Toyota Front Differential and Sway Bar Drop Kits

Contents:

• Introduction
• On-line ordering
  • International Shipping and Tracking information
  • Returns
• Installation Instructions
• Related products:
  • Ball Joint Spacers
  • Sway Bar Disconnects
  • Multiple Item Orders
• Contact Info.

Introduction:

On the Toyota Tacomas (1995.5 and later) and the 4Runners (1996 and later), with suspension lifts over 2", the front CV axles operate at too great an angle which increases wear and tear and can cause them to break under off-road conditions. One simple cure for this problem is to lower the differential on the front axle to reduce the angle on the CVs. So with a 1" differential drop (i.e. Diff Drop) on a 3" lifted truck, it returns the CV angles closer to that of a more mild 2" lift.

A: 1" Diff. Drop Basic Kit	B: Stock Setup	C: Drop Spacer Installed

Pictured above (A) is the diff spacer or drop kit. It includes 2 - 1" tall x 2" OD T6061 aluminum spacers and a pair of long 1/2" bolts and lock nuts to replace the stock bolt and a pair of 8mm bolts (not pictured) to reattach the front skid plate. In (B) above, you can see the stock differential mounts and in (C) you can see the 1" spacer installed which in turn lowers the differential assembly. The differential mount to the rear is left as-is, the front differential assembly pivots down around that fixed point.

And now available for the 1986-1995 IFS Toyota 4WD pickups and 4Runners, the same front differential drop kit technology is now available:

D: 1" IFS Diff Drop Basic Kit	E: 1" IFS Sway Bar Drop Kit	F: IFS Drop Kit Installed

Pictured above (D) is the 1" IFS front diff. drop kit. The spacers install between the frame and front diff bushing (shown circled in RED in image F above). Pictured above (E) is the 1" front sway bar brkt. drop kit. The spacers install between the frame and front sway bar brkts. (sway bar bracket shown for clarity, it is not included in the kit) and lowers the front sway bar 1". This does two things, one is to provide room for the lowered front driveshaft to clear the sway bar (see clearance in image F above). It also lowers the sway bar to help compensate for the suspension lift, restoring the sway bar to a more neutral orientation for better performance. This spacer kit is ideal for trucks with "cranked up" torsion bars or with the popular ball joint spacers.

Differential Drop Notes:

The differential mount to the front is left as-is, the front differential assembly pivots down around that fixed point. The drop kit thus will slightly increase the u-joint angle on the front driveshaft, so it is a trade-off; lowered CV joint angles but increased u-joint angle. Since the u-joint is operating at a near zero degree angle and the CVs are operating at near their maximum angles, this is a fair trade-off. Also, the front driveshaft will only be turning when you are actually using 4WD, it will not be turning all the time. The CV axles can be moving all the time if your vehicle has the popular Automatic Differential Disconnect (ADD) front axle.

A diff drop will have no impact you the lift or ride height of the vehicle. It will neither raise nor lower the front suspension. It only affect the location of the front differential relative to the frame. Likewise it will have no impact (positive or negative) on the front end steering geometry (e.g. toe in, camber, caster).

Front Sway Bar Drop Brackets:

With a front suspension lift, you are in effect moving the suspension control arms away from the frame an amount equal to the height of the lift. One problem this can cause is that the front (anti-)sway bar, if attached, is now no longer sitting in it's original horizontal orientation, since the center of the sway bar is attached to the frame and the end links are attached to the suspenion control arms. This can lead to less efficient anti-sway bar operation. Why? Because if the ends of the sway bar are closer to level, one side will twist upwards and the other side will twist downwards by an equal amount when you are in a hard turn. It is the torsional stiffness of the center of the sway bar that resists this twist and helps to level the body by controlling the body roll (or sway) in hard turns. When the sway bars ends are down at an extreme angle, you end up with one end twisting down farther and the other end twisting less far down. With these unequal angles, you end up needing more twist of the bar to control the body roll and that means there is more body roll than you had with a level sway bar. See this web page for a more detailed explanation...

So there are two ways to fix this issue.

