2 inch emulsion shocks but an external bypass shock is recommended for its tune-ability if you are going to go this route.

Running dual shocks is probably overkill and not necessary for the occasional wheeler, but does add a lot of durability and a little bling to the overall package.

If you think you can save some cash and purchase the longer axles down the road, you can’t. You will have to suck it up and buy the longer axles at the time of installation. To save some money you can go to the junk yard and pull some factory axles out of the front of a Toyota Tundra. But you will have to swap out the CV Boots on the Tundra axles with a set of Porsche boots. You will also have to trim the metal on the mounting surface on the Tundra shafts slightly for the boots to fit properly. If this sounds like too much running around and you’re not excited about crawling around in the dirt at the local junk yard, there is an easier option. The complete axles with high-angle boots can be purchased from Total Chaos as part of the package. These simple plug-n-play axles are complete with new shafts and the Porsche boots for about $75 more than what you would spend doing it all yourself.

It’s your call, but we went the easy route and just bought it all from Total Chaos. In addition to new axles and shocks you will want to invest in a set of fiberglass front fenders at some point. The TC kit will have you sitting 7” wider so fiberglass fenders are necessary to can take advantage of the 13” of travel and have a place to stuff your tires when the going gets rough. I have yet to make this final purchase and have chased the Baja 500, and Vegas to Reno races without incident. But the day will come when my penny pinching will bite me in the butt and the tires will take out my fenders.

Tips to make your install easier:

- Read the directions. Total Chaos gives you easy to follow step-by-step instructions. Follow them and if you get a sticky point do not be afraid to give them a call.

- Allow a day or two extra for teardown and button up. Tearing out the old takes longer than it would appear and taking the time to do it right is worth the extra effort.

Before and after. See the difference?

- Let it soak: Day’s prior to your teardown squirt every nut and bolt down with PB Blaster or WD-40. My 4Runner spent a little time back east and its older rusty hardware put up a good fight.

- Get good help. Can you do it by yourself in a weekend’s time in your driveway? Yes, but it will tax your Christianity. I cannot express enough how valuable the help was that I received from Long Beach Racers. Not only did they let me use their shop, but newlywed Matt Weal, LBR co-dog and TRD Product Developer helped me with all the sticky parts.

Matt W: Hey, he just got married, he’s allowed to talk on the phone!

- Make a trip to the dealership to purchase hardware: Buy a couple camber sub assembly bolts from Toyota (part #48409-35050) prior to the install. My old Toyota bolts were frozen solid requiring a torch to remove. Other Toyota parts that were replaced were caliper bolts (part#90080-10129), hub oil seal(s) (part#90316-69001 & 90312-95001) and ball join/steering arm bolts. All were replaced with factory Toyota hardware. The upper ball-joint must be pressed out of the spindle. Total Chaos makes a tool for this purpose that costs only $15, money well spent and a good tool for the pit box.

- Change out the steering rack bushings with the polyurethane kit TC offers. You're already under the truck, now is as good a time as any to change them out.

- Get your shocks valved: When ordering your shocks, no matter what color you chose, remember a shock is only as good as its valve job. Brian Bell of Sway-A-Way valved all four of my shocks per my application and it made a world of difference. Let Sway-A-Way know what your application is and request the appropriate valving when purchasing them.

Brian Bell of Sway A Way tuning my shocks.

- Request 90degree hose fittings on your shocks, otherwise your hose will rub on the upper arms.

Sway A Way hose: Hose without 90 degree fitting will rub on upper arm.

- Measure your steering angle: Factory steer-stops will hit the boxed arms sooner requiring them to be ground slightly. Grind only a little at a time to get back to the stock angle, taking too much off will put undo stress on your new axles.

- Uniballs don’t like power washes: Keep the high-pressure away from the uniball and lubricate them for noise free use with a dry lubricant.

- After you play a few hundred miles, re-torque EVERYTHING!

Negatives of the install:

- All this performance does not come cheap. By the time you purchase the kit, shocks, axles and fenders you will spend some Benjamin’s. Keep in mind this isn’t a kit for the “bro’s” out there that want a blinging ride-high look-at-me “lift kit.” Total Chaos and Sway-A-Way products are for the serious offroader that demand a return on performance. You will not be disappointed this setup is worth every penny spent.

- I would have preferred longer stainless steel brake lines.

- The TC suspension system goes together real easy, but I was not prepared for the fight to tear out the old.

- Trying to wipe the smile off your face when you’re bombing through the desert.

Total Chaos Fabrication LT kit Parts Included:

> Upper A-Arms W/ Bushings, Uniballs, & Clips

> Lower A-Arms W/ Bushings, Shock Mounts

> Tie-Rod Extensions o Uniball Spindle Adapter Slugs & Retaining Clips

> Braided Stainless Brake Lines D.O.T. Approved

> Bolt-on Upper Shock Mounts - Specify Brand

> Hardware

> Adjustable Limit Straps & Mounts

Limit Straps: Total Chaos kit is complete down to the washer and their limit straps adjust for straps stretching.

Parts NOT Included:

> Shocks (required for install)

> Fiberglass Fenders ( highly recommended)

> Modified 4WD Tundra Axles to retain 4WD (required for install)

TC Accessories:

> Dual Shock hoop for 8" Travel Secondary Shock *

> Tacoma Steering Rack Urethane Bushing Replacement Kit *

> Modified Tundra axles to retain 4WD *

> Weld-On Spindle Gussets *

> Ball joint removal and slug adapter installation tool *

> Heim-Joint Tie Rod upgrade *

* Accessories the author purchased from TC

TC installation tool and preassembled axles will save you precious time and the Spindle Gussets will add to your strength.

I have now chased 3-major desert races, crawled around Moab and Johnson Valley’s rocks as well as driven over 15,000 miles on this suspension system this summer. Outside of an alignment and keeping things greased, it has been maintenance free. My only regret has been not purchasing fiberglass fenders from the start and not going with the bypass shocks as my secondary shock. This suspension system has turned my 4Runner into a FUNRunner, it now has the off road performance to let me chase high speed desert races and still returns a comfortable and safe ride for street driving. The 4-Runner is a joy to drive and the Total Chaos system is worth every ounce of sweat and every penny spent. Stay tuned, the next step is adding some much needed suspension travel to the rear so that it works as well as the front.

Steve Hansen is the Chaplain for Rockcrawlers For Christ and he and his ministry can be reached here.

By Steve Hansen