New RCD Suspension Installation Pictures....

Downsouth Motorsports and RCD Suspension have teamed up to unvail the new 4.5" suspension system for 2005-2009 Toyota PreRunner and 4WD Trucks.

We were given one of the first kits available on the market to install and test on one of our own vehicles. We jumped at the opportunity to illustrate the installation process and what to expect when purchasing this kit. We hope to also educate members who are unfamiliar with the lower control arm style suspensions systems how the kit works.


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Starting Point



We started with a 2007 Tacoma Double Cab TRD PreRunner that previously had a aftermarket 3" coil over kit installed. Because of the RCD kit'suse of a full length Bilstein strut the factory springs and mounting plates are required.



Once we had recived the suspension system from RCD we then headed to a local shop to utilize a Hydrolic Truck Lift. Fist step in any instalation is to lift the vehicle off the ground securely and safely in preperation for tear down. Once the truck is ready to be lifted off the ground remove the negitive side of thae battery cable, once removed lift the truck and check for stability.





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Inspection of existing suspension components that will be reused in the kit

After the truck is off the ground remove the tires and wheels from the vehicle. Check tires for improper wear that can be caused by faulty suspension parts. The key to a quality install is starting with a mechanically sound platform so to achieve best results and longevity.



Checklist of parts that are re-used in this kit:

1. Upper and Lower Ball Joints:
Inspect for torn or cracked boots, play in ball socket, up and down movement of ball, grease if needed

2. Tie Rod Ends:
Inspect for torn or cracked boots, play in ball socket, up and down movement of ball, grease if needed

3. Hub Bearing Assembly:
Inspect for slightest movement in hub, Listen for noises, check for debris in spindle

4. Brake System and ABS:
Check for worn pads, discolored or grooved rotors, bent lines, any dash lights indicating system failure

5. Steering Rack:
Check rubber mounts for failure, play in steering wheel, leaking lines

6. Rear Leaf Springs:
If you have the 3 leaf pack you may be eligible for the Toyota TSB which will replace the faulty packs for the new 4 leaf packs. Check with your local dealer to see if you qualify.


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Ohh excited to see it all done!!!!

 

Tear Down

Once all the suspension components are inspected for safety we found that our truck needed a ABS sensor that had previously not been properly secured out of the wheels travel, resulting in a hole in the plastic lining. We also cam e across the passenger side wheel bearing that had a marginal amount of movement and had noise. With the wheel bearing being such an important part of the suspension we decided to order a new one along with the ABS line from the dealer. Now that the parts were on there way we started with tear down, First we removed the sway bar from both ends of the truck at the spindle. After that we then removed the frame brackets that held it to the frame, Next we removed the bolts holding the calipers to the spindles and removed rotors and calipers. We made sure to secure the calipers with zip ties to the frame to prevent stretching of the hard brake lines



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subscribed..patiently waiting

 

Removing the strut assembly or coil over

After the brake system had been safely removed we moved on to the strut removal or in this case the coil over. First we removed all cotter keys from ball joints and placed a screw jack under the lower control arm next to the ball joint. Once securely placed we lowered the rack to compress the suspension and preload the coil over to remove the upper ball joint from the spindle. Now that the suspension was compressed we removed the nut holding the spindle to the ball joint. Due to the taper in the ball joint you may require to shock the joint in order to separate. We did this with a small sledge hammer hitting the designated area by the top of the spindle close to the joint. Once separated we were able to lift the truck and slowly remove the screw jack. Now the spindle can be separated from the lower control arm by removing the two bolts in the bottom of the spindle. Once removed set aside for hub removal, next remove the lower control arms and place under truck for next step.


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^^^I'll jump on the wagon as well.................

 

Swapping the stock coils on to the new Bilstein 5100 replacement struts



To complete this step properly we needed to use a strut compressor. This is dangerous if the right tools are not used due to the preload on the coil springs. We first placed the O.E. strut in the compressor and aligned the body to be straight, next we screwed down the fingers that grab the coil spring and secured them. Once the springs were secure we compressed them and removed the top strut bolt and removed the original strut.



