RCLT, Heavy Duty

Based on current demand, please allow approximately 10-12 weeks for your RCLT HD order to be shipped.

Production Preview Pics!Production Preview Pics!RCLT HD One-piece Knuckle vs. Stock two-piece KnuckleRCLT HD One-piece Knuckle vs. Stock two-piece KnuckleRCLT HD One-piece Knuckle vs. Stock two-piece KnuckleOur Double-sheer Tie Rod Ends are larger than factory steering arms!RCLT HD Lower Control Arm DetailRCLT HD Lower Control Arm DetailRCLT HD Lower Control Arm DetailRCLT HD Lower Control Arm DetailRCLT HD Lower Control Arm DetailRCLT HD Lower Control Arm DetailTypical LCA bushing (left) vs. Oversized RCLT HD LCA bushing!RCLT HD Upper Control Arm DetailRCLT HD Upper Control Arm Detail (shown upside-down)
Price:
$6,999.00 Introductory Price!

Six payments of only $1,166.50!

Update June 13: Instruction update v1.02 now available!!

Click here to view 'Instructions' tab.

Update June 17: First half-dozen kits shipping tomorrow! Second six kits shipping next week. Following shipment already at powder coat. Following shipment already fully fabricated. We'll continue notifying customers as shipments are prepared and sent their way!

        

Update June 18: HISTORY IS MADE! Another industry-first has been achieved by Marlin Crawler! #RCLTHD

  

"I am incredibly proud of the entire Marlin Crawler crew for making this dream a reality. Today we witnessed the creation of a brand-new heavy-duty IFS industry with our very first IFS product. We have gone from zero-to-Ferrari Enzo without any financial assistance or out-side design help. It's only impossible until it's not." -BigMike, Marlin Crawler President

  


Also June 18: More history was made as the first Long Travel IFS on 40s completed Fordyce, Northern California's most difficult trail, doing the entire trail in a V8 4Runner without any winching. Congratulations Fred & Dave from Dirt Every Day! Photo credit @harrysituations

  

"I can honestly say I was not sure how this beefy IFS was going to hold up. So far its very impressive. @marlincrawler RCLT is straddling big rocks, @rcvperformance axles are super strong! And the @arb4x4 air locker and @nitrogears are doing work. If it survives Fourdyce Im pretty sure its a winner." - Fred Williams, Dirt Every Day

  

Kits now shipping. #RCLTHD


Welcome to the BRAND NEW WORLD of Toyota IFS Rock Crawling

Welcome to the birth of the Toyota Rock Crawling IFS industry, brought to you by the founder of the Rock Crawling industry, Marlin Crawler.

The facts are simple:

  1. A 35" tire is the minimum entry size to be taken serious as a Rock Crawler
  2. No Long Travel IFS Kit can Rock Crawl 35" tires without modifying the cab A-pillar mount, and therefore
  3. No Long Travel IFS Kit is designed for Rock Crawling

The goals of the all-new Marlin Crawler Long Travel IFS:

  1. To install 35" tires without cab mount modification
  2. To improve approach angle closer to or on par with Solid Axle Conversions
  3. To take full advantage of the Heavy Duty MarRack Steering System
  4. To carve a new path away from existing Long Travel kits not designed for Rock Crawling

How Marlin Crawler accomplished this:

  1. By moving the knuckle forward for tire clearance & approach angles never done before
  2. By increasing ground clearance of the traditional lower control arm design to a level never done before
  3. By having the strongest factory-style steering system integrated with the IFS in a way never done before

The Patent-pending RCLT HD is born

RCLT HD stands for Rock Crawling Long Travel, Heavy Duty, and is the very first Long Travel IFS Kit specifically designed for the Rock Crawler.

RCLT HD has many unique industry first features that puts it in a newly created market segment strong enough for Rock Crawling. Main features include...

  • Relocate front axle so far forward it requires a new steering system,
  • Unmatched IFS approach angle,
  • Unmatched IFS ground clearance,
  • Unmatched IFS knuckle strength,
  • Unmatched IFS steering strength,
  • Flex equal to wider LT kits yet without requiring fiberglass fenders,
  • Ability to run 35" tires without body mount modification, and
  • It is the first IFS system that challenges the benefits of a Solid Axle Swap

For these reasons, RCLT HD avoids competing with existing Long Travel kits and is why RCLT HD is proudly Patent Pending!

