RCLT HD > FAQ

BigMike’s Q&A to Dirt Lifestyle’s RCLT HD Install Video

Below are additional answers by BigMike to video comments from Dirt Lifestyle’s RCLT HD installation.

BigMike: I’d like to first define the term “Long Travel” Long Travel (LT) refers to replacing factory lower & upper control arms (LCA & UCA) of an IFS with new arms that are longer than stock. There are much longer LT setups in the world, from Ultra4 to Trophy Trucks, where the LCAs are inboard-mounted close to one another for maximum arm length. But arms from a “LT kit” attach directly to your existing frame mounts as a simple remove-and-replace install. As the arms are longer, we get more suspension travel, articulation, stability, and an improved ride, but at the expense of adding overall width to the vehicle. It’s a compromise: Really long arms are great for performance, but the vehicle becomes excessively wide and difficult to drive in cities and narrow 4WD trails. In addition to more flex, longer arms extend further down for the same arm angle providing natural lift without incurring excessive CV joint and steering component angles. This is how we’re able to get more lift instead of using a Frame Drop Bracket Kit which negates the ground clearance advantage of IFS.

Q: When will RCLT HD be available? A: Kits have been shipping since Spring 2021.

Q: What does RCLT HD fit? A: Type III & IV Toyota IFS frames (2003+ 4Runner/Lexus GX, 2005+ 4WD/PreRunner Tacoma, 2006+ FJ Cruiser).

Q: What makes RCLT HD different from other Toyota LT kits? A: RCLT HD has created a new market segment and does not directly compete with existing LT kits. Specifically, RCLT HD is the first LT kit designed for Rock Crawling and provides unmatched approach angle, ground clearance, and steering strength. Some of its “firsts” include: (1) First LT with an integrated replacement HD steering rack built with 1-Ton double-shear components providing more steering power & reduced driver fatigue, proven strong enough for King Of The Hammers (KOH) and 40″ tires, (2) First LT to incorporate two-inch forward-mount knuckles, whereby a 35″ tire easily clears the body mount frame bracket, 37s fit like 33s, and up to a size 42″ tire may be installed without relocating the body mount, (3) First LT to incorporate an inverted lower arm with inset shock mount equaling the ground-clearance gain of going from 31 to 40″ tires, (4) First LT strong enough for Rock Crawling, and (5) First LT that challenges the benefits of a Solid Axle Swap (SAS).
The fact “SAS” is even listed on this product page tells you all you need to know.

Q: What frame modifications are required compared to other LT kits? A: RCLT HD requires a steering rack insert to be welded into the frame.

Q: What skills and equipment are needed to install RCLT HD? A: “If you can drill a hole and weld upside down, you can install RCLT HD” – Nate, Dirt Lifestyle

Q: How long does it take to install RCLT HD? A: The experienced mechanic may install RCLT HD in 8 to 12 hours and the first-time home-mechanic should be able to do it in two weekends. Expect an average shop install time to be 2-3 days.

Q: What are the advantages of RCLT HD over an SAS? A: While RCLT HD was never meant to replace an SAS, it challenges the benefits of an SAS by having vastly more ground clearance, less unsprung mass, is 99% bolt-on, may be removed & transferred vehicle-to-vehicle (ex. if you have a Tacoma now but later switch to a 4Runner), retains factory speedometer/ABS/cruise/traction control systems, no death wobble, reuses original brakes & hub components for ease of service & parts sourcing, can be aligned by any shop without special instructions, and retains superior IFS handling, ride-quality, & stability for daily-drivers.

Q: How does installation of RCLT HD compare to an SAS? A: Shops typically schedule 2 to 2½ weeks to SAS a Type III/IV frame, whereby RCLT HD can be installed in a couple days. Moreover, the average home mechanic able to install a LT cannot build a custom late-model SAS.

Q: How does the price of RCLT HD compare to an SAS? A: SAS’ing a late-model Toyota IFS cannot be compared to SAS’ing a 1986 Hilux. Many shops charge $25,000 or more for a turn-key SAS which is more than double a turn-key RCLT HD. When installed at home, a complete turn-key RCLT HD costs less than just an SAS labor charge. If you’re unable to install RCLT HD yourself, expect a 2-day shop labor charge to be just over $2,000.

Q: Why is it you didn’t want to remove the IFS in favor of a solid axle swap but in the same breath you tore the rear suspension out to go linked and coilovers? A: Keep in mind that a rear SAS does not require removing the two strongest cross members of the frame (IFS sub-frame), removing existing shock towers, adding at least two new crossmembers (radiator support and under the bellhousing), changing to an entirely new steering type (gear box) with matched panhard-to-tie rod angles, and avoids all the complications of packaging new hydraulic lines, pan hard bar, upper tower & link, and taller shock towers under and around the engine oil pan, exhaust manifolds, and cylinder heads as well as clearancing into the cab and front wheel well which is much more limited and time consuming than simply removing inner fender plastic from the truck bed. As Nate shows, a 3-link conversion to an existing rear solid axle without any engine and steering complications is easier than a front SAS, and he even reused the factory rear leaf spring hangers and avoided cutting the frame entirely! Case in point, shops can do rear 3-links like Nate’s in 2 days whereas an SAS to a late-model Toyota can take up to 3 weeks.