The first is to add longer sway bar end links, you can either modify your existing end links for the added length, or here is a custom built option.

A second option that is less expensive, is to simply lower the sway bar mounting brackets under the frame. This can be done with a simple spacer and longer bolts. See below for this option.

On-line Ordering:

Two main versions of the front differential drop kit are available:

• For 1986-1995 Toyota 4Runner 4WD Pickups/Hilux/4Runner/Surf models
• For 1995.5-2004 Toyota Tacoma and 1996-2002 Toyota 4Runner 4WD models

Please be sure to order the right kit to match your vehicle. The "IFS" kits fit the torsion bar front suspension 4WD trucks and 4Runners up through 1995 (in the US anyway). The other diff drop kits are for the coil sprung front suspensions on the 3rd gen 4Runner and Tacoma pickups. The two kits are not interchangeable between those generations.

Returns Policy:

• Parts may be returned for a refund within 30 days of original purchase.
  • A 10% restocking fee will be deducted from original purchase price less outgoing postage.
    • Parts must be in new and unused condition for the refund.
      • Used or blemished parts can yield partial refunds at the discretion of 4Crawler Offroad.
      • The customer is responsible for return shipping charges.
  • One exception to this policy is in the case that the spacers do not fit properly, per the installation instructions;
    • In such a case 4Crawler Offroad will refund the full purchase price less shipping.
• Return to:
  • 4Crawler Offroad Products
  • attn: Roger Brown
  • PO Box 61092
  • Sunnyvale, CA. 94088-1092

1995.5-2004 Toyota Tacoma and 1996-2002 Toyota 4Runner 4WD models:

US: Cost of the basic kit (drop spacers + longer bolts) is $29.00 (includes std. shipping in the US) + applicable sales tax.	US: Cost of the deluxe kit (basic kit + skid plate h/w) is $34.00 (includes std. shipping in the US) + applicable sales tax.	US: Cost of the deluxe kit is $34.00 plus $18.00 extra for Express Mail shipping (US only 1-2 days), + applicable sales tax.
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International: Cost of the basic kit (drop spacers + longer bolts) is $29.00 plus $10.00 discounted shipping world-wide (include local phone number in the "Note to Seller" field).	International: Cost of the deluxe kit (basic kit + skid plate h/w) is $34.00 plus $10.00 discounted shipping world-wide (include local phone number in the "Note to Seller" field).	International: Cost of the deluxe kit is $34.00 plus $29.00 for Express Mail International shipping (most countries, 3-5 days).

New pricing/options and free standard US shipping:

• Your order will be shipped via Priority Mail for domestic (US addresses, including APO/FPO - provide phone number with the order for customs form) with a delivery tracking number provided at time of shipment (tracking not available on some APO/FPO addresses), 2-3 days delivery time typical.
• International orders will be shipped via Priority Mail International, 6-10 days delivery time typical.
• Please be sure to double check your shipping address, both that it is correct and that it is able to receive US Mail deliveries.
• Also, international shipments require a local telephone number for customs paperwork, include that in the "Note To Seller" field of the order form. Lack of phone number will delay shipment of the parts. Note that for international shipments, package tracking information is limited and there is no shipping insurance available.
  • If you wish to have a more trackable and fully insured shipment, inquire about Express Mail shipping. Cost is typically US$29.00. Also, US shipments with the included shipping options are not insured, so if you wish to have an insured shipment, select the Express Mail shipping option, cost is US$18.00 as noted above.

Order the basic kit if you do not have a factory skid plate (or intend to remove yours) and order the deluxe kit if you have the factory skid plate as it will need to be lowered to install the differential drop kit.

Front Sway Bar Drop Kits:

Below are front sway bar drop kits for use on the 1996-2002 Toyota 4Runner and 1995.5-2004 Toyota Tacoma vehicles. These will work with the 4WD and PreRunner model vehicles. Note that the Tacoma (2-3/4" center-center, 7/16" offset) and 3rd gen 4Runner (3" center-center, 7/16" offset) sway bar brackets have a different bolt hole spacing (as noted), so be sure to specify which type you need below, and feel free to double check your bolt hole spacing to see if it matches the above dimensions. If not, a custom sway bar drop bracket may be possible. Also note that this drop kit is designed to work with sway bar brackets that either attach with a pair of 8mm bolts or a bolt and stud where there is at least 1" of thread exposed on the stud past the end of the nut.

