1996-2002 4RUNNER PARTS AT OFF ROAD SOLUTIONS
Order Online or Call 000-000-0000Suspension
Engine/Drivetrain
4Runner Suspension
Coilover Description
Tacoma & 4Runner Coilover System
Tacoma & 4Runner Coilover Components & Accessories
Performance Suspension Components
Performance Suspension Upgrades
Coilover Description
We have spent the last several years on the trail in coilover suspension equipped Toyotas. We have also helped many sets of coilover shocks find their way under Toyotas. We have seen tough trails, and we have seen extreme trails. Here at ORS, we’ve had some good schooling about building a coilover multi-link suspension that works. We are ready to pass this education onto our fellow wheelers. We are very proud to introduce the ORS Coilover Suspension Systems.
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These are not "good enough" multi link suspension systems. These are serious suspension systems, designed to be used. These suspensions were not designed to sell by the truckload. They were not intended for the entire 4WD market. These suspensions were designed for those who want to abuse their rig on the rocks. Why are these systems the best?
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- Superior vehicle control, even at a crawl
- Improved articulation
- Front axle wrap eliminated
- Fine tuning ability
- Front axle moves forward during compression for better tire to firewall clearance
- Superior strength by design and components
- Improved ride characteristics
- And, yes, the cool factor, or bling, or whatever you call it...
Our lower control arms are constructed from 2.25" x .375 wall DOM tube. They are fitted with 1.25" heim joints or 2.5" x 1.25" Johnny Joints at one end and oversized polyurethane bushings at the other. We don’t want them to bend when you slam down on that pointy, unseen rock.
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Our upper control arms are constructed of 1.75" x .250 wall DOM tubing. They are fitted with .825" heim joints or 2.5" x 1" Johnny Joints at one end and oversized polyurethane bushings at the other.
The Heim Joint Systems are for those who truly want their suspension to be overkill. The heim joints we use can be found on hardcore off road racing vehicles due to their amazing strength. The Johnny Joint Systems offer a more economic option while still providing exceptional strength. Johnny Joints can be found on the rigs of many professional rock crawlers. The Johnny Joints also offer the advantage of being re-buildable.
All components are computer designed. All brackets are made from 1/4" or 3/16" steel and are CNC laser cut for precision. These brackets aren’t weakly attached to your rig. All major mounting points are plated, sleeved, and/or generously braced.
How about geometry? Our lower control arms stretch near the 40" mark, re-defining a "long-arm" system. Geometry is derived from of a combination of real-world experience and computer design, to provide flexibility and traction while keeping the vehicle under control in varied off road situations.
14" travel coilover shocks are the star in this show. Our systems are designed around 14" travel 2.0" or 2.5" diameter remote-reservoir coilover shocks. That’s a lot of shock. But when you go this far modifying your rig, these shocks become the "norm." Sheet-metal mounts don’t seem to be enough to fully support the abuse that you may bring upon these shocks. This system uses 1.75" x .120W DOM pre-bent shock hoops, with 1/4" shock mounting tabs, 3/16" gusset plates, and optional shock hoop tube braces.
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Note: Air shocks can also be used with these systems. However, the front-end of these trucks tend to be a little "heavy" for air shocks.
These systems are designed to convert a suspension from independent or leaf spring to a multi-link configuration. Cutting, grinding, welding and automotive skills will be required by the installer. An installer with fabrication and automotive experience is highly recommended. The ORS Coilover Suspension Systems are only as good as the installation. Difficulty of installation parallels that of performing a leaf sprung solid axle swap.
These kits were intended for rock crawling and off-road use only. Check your local laws before using these systems on road. Any suspension (including leaf springs) that is not "bolt-on" is not street-legal in many areas. The purchaser/installer of these systems accepts all responsibility for the use and abuse of this system on and off-road.
Note: Coilover kits available for in house install starting @ $2600
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Tacoma & 4Runner Coilover Systems
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We are proud to announce our long-awaited ’95.5-’04 Tacoma 4x4 Front Coilover Solid Axle Swap Kit. This kit is based on years of R&D not only with coilover suspension, but also Tacomas in particular. This system is designed to be used and abused. This is also a very complete and comprehensive kit. Everything has been thought of and designed for a simple install.
- Long-arm system utilizing 3 lateral links and a panhard bar. Lower control arms are 39" long (center of bolt to center of bolt).
- Based around 14" travel coilover shocks.