Approach Angle, Ground Clearance, and Steering Strength are all serious handicaps to the IFS off-roader and RCLT HD greatly improves all three!

RCLT HD is made from 242 carefully designed individual parts and is not just another Long Travel kit. This is a first-of-a-kind full IFS and steering systems integrated replacement consisting of...

  1. Never-before-done two-inch forward arm geometry,
  2. Never-before-done knuckle geometry, and
  3. Never-before-done steering geometry
...and made possible by the MarRack steering rack replacement and our extended length steering arms that reduce driver steering effort perfect for handling oversized tires on- or off-road. In fact, RCLT HD has the strongest Toyota Long Travel Knuckle ever made, with our signature one-piece steering-hub-caliper solid lower section cut from billet larger than two dual case adapters!

Strength, handling, steering, ride quality, & on/off-road
traction is unparalleled in the Toyota IFS market

While RCLT HD was never meant to replace a Solid Axle Swap, it greatly challenges the benefits thereof in the following ways:

  • RCLT HD has vastly more ground clearance and less unsprung mass than a SAS
  • Is 99% bolt-on and easily transferable from vehicle to vehicle
  • May be removed and all original IFS components reinstalled
  • Retains all factory ABS, cruise, and traction control systems
  • Reuses OEM brakes and spindle components for ease of service
  • Can be aligned by any shop without special instructions
  • Retains superior handling, ride quality, & stability for daily-drivers

Testing Score Card

Iterations of RCLT HD have been tested on the following trails without failure:

On 40" x 13.5" tires:
Northern California:
      Rubicon (6-times), Fordyce (all winch hills successfully climbed and descended without winching)
Central California:
      Dusy/Ershim, Coyote Lake, Red Lake, Bald Mtn, Cheapo Saddle
Moab, Utah:
      Pritchett Canyon, Top Of The World, Cliff Hanger Gatekeeper
Southern Utah:
      Hole In The Rock
Colorado:
      Poughkeepsie Gulch, Imogene Pass, Black Bear Pass

On 35" x 12.5" tires:
Southern California/Johnson Valley:
      Jack & Sledge Hammer, Aftershock, Fissure Mtn, Not Her Problem, Guacamole, Cougar Buttes

 

 

 

 

BigMike's 2016 Tacoma now has over 35,000 miles of daily driving and off-road wheeling with RCLT HD + 40" tires (never been trailered). Drives to, wheels hard, and returns home with zero suspension, steering, or RCV axle shaft failures. His truck averages 19.5 MPG with cruise control set to 70 MPH. Quite possibly the most accomplished street-legal IFS truck on 40-inch tires of all time!

BigMike is running approximately 5.25" of front end lift compared to stock.

Please click here to return to the top to explore more about RCLT HD through the page tabs above. Thank you!

The designation of RCLT HD is as follows:

"+2 RC": Rock Crawling (RC) Capability!

  • Knuckle moved forward +2.00 inches (50.8mm)
  • Approach Angle comparable to a mild Solid Axle Swap setup
  • Target goal of fitting 35" tires without requiring body mount modification

"+2.75 LT": Extended control arms for Long Travel (LT) capability

  • +2.75 inches (69.85mm) longer per side, overall track width increase of +5.50 inches (139.7mm)
  • Greatly improved side-hill stability, ride quality, and smoothness over large objects
  • Includes Secondary Shock Mounts (not shown in Preview photos)
  • Sets the bar for a New Mid-travel Solution:
    • Exactly between the industry standard of 2 and 3.50" LT widths
    • Maneuverability: Being too wide is often detrimental for use on technical trails
    • Flex: We use horizontal ball joints that exceed the articulation of vertical joint LT setups
      • Our +2.75" kit achieves up to 12.5" of travel at the hub, which is 96% as much as typical +3.50" kits yet is 27% more narrow for better maneuverability in technical trails.
      • Example: With 9" wide 4.06" backspace -24mm offset wheels this equates to 14.5" of travel at tire centerline, or 29" of real-world/RTI cross-articulation.
    • Fenders: The articulation performance of a +3.50" LT without requiring fiberglass!

