The Toyota Hilux, particularly the Gen 2 (1986-1995) models, are renowned for their ruggedness and off-road capabilities. But even these beasts can be improved. Upgrading to a long travel suspension system significantly enhances your Gen 2 Hilux’s performance, allowing it to conquer even the most challenging terrains. This comprehensive guide delves into the benefits, features, and components of a long travel suspension upgrade specifically designed for the Gen 2 Hilux.
Why Choose a Long Travel Suspension for Your Gen 2 Hilux?
A long travel suspension system dramatically increases wheel travel, enabling your tires to maintain contact with the ground even over rough and uneven surfaces. This enhanced traction translates to superior control and stability, especially during off-road adventures. A wider track width, achieved through extended control arms, further improves cornering stability both on and off-road. The increased articulation provided by long travel systems results in a smoother, more comfortable ride compared to stock suspension, while simultaneously strengthening key components to withstand the rigors of off-road driving. Finally, a long travel system allows for extensive customization and tunability, enabling you to fine-tune your ride quality to accommodate varying vehicle weights, terrains, and driving styles. Dual shock capability offers even greater control over damping and performance.
Key Features of a Gen 2 Hilux Long Travel Kit
This long travel kit for the Gen 2 Hilux boasts a range of features engineered for superior off-road performance:
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Extended Control Arms: Chromoly upper and lower control arms are extended, widening the track width by 3.25″ per side for enhanced stability. These arms bolt directly to the factory mounting points for a straightforward installation. This setup allows for 12″ of wheel travel with 4WD (requires extended axles).
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Coilover Conversion: Designed to replace the factory torsion bars with 2.5″ coilover shocks, this kit dramatically improves articulation and ride quality.
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Chromoly Shock Hoops: Pre-bent 4130 chromoly shock hoops are designed for seamless integration of 8″ 2.5″ coilover shocks.
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Upgraded Ball Joints: High-strength 1″ uniballs replace the factory ball joints for increased durability and wheel travel. These uniballs feature a heat-treated stainless steel ball and race for exceptional corrosion resistance. A military-grade PTFE woven fabric liner minimizes noise.
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Performance Bushings: Urethane bushings minimize deflection compared to standard rubber bushings, resulting in a more responsive steering feel and improved trail handling.
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Reinforced Lower Control Arms: Internally gusseted and fully boxed lower control arms feature dual shock tabs for maximum strength and mounting flexibility. Secondary shock tabs allow for the addition of external bypass shocks for even finer damping control.
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Brake Lines and Spacers: Includes DOT-approved stainless steel braided brake lines (resistant to expansion) and custom 17-4 stainless steel hi-misalignment spacers. All necessary Grade 8 mounting hardware is also included.
Installation Considerations and Requirements
- 4WD Compatibility: Requires T100 4WD axles to retain four-wheel drive functionality (sold separately).
- Fender Modifications: Fiberglass fenders are necessary to accommodate the increased wheel travel.
- Lift Kit Incompatibility: Not compatible with 4″-7″ spindle/drop bracket lifts or 2WD models.
Components Included in the Kit
- Total Chaos Gen 2 Caddy Kit Long Travel Kit: (PN: 95200-B)
- King 2.5″ Front Long Travel Coilovers with Remote Reservoirs (Pair): (PN: TC522-01)
- Gen 2 Caddy Kit Weld-on Shock Hoop Kit: (PN: 95602)
Recommended Wheel and Tire Specifications
- 15″ Wheels: 15″ x 7″ with 3.75″ backspacing
- Tires: 33″
Conclusion
Transform your Gen 2 Hilux into an unstoppable off-road machine with a long travel suspension upgrade. The enhanced performance, increased durability, and customization options make this a worthwhile investment for any serious off-road enthusiast. This kit provides all the necessary components for a comprehensive upgrade, ensuring your Hilux is ready to tackle any terrain. Remember to consult with a qualified mechanic for professional installation.