- Lower control arms constructed of 2.25"x .375wall DOM tube with 1.25" Heim Joints or 2.5" Johnny Joints on one end and 2" oversized polyurethane bushings on the other.
- Upper control arm constructed of 1.75" x .250wall DOM tube with a .875" heim joint or 2.5" Johnny Joint on one end and a 2" oversized polyurethane bushing on the other.
- Panhard bar constructed of 1.75" x .250wall DOM tube with a .875" heim joint at one end and a polyurethane bushing on the other.
- All brackets are CNC laser cut from 1/4" or 3/16" steel.
- The front section of the frame is completely plated for strength and elimination of the factory "crumple zone". Many mounts are also sleeved for even more strength.
- Complete w/ bumpstops, limit straps, and mounting brackets to control suspension movement.
- All kits are based around 14" travel high-quality Fox Racing Shocks
- Bumpstops and limit straps are not only offered but included in all kits. This keeps the suspension under control and protects those expensive components.
- Longer control arms for improved geometry and control
- Frame fully plated and crumple zone is eliminated
- HD steering provisions built into frame plating and included in all kits
- Stronger control arm setup, 2.25" x .375wall DOM tubing
- The strongest bracket attachment available. All frame brackets are plated or sleeved at their mounting points.
- High quality brake plumbing kit is available
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This kit is available for the Diamond Axe Housing with a Toyota 8" center-section. The minimum required Wheel Mounting Surface width of this housing is 67" for 36" and larger tires and 64" for 35" or smaller tires. These housing were selected to match our kit because they are some of the most rugged housings we have found in rockcrawling and some of the only housings that can stand up to the abuse that a truck with this suspension can dish out.
Here is a list of the other parts or components required for the Tacoma system that are not included in our suspension system:
- Diamond axle housing w/ all internal components
- SAS oil pan conversion kit
- ’86-’95 Toyota 4Runner/4x4 Truck steering gear
- Conventional "high steer" system w/ custom length tie rod and drag link (Front Range Off Road, Marlin Crawler, All-Pro, etc.)
- ’84-’88 Toyota 4Runner, 4x4 truck steering shaft (or custom fabricated shaft)
- Front Range Off Road Tacoma Crossmember (or custom fabricated crossmember)
- High and low pressure power steering hoses w/ cooler
- Front driveline modifications
- ORS Tacoma Front Brake Conversion Kit highly recommended
- Steering Stabilizer highly recommended if driven on the road w/ out hydraulic assist
- ORS Shock Hoop Brace highly recommended
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Tacoma & 4Runner Full Coilover System
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Tacoma Front Coilover Suspension System - Full KitThe full kit covers the suspension components needed for this swap. This kit includes:
- Fox Coilover racing shocks with remote reservoirs and reservoir isolators, 2" body
- Dual rate Eibach springs
- Lower control arms, complete
- Upper control arm, complete
- Panhard Rod, complete
- All frame brackets
- All axle brackets
- Shock hoop set
- Shock axle mounts
- All frame plates w/ steering gear provisions
- Gussets
- Frame bracing tube
- Limit straps with mounting tabs
- Bumpstop set and mount system
- Firewall steering shaft seal plate
- All necessary hardware
Johnny Joint Kit for 1995.5-2004 Tacoma - ORS-SP301 - $2955.24
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Tacoma & 4Runner Basic Coilover System
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Tacoma Front Coilover Suspension System - Basic KitThis is our full kit less the shocks and springs. This is a great kit for those who already have coilover shocks and springs or have another source to purchase them. This kit is designed around 14" travel coilover shocks of most brands. Please inquire with ORS to be sure your shock will work with the provided mounts.
The Basic Kit includes:
- Lower control arms, complete
- Upper control arm, complete
- Panhard Rod, complete
- All frame brackets
- All axle brackets
- Shock hoop set
- Shock axle mounts
- All frame plates w/ steering gear provisions
- Gussets
- Frame bracing tube
- Limit straps with mounting tabs
- Bumpstop set and mount system
- Firewall steering shaft seal plate
- All necessary hardware
Johnny Joint Kit for 1995.5-2004 Tacoma - ORS-SP303 - $1928.44
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Tacoma & 4Runner Link & Bracket Coilover System
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Tacoma Front Coilover Link & Bracket KitThis is our Basic Kit less the shock mounting system. This is ideal for those who wish to use this kit with different length coilovers, traditional coil springs, air bags, etc. This kit includes all that is needed to set up the "multi-link" system.