Q: What makes RCLT HD cost more than typical LT kits? A: Simply put, RCLT HD has the most massive and strongest Toyota LT replacement knuckles ever made. This is because our HD Knuckles are made from one-piece solid steel lower sections, where the brake caliper mount, hub, and double-shear steering arm are all one interconnected solid part. This billet chunk of steel starts out at 50 pounds and is both larger than the billet we use to make our MC08 Dual Case Adapters and requires nearly twice as long to machine. In addition, we use 1/4″ plate steel instead of 3/16″ and have extra front & rear double-wall plating where stress forces are the highest. When you consider how each knuckle requires more manufacturing than a Dual Case Adapter with additional laser cutting, forming, assembly, welding, and powder coating, you can see how each knuckle is valued at $1,500. Without the knuckles, our retail price would be $3,999, which is on-par with typical LT kits despite our kit also having double-shear HD upper arms with 1/4″ steel plating, double-shear HD lower arms with 1/4″ steel plating, and parts to build and install a replacement HD MarRack with DOM MiniMarlinks, 1-Ton ⁵⁄₈” tie rod ends, and patented steering geometry. (Most all LT kits use single-shear connections, only 3/16″ plating, and are not an integrated HD steering rack upgrade.) Comprised of 248 parts, RCLT HD is the most complex LT kit by a wide margin and I believe it is reasonably priced for what it offers: The strongest and most reliable LT kit ever made with Rock Crawling ability no other LT kit can hold a candle to.

Q: How strong is the MarRack? A: The MarRack is the only DOT-approved steering rack to survive KOH as well as more than 70,000 miles of daily-driving and rock crawling across six-states with 40″ tires, Triple Transfer Cases (580:1 Crawl Ratio), F&R lockers, cutting brakes, & never trailed. It has three frame mounts instead of two with M14 mount hardware instead of M12 (2.1 X stronger frame connection), mounts are wider than stock for greater force loading, uses M28 ITRs instead of M14 (4.0 X stronger connection), and is built from a one-piece oversized aluminum housing that is 54% more massive than stock. On top of all this, our HD Knuckle steering geometry reduces load upstream to steering components, so every trail object the MarRack “feels” is reduced by our patented design.

Q: Can the MarRack be used with stock IFS or other LT kits? A: No. Because the MarRack is derived from a Land Cruiser, which is wider than the mid-size SUV/Tacoma, a new steering, knuckle, and suspension geometry is required for it to work safely & properly. I spent over two years perfecting this geometry to be stable throughout 14-inches of travel and patented the design allowing an oversized rack to work in narrow frames.

Q: Do we offer the MarRack? A: UPDATE 11/21/2023: Yes, we do! Please visit our 200-series Steering Rack product page for details. Please note that because there is no way we can ensure the installer properly flushed the steering system in order to warranty a MarRack, once the rack has been modified or installed, we are unable to accept it as a warranty or return as we also would not be able to return it to Toyota. Please see the Disclaimer on the product page for more details.

Q: Any power steering pump mods required? A: No. Our steering geometry increases steering strength, so an increase in pump pressure or cooling is not needed.

Q: Aren’t other LT kits used for Rock Crawling? A: While you could go rock crawling with other kits, none are designed for it. It is well accepted that a 35″ tire is the minimum entry size to be taken serious as a Rock Crawler, and because factory inner tie rods fail with 33s, knuckles bend with 34s, and steering racks die with 35s, there is no Rock Crawling LT kit. In fact, other LT manufactures advise against technical rock crawling altogether. We are not only confident in technical Rock Crawling RCLT HD with tires up to and including 40″, but our patented design provides SAS-like approach angles, increases ground clearance beyond other kits, and has steering and knuckle strength proven strong enough for KOH underneath 4.7L V8 4Runners. We are achieving this with non-upgraded factory MarRack inner tie rods (ITR) and have yet to bend or break a single one, even with 40s. RCLT HD is in a league its own when it comes to IFS Rock Crawling capability and performance.

Q: What’s the point of all this strength when you’ve still got the front IFS differential? A: We covered this from the 19:55 to 22:01 min video mark, but another thing to add is that the reverse-rotation high-pinion 8″ Type III/IV IFS differential uses the same R&P from the 100-series 4.7L V8 Land Cruiser, which is the same R&P as the venerable and popular 80-series High Pinion except it’s even stronger due to it having a wider & thicker ring gear. So the SUV/Tacoma 2003+ front IFS differential is (1) stronger than the Toyota Solid Axle 8″ High Pinion, (2) is from a V8 Land Cruiser, and (3) has well been proven strong. The strength or reliability of my front diff has never crossed my mind throughout my entire 70,000 miles of daily driving and Rock Crawling with the same front diff, a 580:1 Crawl Ratio, and 40″ tire/wheel combo that weighs 145 lbs each.