Model: Select model: 1996-2001 4Runner 1995-2004 Tacoma

US: Cost of the front sway bar drop (only) kit is $25 (includes US shipping) + applicable sales tax.

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Model: Select model: 1996-2001 4Runner 1995-2004 Tacoma

International: Cost of the front sway bar drop (only) kit is $25 - plus $10 shipping to most countries. Include local phone number in the "Note to Seller" field.

Notes:

• Sway bar bracket and bushing (pictured above) not included
• Your order will be shipped via Priority Mail for domestic (US addresses, including APO/FPO - provide phone number with the order for customs form) with a delivery tracking number provided at time of shipment (tracking not available on some APO/FPO addresses), 2-3 days delivery time typical.
• International orders will be shipped via Priority Mail International, 6-10 days delivery time typical.
• Please be sure to double check your shipping address, both that it is correct and that it is able to receive US Mail deliveries.
• Also, international shipments require a local telephone number for customs paperwork, include that in the "Note To Seller" field of the order form. Lack of phone number will delay shipment of the parts. Note that for international shipments, package tracking information is limited and there is no shipping insurance available.
  • If you wish to have a more trackable and fully insured shipment, inquire about Express Mail shipping. Cost is typically US$29.00. Also, US shipments with the included shipping options are not insured, so if you wish to have an insured shipment, select the Express Mail shipping option, cost is US$18.00 as noted above.

1986-1995 Toyota 4Runner 4WD Pickup/Hilux/4Runner/Surf models:

US: Cost of the IFS diff drop basic kit is $29.00 (includes US shipping) + applicable sales tax.	US: Cost of the IFS sway bar drop (only) kit is $25.00 (includes US shipping) + applicable sales tax. Note: sway bar brkt/bushing not included	US: Cost of the IFS diff drop deluxe kit is $49.00 (includes US shipping) + applicable sales tax.
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International: Cost of the IFS diff drop basic kit is $29.00 (plus $10.00 shipping - world-wide to most countries - include local phone number in the "Note to Seller" field)	International: Cost of the IFS sway bar drop (only) kit is $25.00 (plus $10.00 shipping - world-wide to most countries - include local phone number in the "Note to Seller" field)	International: Cost of the IFS diff drop deluxe kit is $49.00 (plus $10.00 shipping - world-wide to most countries - include local phone number in the "Note to Seller" field)

New pricing/options and free standard US shipping:

• Your order will be shipped via Priority Mail for domestic (US addresses, including APO/FPO - provide phone number with the order for customs form) with a delivery tracking number provided at time of shipment (tracking not available on some APO/FPO addresses), 2-3 days delivery time typical.
• International orders will be shipped via Priority Mail International, 6-10 days delivery time typical.
• Please be sure to double check your shipping address, both that it is correct and that it is able to receive US Mail deliveries.
• Also, international shipments require a local telephone number for customs paperwork, include that in the "Note To Seller" field of the order form. Lack of phone number will delay shipment of the parts. Note that for international shipments, package tracking information is limited and there is no shipping insurance available.
  • If you wish to have a more trackable and fully insured shipment, inquire about Express Mail shipping. Cost is typically US$29.00. Also, US shipments with the included shipping options are not insured, so if you wish to have an insured shipment, select the Express Mail shipping option, cost is US$18.00 as noted above.

Notes:

• Order the basic kit if you do not have a front sway bar or intend to remove it.
• Order the deluxe kit if you have a front sway bar as it will need to be lowered with the differential drop kit.
• The sway bar drop kit is available separately and can be used with other differential drop or suspension lift kits to lower the front sway bar for better operation.
• Some rare vehicles will have one or both of the stock diff mount nuts welded to the upper cup on the frame (maybe 1 in 100 vehicles). If you think yours may be, an extra long bolt kit is available that lets you run the diff drop bolt through that welded in place nut and then put a new lock nut on top of the stock nut.
  • If you think you need the extra long bolt(s), add a note to seller in the order form to indicate this requirement.
  • Or if you find you need the extra long bolt after ordering, you can usually pick up a 1/2"x5-1/2" fine thread bolt at the local hardware store or you can order one for US$5.00 plus shipping.