The Link & Bracket Kit includes:
- Lower control arms, complete
- Upper control arm, complete
- Panhard Rod, complete
- All frame brackets
- All axle brackets
- All frame plates w/ steering gear provisions
- Gussets
- Frame bracing tube
- Limit straps with mounting tabs
- Bumpstop set and mount system
- Firewall steering shaft seal plate
- All necessary hardware
Johnny Joint Kit for 1995.5-2004 Tacoma - ORS-SP305 - $1585.53
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Tacoma & 4Runner Coilover Components & Accessories
High Pressure Power Steering Hose, V6 - ORS-SP347 $95.00This custom high pressure power steering hose is designed for Tacoma/4Runner with the 3.4L V6 engine and a Toyota ’86-’95 4x4 steering gear installed. Ideal for customers with the ORS Front Tacoma Coilover System. This hose routes from the power steering pump to the steering gear. Hose includes necessary fittings and is constructed to be a direct bolt-on.
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ORS Tacoma Front Brake Conversion Kit - ORS-SP345 $215.00Why do we recommend the ORS Tacoma Front Brake Conversion Kit? Traditionally the front brakes are plumbed by 1 hose at each wheel. This method still works, but the hose is in danger of being pinched between the coil springs during suspension compression, spelling disaster. The ORS system routes the brake plumbing down the upper control arm where it is split at the axle. At each wheel there is a short hose from the axle to the caliper, keeping the hose out of harm’s way. This kit is complete with stainless steel hoses, 4 pre-bent lines, 3-way junction, 5 weld-on retaining tabs w/ clips, routing clamps, and hardware.
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ORS Shock Hoop Brace - ORS-SP344 $160.00The ORS Shock Hoop Brace is recommended for applications that will see some abuse. Not only will it distribute the shock forces between both sides of the frame but it will stiffen up the frame in general, giving the front end of the truck additional strength. This Brace has flanges that allow the center section to unbolt for engine service. This brace will fit with supercharged and non-supercharged V6 engines.
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3.4L V6 Oil Pan Conversion Kit - ORS-EC088 $263.00Fits 2wd, 1979-85 4wd, or SAS vehicles
Tacomas, Tundras and 4Runners with the 3.4L V6 have an oil pan sump in the front of the engine. This prevents the installation of this engine into an older 2WD, ’79-’85 4x4, or SAS’d vehicle. The parts needed are found on a 2WD T100 and convert the pan, sump, and dipstick setup to the rear. This kit includes all the parts needed to complete the rear sump swap-over. Genuine NEW Toyota parts include: oil pan, sump, sump gasket, pan gasket maker, dip stick, dip stick tube, tube adapter, and tube O-ring. Also included are a tap and plug to seal the original dip stick tube hole.
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ORS 3.4L Dipstick Drill Guide - ORS-EC093 $45.00 SALE! $35.00)
As many may know, the ’00 and newer versions of the Toyota 3.4L require a hole be drilled into the block to accept the dipstick tube during a rear sump oil pan installation, such as during an engine swap or live axle conversion.After tediously drilling many holes ourselves, we developed a drill guide to assist this operation. Simply bolt it on and drill your hole. Truly worth it’s weight in gold......
The kit includes the necessary sleeves and hardware. 3/8” drill bit NOT included.
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Fox Steering Stabilizer Kit - ORS-SP346 $175.00Works with All of Our Coilover Kits
We offer this Fox steering stabilizer for those who will be seeing street use and do not have hydraulic assist. The amount of movement and dampening this suspension is capable of calls for a stabilizer of the same caliber. This is one of the few nitrogen-charged stabilizers on the market and is designed for trucks with large tires. Stabilizer comes complete with weld-on mounting tabs and hardware.
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Diamond Axle Housing, 8" Toyota differential, birfield outers $900.00This axle housing is ready for the abuse that a truck with the ORS Coilover Suspension System can dish out. It is constructed of 3.5" x .375 wall DOM Tube, 1/2" steel at the differential flange, and 1/4" CNC formed steel at the "cover". We feel this is superior to the Dana 60 and Dana 44 housings because it is one solid part and cannot "separate" and "flex" like we have found the Dana housings to do. This housing also integrates Diamond Axle Housing additional inner axle seals at the differential to prevent premature inner seal failure. Also available w/ Ford 9" differential, Dana 60 outers, FJ80 outers. If not ordering your axle from ORS, be sure to check with ORS for the proper ordering specs to work with our kit. For more info, check out www.diamondaxle.com.