Q: Can RCLT HD be used for High Speed? A: Absolutely, as proven at KOH. However, please bear in mind that our design is optimized for rock crawling strength & performance. Therefore, (1) our parts are heavy which reduces high speed efficiency and (2) because our lower arms are optimized for ground clearance, the CV boot will contact the lower control arm at full droop. See Instructions | Appendix A13: “High Speed Use Tips” for more details.

Q: Can RCLT HD be installed onto a non-USDM Hilux/Surf Toyota vehicle? A: So long as the vehicle shares the same Prado 120/150-series IFS, then there is a good chance it can. Also, the MarRack can be made for LH or RH configurations. The only unknown variable is space beneath non-USDM engines such as turbo diesels, so oil pan modifications may be required to clear the oversized steering rack.

Q: Can I use a Big Brake Kit on RCLT HD? A: Customers have successfully installed oversized Wilwood, CEIKA, and OEM brakes with RCLT HD. I run oversized Lexus GX460 brakes on my Tacoma. It is known that 6-piston AlconUSA and StopTech brackets must be modified for speed sensor and knuckle upright fitment. RCLT HD Owners: Please see this thread for more info on aftermarket brake kit compatibility: Big Brake kit

Kits shipped since summer 2022: Our HD Knuckles now use Toyota’s larger M14 caliper hardware found on 2015 and newer SUV applications. This means 2014 and older SUVs and all Tacoma applications will need to order 4× larger caliper bolts (product page) and upgrade existing caliper through-holes using a ⁹⁄₁₆” drill (Amazon search). Each caliper flange has a lot of surface area and drilling one size up has no impact to safety or brake performance. (Optionally, you may choose to upgrade to larger 08/2013+ 4Runner/GX460 M14 calipers with matching 08/2010+ 4Runner/GX460 rotors for an OEM “Big Brake” setup.)

Six-piston Wilwood and CEIKA brake upgrades with RCLT HD

Q: How much travel to expect from RCLT HD? A: This depends on how much up-travel you’re looking to have, pending tire size and clearancing plans (see “Bump Stop Consideration” Page 34 of our Online Instructions). For example, on Nate’s +3.50″ setup, he is intentionally limiting up-travel to minimize 38″ tire clearancing requirements, and is only expecting about 12″ of travel. On my shorter +2.75″ setup, I get 14″ of travel at hub centerline because I relocated my bump stops. This is why we did not cover this in the video because Nate is not sure how things will turn out pending his fiberglass fender install. He has a lot more down travel than I do so if he did the same amount of clearancing as I did then I’d expect him to have around 16″ of travel.

RCLT HD (+2.75) achieves up to 14″ of travel at the hub. Click here for more info

Q: How close are the 2nd & 3rd gen Tacoma front suspensions? A: See Appendix A6 of RCLT HD’s Installation Guide.

Q: Are factory and aftermarket skid plates compatible with RCLT HD? A: As far as we know all skid plates, stock and aftermarket, are compatible with RCLT HD. Update 8/3/2022: Skid plates that utilize the M12 bolt hole in front of the factory steering rack’s LH frame mount may require modification to work.

Q: How long will the uniballs last? A: While uniballs do not last as long as sealed joints, I did not want to settle on anything less than the ultimate strength of double-shear top-and-bottom mounts which means uniballs are the only option. How long they last depends on mileage and climate type. For daily driving in dry climates, expect them to last 5 years or more. For daily driving in cold climates where road treatments like salt are used, we’ve heard they may only last up to 1 year. We use 1″ high quality USA-made FK Uniballs. Rebuild kits are currently available by phone.

Q: Do you have to relocate headlights in order to run 40″ tires? A: When I allowed my TacomaWorld forum thread to get hijacked last year, some user who has never ran a LT with 40s claimed I relocated my headlights in order for this to work. He is mistaken as I run my 8″ Radflo shocks (p/n 6CT-001-5A) to full compression and all my components are in their stock location, including headlights and battery.

Q: How is the ground clearance comparison fair when Nate’s Tacoma is on jack-stands? A: Nate can easily set his ride height to match what’s shown, and also the Jeep is on taller 39″ tires while the Taco is only on 38s!!

Q: Will Nate’s truck be at the 2022 KOH? A: Hopefully yes and come see it & meet Nate in person at our Marlin Crawler booth!

Q: How did Mike like Nate’s coffee? A: It was delicious and was served in a stainless tumbler with “Dirt Lifestyle” logo!

RCLT HD with 40×13.5″ tires under a 2016 V6 Toyota Tacoma
More than 70K miles of testing with 40s and zero steering, axle, or differential failures