"HD": Heavy Duty (HD) Boxed design
          Including HD Knuckles and integrated HD MarRack Steering Rack

  • Maximum strength for Rock Crawling
  • Double-sheer Horizontal Ball Joints top and bottom
  • Suspension travel no longer limited by ball joints
  • Double-sheer 1-ton SAS-sized Steering Tie Rod components
  • Extended height knuckle for greatly reduced bump steer and rate of camber change
    • Maintains alignment parameters for a far greater range of motion
  • Handling and ride quality vastly improved over Long Travel setups re-using factory knuckles
Put the three together and you get,

+2 RC +2.75 LT HD

We have a +3.50-inch LT design already being tested, however, we are currently only focused on the +2.75-inch LT.


Click here to read BigMike's TacomaWorld Reply #1,086 of how
RCLT HD is changing his 38 years of off-roading experience!

Click to read BigMike's technical break-down of wheel'n with RCLT HD     Click to read BigMike's technical break-down of wheel'n with RCLT HD


The first production RCLT HD will be our +2.75" version that fits:

2003+ Lexus GX470
2003+ Toyota 4Runner
2005+ Toyota 4WD Tacoma
2006+ Toyota FJ Cruiser


We have a +3.50-inch LT design already being tested, however, we are currently only focused on the +2.75-inch LT.



What Parts are Included?

  • Heavy Duty Lower Control Arms, 2.75-inch longer than stock (5.50-inch track width increase)

  • Heavy Duty Double-sheer Upper Control Arms with adjustable caster

  • Heavy Duty Double-sheer Knuckles with unique geometry only compatible with a MarRack
    • Not compatible with factory racks or narrowed Tundra racks
    • Not compatible with sway bars or K.D.S.S.
    • Not compatible with 15- or 16-inch wheels (see FAQ for more details)

  • Heavy Duty 1-ton SAS-sized Double-sheer Steering Hardware

  • Mounting Templates, Sector Shaft Adapter, & Hardware to install a MarRack

  • Adjustable 15,000 lb-rated Limit Straps with Heat Treated Chromoly Ends

  • Military grade USA-made Steel Braided Brake Lines

  • Complete Hardware Kit

Full Kit Photo and Online Instructions will be posted prior to shipping the first Production Run

Please see the "Required Parts" tab for remaining parts required to install RCLT HD.

Three Required Parts NOT Included

• MarRack Heavy Duty Steering Rack

The MarRack is a central component of RCLT HD and our Patent would not be complete without it.

The late-model 2003+ Toyota IFS System uses a light-duty rack & pinion that uses light-duty "fused" inner tie rods. These light duty components are known to fail with 34" tires, and because 35" is the entry point into Rock Crawling, by definition your steering system MUST be upgraded if you wish to off-road without failures. This is where the MarRack comes into play.

The MarRack is the first Heavy Duty Steering System that integrates with Long Travel in a way never previously done before. By using a 54% more massive and seriously heavy-duty steering rack, we custom designed the first Rock Crawling Steering and Long Travel Integrated System with new & improved geometry designed for lifted applications & focused on maximum strength. Our unbreakable double-sheer CNC billet steering arms provide 15% more steering power while reducing steering effort by the driver by 15%. Moreover, this unique design decreases stress acting on steering components from objects encountered on the trail. A serious win-win! Finally, the MarRack enables our knuckles to be pushed forward more than double any other Toyota LT for unparalleled Rock Crawling IFS performance!

So exactly what is the MarRack?
The MarRack was originally designed from the strongest Koyo Seiko steering rack used on a non-commercial vehicle and was meant to be a 100% custom & bolt-in Marlin Crawler product. We sent RCLT HD designs to Japanese and US rack manufactures but ultimately could not make a MarRack at a competitive price point. As a result, the design of RCLT HD was carefully altered to allow a Toyota-based solution to work which is internally known as the "MarRack 2.0", now sourced from a 200-series Land Cruiser. Compared to a 2nd gen Tundra rack, the MarRack is stronger, larger, has an increased cooling capacity, and has three frame mounts instead of two. Best of all, the MarRack never needs to be narrowed or shortened because RCLT HD has its own geometry!