**All kit components are available separately, please call for pricing**
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4Runner Performance Suspension Components
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Total Chaos Upper Control Arm - TOT-96500 $720.00Fits 1995.5-04 Tacoma & 1996-03 4Runner
When the front of a Tacoma is lifted using coilover modifications, the upper ball joint is forced to operate at an angle that it was not intended for. This kit replaces the original upper control arms with 4130 chromoly tubular units that house 1" Teflon-lined uniball joints, in place of the original ball joint. The uniball joints are designed to handle the extra angle while offering more strength. The control arms are powder coated and clear coated. Did we also mention that this kit looks really cool? All necessary parts for a complete installation are included. This kit will allow an additional 1" of down travel when used with the Icon coilovers.
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Total Chaos Long Travel Suspension System - TOT-96000 $2725.00Fits 1995.5-04 Tacoma & 1996-03 4Runner
This kit offers the most suspension performance that can be bolted on to the front of the Tacoma. This long travel suspension system replaces the upper and lower control arms with extended 4130 chromoly tubular units that widen the front vehicle stance by 7". The upper ball joint is replaced by a 1" uniball joint for strength while the original lower ball joint is retained for longevity. The kit includes 4 control arms, bushings, brake hoses, extended tie rods, limiting straps, bolt on upper shock mounts, spindle slugs, and all necessary hardware. When coupled with the proper parts this kit will drastically improve suspension travel and performance. Off Road Solutions can provide the proper shock absorbers, axles, and rear suspension components to complete the job. If using 33" or taller tires with this kit larger fenders or body modifications will be required. *Shipping price may vary from online due to the size and weight of the boxes sent, please check your e-mail for a confirmation of your order.
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Live Axle Conversion Kit - FRR-TSAH $249.95Fits 1995.5-04 Tacoma & 1996-03 4Runner
This kit from Front Range Off Road is a weld-in kit designed for the "do-it-yourselfer" wanting leaf springs and a solid axle under the front of their Tacoma. This kit includes a frame cross brace, spring hangars, shackle hangars, bushings, gussets, and all necessary hardware to hang a set of leaf springs under the Tacoma. A great deal of time was invested in this product to insure high quality, strength, proper geometry, and ease of installation. Off Road Solutions can also set you up with all necessary parts to complete this project, such as springs, shocks, brake hoses, etc.
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4Runner Performance Suspension Upgrades
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Rear Brake Proportioning Valve Lift BracketThis lift bracket is a must for any lifted Toyota equipped with a rear brake LSPV (Load Sensing Proportioning Valve). The LSPV is used to regulate rear brake pressure based on ride height, due to vehicle load. When a vehicle is lifted, the LSPV will compensate for a lighter load, decreasing rear brake pressure. This bracket can be used to raise the axle mount for the LSPV, bringing the rear brake pressure back to normal operating range. This bracket kit is available for 2.5", 4", and 6" lift heights and comes with mounting hardware.
2.5" Lift Bracket - ORS_SP101 - $13.00 SALE! $5.00
4" Lift Bracket - ORS_SP102 - $14.00
6" Lift Bracket - ORS_SP103 - $15.00 SALE! $7.00
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Energy Suspension Steering Rack Bushing Set - ENE-8-10101 $24.50Fits 1995.5-04 Tacoma
The rubber bushings that mount the steering rack to the frame tend to wear out and create excessive play at the steering wheel. This happens very fast with larger tires and/or off road use. This bushing set addresses that problem by replacing the original rubber bushings with durable polyurethane bushings.
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Energy Suspension Sway Bar Bushing SetFits 1995.5-04 Tacoma
This polyurethane replacement bushing set replaces the factory rubber sway bar bushings, offering stiffer cornering characteristics. Measure the diameter of your sway bar to determine which set is necessary.
27mm Set - ENE-8-5118G - $22.95 SALE! $18.00 26mm Set - ENE-8-5117G - $21.95 SALE! $17.00
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4Runner Drivetrain Parts
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ORS Manual Hub Conversion KitThis kit is recommended when lifting the front of your Tacoma, 4Runner, or Tundra above 2.5" to prevent CV boot and joint damage. This kit can be used with all ADD and ABS systems. The kit includes new heat-treated axle shafts, outer CV joints, hubs, seals, Toyota wheel bearings, Warn Premium lockouts, grease, boot clamps, and all necessary hardware. The kit does not include new CV boots, they are also available through Off Road Solutions. Please read our technical article about this kit.
