Ironman 4x4 Leaf Pack Thread

Hi TW,

I recently purchased the 440 Constant Load Leaf packs from Ironman 4x4 U.S. in November of 2021. I wanted to go over my experience with them, and post regarding ongoing troubleshooting with the vehicle. Honestly, this may get moved to another thread in the future, but here it is now.

Buyer be forewarned. If you want the Ironman 440 CONSTANT Load, you better have at least 500-1000 lbs in the back of the truck.

First off--Why did I buy this leaf pack, and not the Performance?
I have 2 Anatolians that I lug around, as well as whatever other lead-filled items.
The average load math was an average of 390 to 430 pounds. If I go camping, the load increases to 650-750. The truck was already in a state of Cali-Lean before hand, even with AAL and helpers.


Parts and Maintenance:
2015 DCSB 4X4 4.0 65K Daily-Driven
ARE Z Series, 2009 manu date.
265/75/16 Cooper Discoverer M+S 116s (winter)
ECGS Bushing
3' Axle Shim
B110 Rears
Freedom Off-Road Fronts (set up for +1.5")
Sway Bar Relocation

Full on Maintenance every 5K. This includes all [X] extra or special case maintenance; greasing zerks, undercoatings, cat and muffler replacement, alignment checks, engine and fuel system cleaners, etc.

Special Cases: Driver side LCA replaced with OEM and re-aligned.

How the truck currently sits.


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I completed my 60K service interval 1000 miles beforehand
After immediate install of this pack, the truck sat up almost 6 or more inches higher in the rear. Center cap to fender was 29". Disgusting driveline vibrations. It was unsafe to drive, although the rear ride was VERY nice and soft for my 10 miles of testing.





After a very long weekend of frustration, research, math, and a chat with Ironman- we decided to remove the 3rd and 7th (overload) leafs. This was completed. Center cap to fender 24.75".The truck was a little more level, and looked much better. Unfortunately, there were still major driveline vibrations.





Acceleration driveline vibrations are typical on lifted Tacomas. A long, extensive week of testing and troubleshooting ensued. Keep in mind, that the testing for each 'setup' lasted about 100 miles of both city and highway driving. This is where it gets fun for the average DIYer. (this is not me...)

1) Three Degree Axle shim.
Followed this thread: https://www.tacomaworld.com/threads/drive-shaft-vibrations-solved-step-by-step.244535/
Math completed. Ordered and installed with the leaf pack. Acceleration Vibes still there, albeit alleviated.

2) CB tested for play or noise- dropped 1/8", then 1/4". Checked driveline math again for good continuity. Vibes persisted.

3) Leaf Spring "clamps". Tried one, then two on each side. Following threads similar to: https://www.tacomaworld.com/threads/spring-clamp-solved-my-axle-wrap.228091/ Clamping every possible combination. Vibes Persisted.

4) Leaf Spring Helper mounted front-side of spring, previous clamps removed. This is the best one yet. Vibrations still persist upon acceleration. https://www.tacomaworld.com/threads/goodbye-axle-wrap-mod.108316/

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I am still troubleshooting this issue, expecting it to be axle wrap. My next troubleshooting or information-gathering step is going to be putting a go-pro down there and taking a video. The problem only persists during an acceleration. I know that driveline angles are good, according to the linked article in Step 1 above. Currently, I am driving with the 3' axle shim and helper, as this has provided the best alleviation to what may be axle wrap.