Now then, when we show you the following pricing, you're going to be astonished which is why we could not make our own rack in a cost effective manner.

Standard Build: $330
Aftermarket overseas manufactures. Random examples shown, pricing as of 5/23/21
RockAuto » Ultra-Power P/N 3676N for $289.79 (link, Region-based network)
RockAuto » AAE P/N 3676N for $351.79 (link, Region-based network)
BuyAutoParts » New P/N 80-01660 AN for $408.22 (link, Kentucky)
BuyAutoParts » Remanufactured P/N 80-01660 R for $373.95 (link, Kentucky)

Ultimate Build: $500
Genuine Toyota P/N 44200-60170. Random examples shown, pricing as of 5/23/21
MC George Toyota » $468.43 (link, Richmond, Virginia)
Olathe Toyota » $478.41 (link, Olathe, Kansas)
Toyota Parts Deal » $492.75 (link, Nation-wide dealer network)
Your Local Dealership » $703.54 (link, Nation-wide dealer network)

Compared to other LT setups, the $330 to $500 MarRack is the only new expense required. Should you desire to refresh the MarRack after say 100,000 miles of trouble-free rock crawling, you don't have to pay extra for a special narrow or custom tig-welded rack; You simply order one from anywhere, re-use our simple parts to modify it, and install.


The remaining two parts are standard required parts for any Long Travel Kit or Solid Axle Swap conversion.

• Axle Shafts

We recommend RCV Axles

Standard Build (for tire sizes up to 35"): $750
RCV Chromoly Replacement Inner Shafts
Two required @ $375 each, currently available direct from RCV (815) 877-7473 with a typical lead time of 6 to 8 weeks. Specify "OEM +2.75 Shafts". Reuses your original factory inner & outer joints & boots.

Ultimate Build (35" tires or larger): $2,195
RCV Ultimate CV Set -- Click to view RCLT HD Axles on rcvperformance.com
P/N CVJIFS-TOY2X2.75, one set required @ $2,195, available direct from RCV (815) 877-7473 with a typical lead time of 6 to 8 weeks. Complete axle, joint, & boot replacement using unbreakable Dana 60 35-spline 300M Chromoly with a lifetime warranty up to 40" tires.


• Long Travel Coil-overs

2.5-inch LT coil-over with a 24.5" extended length and 8" stroke, or equivalent. For best results we recommend Radflo.com coil-overs which have been custom built by our own specifications in testing and tuning RCLT HD and have a true 8.0-inch stroke. See FAQ for more details.

Standard Build: $1,700
The standard build has a remote reservoir without compression adjustability.
Radflo P/N 6CT 001 5R sold as a pair @ $1,702.00. Coil: 550 lb-ft, other rates available by request.
Icon P/N 59730-CB sold as a pair @ $1,679.95. Coil: 600 lb-ft, other rates by request.
Fox P/N 880-02-953 sold as a pair @ $1,749.00.

Ultimate Build: $2,000
The ultimate build includes compression adjusters for fine tuning of suspension ride and performance.
Radflo P/N 6CT 001 5A sold as a pair @ $1,974.00. Coil: 550 lb-ft, other rates available by request.
Icon P/N 59730C-CB sold as a pair @ $1,952.84. Coil: 600 lb-ft, other rates by request.


Total Cost Overview based on the above

Standard installation of RCLT HD:
$286.79 (MarRack) + $750 (Inner Axle Shafts) + $1,679.95 (Icon Coil overs) = $2,716.74 needed parts
$6,999 RCLT + $2,716.74 needed parts = $9,715.74 total

Ultimate installation of RCLT HD:
$461.03 (MarRack) + $2,195 (Ultimate CV Set) + $1,974.00 (Radflo, adj.)     = $4,630.03 needed parts
$6,999 RCLT + $4,630.03 needed parts = $11,629.03 total

Tools required to install RCLT HD include a welder, grinder, drill, and simple hand tools. The total amount of welding is only around 25" inches of weld and can be done with home garage welders. Our instructions will cover installation in detail and will be posted prior to shipping out the first order.