1996-02 4Runner - ORS-HB002 - $1157.40 SALE! $1057.40
ORS Basic Manual Hub Conversion KitThis kit is the same as the regular conversion kit, except that it does not include the Warn hubs; Aisin or Mile-Marker hubs can be used instead.
1996-02 4Runner - ORS-HB052 - $955.29 SALE! $875.29
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Aisin Hub Lockout Kit - ORS-HB120 $525.00/setA set of brand new Aisin hubs from Toyota. Comes complete with all the necessary hardware.
ORS Manual Hub Conversion Kit Locknut Socket - ORS-HB020 $59.95 SALE! $40.00This HD socket is used to install the large lock nut provided with our manual hub conversion kit. This socket is very helpful because this lock nut carries a torque spec. of 200 ft-lb. As one can imagine, it’s pretty important that the lock nut stay tight!
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Replacement CV BootThese boots are constructed of a softer, more pliable compound than the original boots. Kit includes 1 boot, 2 clamps, and CV joint grease. These boots will work with the original axles or the ORS Manual Hub Conversion.
1996-02 4Runner Inner CV Boot - CAR-CFD-85-1331 - $17.95
1995-04 Tacoma & 1996-02 4Runner & 1999-05 Tundra Outer CV Boot - CAR-CFD-85-1313 - $17.99
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High Angle Inner CV Boot - ORS-HB201 $49.95/side SALE! $45.001995-04 Tacoma & 1996-02 4Runner & 1999-05 Tundra
These CV boots have been completely re-designed to work with high angle applications, such as lifted vehicles. The boot stretches further over the joint and the bellows are placed further apart to keep them from contacting, extending the life of the boot. Kit includes 1 boot, 2 clamps, and CV joint grease, 2 kits needed per vehicle. These boots will work with the original axles or the ORS Manual Hub Conversion. With tulip shaped CV joints the use of the original boot sealing flange is required.
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ORS Replacement Brass Hub BushingA replacement for the brass bushings placed in the wheel hubs of the ORS Manual Hub Conversion Kit. The OEM wheel hub of a manual hub Tacoma. These units are direct press-in replacements.
Outer Bushing - ORS-HB070 - $25.00
Inner Bushing - ORS-HB071 - $26.00
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ORS E-Locker Harness - ORS-EL001 $145.00If you are installing a Toyota electric-locking differential in your own axle, ORS has the wiring solution for you. The actuator on the Toyota E-locker uses a switched motor which prevents simple wiring. We are proud to introduce our new E-Locker Harness. Our harness is complete with the relays needed to make the differential operational at the push of a button. Our harness plugs directly into your E-Locker, preventing any custom splicing at the differential. Installation is a breeze and the harness is custom tailored to your wheelbase, selected axle, and battery location.
Important: When ordering online please specify the following in the Notes section: year and model of truck, front or rear e-locker, and whether your battery is located on the front driver side or front passenger side of the engine bay. Please call or email for custom applications.
*Orders may take up to 4 weeks to ship during our busy seasons due to the custom nature of the harnesses. All harnesses are built to order and we build them in the order that they were received.
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Dual ORS E-Locker Harness - ORS-EL002 $255.00If you are installing a Toyota electric-locking differential in your front and rear axle, ORS has the wiring solution for you. The actuator on the Toyota E-locker uses a switched motor which prevents simple wiring. We are proud to introduce our new Dual E-Locker Harness. Our harness is complete with the relays needed to make the differential operational at the push of a button, and runs both the front and rear E-Locker. Our harness plugs directly into your E-Lockers, preventing any custom splicing at the differential. Installation is a breeze and the harness is custom tailored to your wheelbase, selected axles, and battery location.
Important: When ordering online please specify the following in the Notes section: year and model of truck, front locker year and model, rear locker year and model, and whether your battery is located on the front driver side or front passenger side of the engine bay. We also need to know if the lockers are high or low pinion. Please call or email for custom applications.
*Orders may take up to 4 weeks to ship during our busy seasons due to the custom nature of the harnesses. All harnesses are built to order and we build them in the order that they were received.
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Return Policy (applies to all purchases): 15% restocking fee on all returns. No returns after 30 days. No returns on electrical parts or special orders.
Shipping Note: Shipping prices are valid for the United States only. Orders shipping elsewhere will incur extra shipping charges not included in the online total.
Parts pricing subject to change without notice.