Installation Instructions:

A: Stock Setup	B: Drop Spacer Installed

Allow approximately 30 minutes for the installation, assuming you don't run into any rusted or damaged fasteners. You'll need an assortment of wrenches and/or sockets plus a torque wrench to tighten the differential mounting bolts. Read through the instructions below to familiarize yourself with the steps involved. Note these instructions cover installation on both:

• 3rd Gen 4Runner and Tacoma vehicles (highlighted in RED)
• 2nd/3rd Gen 4WD pickups and 1st/2nd Gen 4Runners (highlighted in GREEN)
• As well as the Sway Bar Drop Bracket kit installation

and cover installation of all components. Depending on your vehicle type and kit ordered, you may not need to do every step listed below:

• For Tacoma and 3rd gen 4Runner:
  • Remove both skid plates under the front of the vehicle
    • Save the OEM bolts, a total of nine 12mm bolts
• Support the differential with a floor jack
• Remove factory bolts and nuts, supporting the front (or rear) of the differential
  • See picture A above for the stock configuration
  • Save the OEM washers for reinstalltion
  • Lower differential far enough to allow insertion of the 1" drop spacers
• Install the 1" spacers between the two front (or rear) differential supports and cross-member
  • See picture B above
  • Fasten to cross-member using new 1/2" bolts and nuts (making sure to reuse the factory washers)
    • If the stock washers hang up on the bolt threads, try dropping the bolt, head first, into a length of tubing or between the jaws of a vise, so that its hanging from the washer. Then use a hammer to drive the bolt out of the washer
  • Tighten to the factory specifications
  • Consult the Factory Service Manual for torque specifications
    • If you don't have the factory specs, 50-70 ft.lbs. should be adequate for this size bolt
• For Tacoma and 3rd gen 4Runner:
  • Install the front skid plate using three (3)OEM bolts on the front and two (2) new 8mm bolts and spacers in the rear
    • The back of the front skid plate will need to be spaced down to clear the now lower differential.
    • If needed, you may need to elongate the holes about 1 hole diameter, so consider drilling a small pilot hole next to the existing hole, then enlarge it and trim out the metal in between the two holes
      • The holes may need to be elongated/enlarged because the skid plate is not resting at an angle and thus the diagonal distance between the mounting bolts is longer than when it was resting flush.
    • DO NOT TIGHTEN YET
  • To install the rear skid plate, elongate the rear mounting holes, again if needed, with a round file or drill bit for fitment
    • You may need to elongate the holes about 1 hole diameter, so consider drilling a small pilot hole next to the existing hole, then enlarge it and trim out the metal in between the two holes
    • Once holes are elongated, mount rear skid plate with OEM M8 bolts
  • Torque all skid plate bolts to the factory specifications
    • Consult the Factory Service Manual for torque specifications
    • If you don't have the factory specs, 10-12 ft.lbs. should be adequate for this size bolt
• Sway Bar drop bracket kit installation:
  • Remove the 4 bolts holding the stock sway bar brackets to the frame (if present)
    • Be careful removing the bolts, if they don't come out easily, spray some penetrating oil up inside the frame onto the ends of the bolts to help free them.
    • Forcing the bolts too hard can break off the nuts welded up inside the frame
  • Insert the sway bar drop brackets between the frame and the stock brackets and attach them back in place with the longer bolts supplied. Use of an anti-sieze compound is a good idea.
• After a few hundred miles of driving, its a good idea to re-check the bolts and make sure they are still tight.
• Here are a few installation writeups:
  • http://www2.innevi.com/~chris/images/rbrown/
  • http://www.toyotasurf.asn.au/techsite/customsuspension.htm

Questions? --> <-- Comments?