Now that the spring was secured in the compressor we were then able to install the new Bilstein 5100 strut in its place. RCD supplies the struts with new bushings and bolts for quality, after installing mounting plates and nuts we released the tension to the struts with the compressor.




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Installing the lower control arm drops, Spindles and Struts

First we laid out the entire kit on the ground and located the drops, then we located the hardware needed to install the drops. Once in place we loosely installed the bolts securing the crossmember to the existing lower control arm holes both front and rear. Next we installed the lower control arms to the crossmembers using the original alignment cam bolts.




Next we bolted the new replacement strut into the top bucket and secured the lower eyelet of the strut into the lower control arm.




Now we are ready to swap the original hub assemblies to the new spindles, remove the O.E. hubs from the O.E. spindles and install on new RCD lift spindles. Make sure to tighten to proper torq specs and use Lock-Tite and all hub bearing bolts. Now we were ready to bolt the new spindles up to the lower controll arms using the 2 original bolts.Next we checked for proper torq on the spindle bolts then again placed the screw jack under the lower control arm in order to preload the suspension again for assembly. Then again we lowered the rack onto the screw jack and connected the spindle to the upper ball joint then tightened to spec and installed cotter keys.


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Installing the Brake System and bump stop drops

Next we installed the rotors and calipers to the new spindles and attached the brake lines to the spindles as well. Once the lines were secured on the spindle we installed the drops to the frame mounts. After the brake lines were solid we then attached the ABS sensor to the spindle and roughted the line properly securing it with addel clamps and zip ties. After checking for clearance of suspension travel as comparison to brake and BBS lines we then installed to the lower bump stop drops using the supplied hardware.




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Lateral Compression Struts

RCD was the first to introduce the lateral compression struts and crossmember drop kits which revolutionized off road industry! The struts are designed to reinforce the new crossmembers for stability and impact. They are made of high polished stainless steel and add great looks to the kit. They are connected with a set of polyurathane bushings and sleeves which are mounted to the frame using the supplied brackets.



Since our truck is a 2WD we didnt use the differential drop pieces that come with the kit, however we installed the diff skid plate that is supplied in the kit.
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Installing Tires and Double Checking Work

The next step was to inspect all of the installed components and ensure proper torq and cotter keys were in place. Once all bolts and nuts were checked then we installed the tires and checked for fitment. We then lowered the truck and cycled the steering from left to right checking for rubbing and brakeline clearance. The new suspension now properly clears the 33" Toyo M/T's that were previously installed.


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Rear Suspension Block and U Bolts along with brakeline drops

Now that the front was completed we then moved to the rear suspension. With the truck back up in the air we again used a screw jack to secure the rear axle then removed the shocks and then moved on to the U-Bolts. With jack in place the U-Bolts were loosened then removed, next we installed the supplied rear blocks and new U-Bolts. After both sides were completed we then installed the brakeline drops and checked for over extension, once checked we torqued the rear U-Bolts to spec.



Next we installed the new Bilstein 5100 rear shocks stem top first then compressed the bottoms to fit into mounts. Once tightened we then lowered the truck and installed the upper shock hardware and tightened .




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That kit looks sweet good job on the install.

 

Finished Product

Here is what the truck looked like before the installation of the RCD 4.5" suspension



Here is now what the truck looks like after the install! No more tire rubbing and amazing ride quality, I am happy to say this is my truck and I am very satisfied with the results!



We are now taking orders for this kit and will be one of the first distributors to receive the kits!
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That looks awesome...Congrats on a sharp addition!!

 

That looks just right. So whats the difference between those 5100's, and the ones that adjust to 2.5"?

I just received mine, w/the 5125's for the rear. Will these work w/that lift?

Also, you guys planning on selling just the front set up. I dont care for the Block in the rear, and wont mind the Cali style look

Awesome right up, sweet truck. Might be giving you guys a call this summer...

 

price??

 

Yeah Steve works for RCD in Santee- The kit will only fit the 6 lug applications