RCLT HD placed 10th in the 2020 King Of the Hammers Every Man Competition (EMC) under a V8-powered 4Runner, becoming the first Toyota IFS to run both desert & rock crawling trail sections at the most abusive single-day off-road race on the planet!

RCLT HD is the only IFS + Steering integrated system strong enough for KOH EMC.

Shannon Campbell approved

At the 2020 King Of the Hammers, RCLT HD received an awesome endorsement from IFS Rock
Crawler and 3-time KOH Champion Shannon Campbell! Shannon races an 800 HP Ultra4 car with
IFS + 40" tires, and is the most successful competition IFS Rock Crawler around!

Del Albright approved

At the 2020 CAL4WD Convention, RCLT HD received another great vote of confidence
from Off-road Motorsports hall of famer and one of the largest land use advocates in
the country, Mr. Del Albright! Del is an incredible ambassador to off-road access and
runs professional off-road training and leadership programs. Please check out his
highly informative website at delalbright.com

Steve Sasaki approved

At the 2020 Fourwheeler Adventure Expo, RCLT HD got endorsed by Steve Sasaki
of PowerTank.com!! Steve said, "This is the new SAS for modern Toyota's."
Steve is the founder of Power Tank and has developed the best portable air system
for airing up tires, reseating beads, and running air tools out on the trail.
We have proudly carried his Power Tank products for close to 20 yrs
and highly recommend them: MarlinCrawler.com/powertank

Fred Williams approved

Also at the Adventure Expo, RCLT HD got endorsed by Fred Williams from
Motortrend's Dirt Every Day TV series!! Here is what Fred had to say:
"Marlin Crawler continues to innovate. What started with
gearing has evolved into a Toyota IFS for the Rock Crawler."

Thank you very much Fred and we absolutely LOVE watching your
show and working on your Toyota Rock Crawler "Clampy"!


RCLT HD Installation Instructions

Click here to download Instructions (v1.02, 49-pages, 8.3 MB PDF)
Updated: 6/13/21

Frequently Asked Questions

Updated: 6/11/21

Coil overs

RCLT HD is designed for use with 2.5" diameter Coil overs typically used on +2.00" & +3.50" Long Travel setups, specifically with a 16.5" collapsed, 24.5" extended, and 8" stroke lengths and a lower mount designed for 1/2" hardware and 1.5" mounting width. Longer or shorter coil overs may be used at the expense of either less up-travel or less down-travel, respectively.

Body and/or Bumper Clearancing

Because RCLT HD repositions your front tires forward 2-inches for an industry-best and patent-pending Long Travel IFS approach angle, you must take into consideration any new tire-to-body, tire-to-fender, and/or tire-to-bumper interference. Depending on your tire size and ride height, another use for a bump stop in such case may be to specifically limit up-travel to avoid tire interference (see Bump Stop section below). However, the high performance nature of RCLT HD begs to be fully realized in which case, just as with a Solid Axle Swap, proper tire clearancing is always recommended to achieve the full range of suspension articulation & steering performance!

Coil Spring Rates

Within the confinements of RCLT HD being a near bolt-on system, it is strong enough to handle anything thrown its way. Due to use preferences ranging from Rock Crawling, Baja, Sand, Mud, Snow, to Overlanding, as well as vehicle configurations from heavier 8cyl SUVs with full plate armor and coil rear suspension to lighter 4cyl single cabs with tube bumpers and leaf springs, there is no one-spring-rate-fits-all solution. The answer to what spring rate is right for you depends on how your vehicle is configured and how you plan to use RCLT HD. You may find yourself tinkering with the spring rate to dial it in to suit your needs.

Additional consideration applies to your rear suspension setup. The goal for Rock Crawling would be to have the front and rear suspension complement one another, whereby the front spring rate is not too high that it causes the rear suspension to be over-worked. Keep in mind that leaf springs are a progressive rate spring that increases with compression.

Please use the following as a general guideline to base your decision with. This information is a work-in-progress and is only meant as a suggestion. As we collect feedback data from customers, we will adjust values as needed:

Use caseEmpty Vehicle WeightRear SuspensionSuggested Spring Rate
Rock Crawling4,500 lbsCoil
Leaf
500 lb-ft
500 or 550 lb-ft
4,500 to 5,250 lbsCoil
Leaf
550 lb-ft
550 or 600 lb-ft
5,250 to 6,000 lbsCoil
Leaf
600 lb-ft
600 lb-ft
6,000+ lbsCoil
Leaf
600 lb-ft
650 lb-ft
Baja / Sand4,500 lbsany550 lb-ft
4,500 to 5,500 lbsany600 to 650 lb-ft
5,500+ lbsant650 lb-ft

Bump Stops

Short answer: Replacement Low Profile Bump Stops (included with kit) may be reused with the original factory frame mount bracket resulting in decreased up-travel. Fitting adjustable air bump bump stops are preferred for best performance and adjustability.

Long answer: RCLT HD's Lower Control Arm (LCA) has two patent-pending features beneficial to Rock Crawling: (1) Inner V-groove for axle shaft clearance & protection and (2) Inverse arm design to maximize ground clearance. These features, however, limit compatibility with the factory bump stop frame bracket because the top of the LCA is closer to the frame resulting in prematurely bump stop activation and decreased up-travel.

See section "BUMP STOP CONSIDERATION" on Page 32 of our Installation Instructions for more info.

     
Designed to be jumped
Prototype 1.0 with custom fabricated
Air Bump Bump Stops
Not designed to be jumped
Prototype 2.1 compatible with
included Low Profile Bump Stops

Sway Bar

RCLT HD is not compatible with factory-style sway bars including the Toyota K.D.S.S. system.

Our Lower Control Arms do have behind-the-axle Secondary Shock Mounts which could be used with a custom fitted behind-the-axle type swaybar (see LCA sway bar examples such as a 2nd gen Tundra or 100- & 200-series Land Cruisers).

Toyota Safety Sense on 2018 and newer vehicles

All products on this website are intended for Off-road use. RCLT HD prides itself in highly stable geometry resulting in superior drivability compared to other lifted Long Travel setups that reuse factory knuckles. Please be aware that if you alter the height of a vehicle equipped with Toyota Safety Sense (MY 2018+) then you may need to recalibrate your vehicle's dynamic radar cruise control, pre-collision with pedestrian detection, and lane tracing assist. Please ask your dealer or contact Toyota Motor Corp. for details.

Traction Control

While RCLT HD is fully compatible with all traction control systems, please bear in mind that a lifted vehicle on larger than stock tires will result in a higher center of gravity that may cause your traction control system to be more active than stock at heavy-acceleration low-speed sharp-cornering during city driving.

Wheel Backspacing

Wheel backspacing should be limited to 4.50" or less. This is due to 1) The oversized Heavy Duty design of the RCLT HD Knuckle, 2) Larger than stock Long Travel Coilover diameters, and 3) Wider than stock tires desirable for increased off-road traction (i.e. 12.5" or 13.5" wide tires compared to only 10.5" wide stock tires).

Here are two examples we've tested: 12.5" wide tires on 17x8.5" wheels with 4.5" backspacing results in roughly 1/2" clearance between tire sidewall and knuckle, and 13.5" wide tires on 17x9" wheels with 4" backspacing results in roughly 3/8" clearance.

If you are partial to 4.75" backspace wheels, then you could try using simple 1/4" spacers to test for wheel-to-knuckle clearance. These are available by many manufactures and can be had for $9 on Amazon. We tested these exact spacers on our V2 prototype and had no problems.

Wheel Diameter

RCLT HD's steering geometry requires a minimum wheel diameter of 17-inch. Therefore, 15- & 16-inch wheels are not compatible.

Three silver linings to this are that 1) Off-road wheel distribution websites shows on average 40-times more 17" beadlock choices than 16", 2) Tire distribution websites list nearly no inch-sized tires (33"/35"/37"/39"/40") available for 16-inch wheels, and 3) Tacoma owners will be able to upgrade to 5th gen 4Runner or Lexus GX460 2010+ brake rotors (23% larger diameter & 28% thicker) and 2010-2015 brake calipers (28% larger piston volume).

Proposition 65 Warning for California Consumers

WARNING: Products we sell can expose you to chemicals which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.p65warnings.ca.gov.