40th Anniversary 2002 Toyota Tacoma 4x4 Pro Comp Suspension

Last month we launched our Four Wheeler 40th Anniversary Toyota Tacoma project truck. One lucky reader not only will win it, but will be invited to use it to chase the BFGoodrich/Toyota unlimited Class 1 team as it races down the legendary Baja peninsula during this year's SCORE Baja 1000. If you recall, we took our four-wheel-drive Tacoma to new heights of torque and power with the addition of a complete TRD Sportparts package that included a stainless-steel header and exhaust system, a high-flow air filter, and best of all, a supercharger system.

Now it was time to look at our Toyota's suspension. The thought of turning our BFGoodrich Toyota into a real prerunner with huge travel did cross our minds, but reality intervened and gave us the sense that we'd be better off going with a moderate lift that would provide excellent day-in, day-out usability.

What then, to do about the suspension system? The answer came from our friends at Pro Comp in Chula Vista, California. Pro Comp offered us an opportunity to test its potent new component package that combines the company's very popular 4-inch lift kit with a brand-new RaceRunner coilover shock in front and its breakthrough Monotube MX-6 units in the rear. Sounded pretty good. While we were there, we also decided to add a set of Pro Comp rear traction bars and stainless-steel skidplate.

Manufacturer's Suggested Retail Prices
Pro Comp Tacoma pickup 4wd System: $1,902.60
Pro Comp rear traction bars: $283.41
Pro Comp rear traction bar mounting kit: $161.57
Pro Comp stainless-steel skidplate: $200.57
Pro Comp MX-6 shocks (each): $119.00
Pro Comp coilover front shocks: Call for info

Our objective? To add some aggressive good looks, provide additional space for a larger set of BFGoodrich Mud-Terrain T/A tires, and give our Toyota the benefits of much better shocks and suspension-but with one important caveat. We wanted to maintain the Tacoma's legendary reliability while preserving the truck's original suspension geometry and drivetrain angles. No breaking down in the middle of Baja for us, or for you.

While Pro Comp recommends that these kits be installed by a trained Pro Comp dealer technician, weekend warriors install almost 20 percent of the kits the company sells. Like the installation of the TRD blower and exhaust system, this type of suspension modification takes time, patience, skill and all the right tools. A detailed set of instructions, a car hoist, and the never-ending help of our Pro Comp technicians made our job that much easier. For all those with the skills to take this on, the kit really fits beautifully-but schedule a whole weekend to do the job.

As soon as our completed Tacoma came off the hoist, we knew our choice for the Pro Comp 4-inch lift was just right-tall enough to be aggressive and give us the stance we wanted, but not so tall as to be a rollover waiting to happen. Now it's time to add some bigger, more aggressive BFGoodrich rubber, a set of great looking custom wheels, and some external goodies to make our package even more complete. Then we'll turn it loose to Molly Designs for paint and graphics.

Don't forget to enter our special Four Wheeler 40th Anniversary contest! After all, this truck could be yours.

Here's a great tip. Hold the brake disc assembly with a long prybar against the caliper to help remove the disc nut.
Here's a great tip. Hold the brake disc assembly with a long prybar against the caliper to
After removing the lower shock bolts and upper nuts, remove the stock shock and coil assembly.
After removing the lower shock bolts and upper nuts, remove the stock shock and coil assem
It's a good idea to use a big zip-tie to hold the front brake caliper out of the way.

It's now time to remove the tie-rod ends. It's always best to use the proper tie-rod end puller.
It's now time to remove the tie-rod ends. It's always best to use the proper tie-rod end p
Now you can pull the front hub assembly away from the front half-shaft. Notice that once again we've used a large zip-tie to hold the shaft out of the way.
Now you can pull the front hub assembly away from the front half-shaft. Notice that once a
To remove the upper ball joint from the hub assembly, remember to use a proper puller.

Front Suspension Cont...

To remove the stock upper ball joint from the front uprights, which you must do in order to install the kit's extensions, use diagonal cutters to clip the wire retainers, then remove the protective boot. Reuse the white Toyota grease-it's some of the best stuff you can find.
To remove the stock upper ball joint from the front uprights, which you must do in order t
Use your long snap-ring pliers to remove the retaining ring from the upper ball joint. Then you've got to use a big press to remove the production ball joint.
Use your long snap-ring pliers to remove the retaining ring from the upper ball joint. The
To install the ball joint into the extension, place the joint sideways and slide it into the hole. Then tighten the ball joint.
To install the ball joint into the extension, place the joint sideways and slide it into t

Reinsertion of the OEM ball joint into the Pro Comp extension can be tricky. It is important to make certain that the joint is straight all the way around before inserting it. Installation is complete when the large snap ring fits solidly and completely into its milled groove.
Reinsertion of the OEM ball joint into the Pro Comp extension can be tricky. It is importa
Attach the new ball-joint assembly to the upright. Make certain that the vertical line in the casting is lined up with the center of the hub assembly.
Attach the new ball-joint assembly to the upright. Make certain that the vertical line in
Pro Comp has a great method of strengthening the stock Toyota upright/spindle assembly. Use of this additional spindle support bracket (arrow), supplied in the kit, adds strength and rigidity.
Pro Comp has a great method of strengthening the stock Toyota upright/spindle assembly. Us

Use a large hammer to conform the U-bolts to the back of the spindle assembly.
Now the real work begins. Start by loosening the driveshaft at the front of the truck and removing the steering rack. It is critical to lock the truck's steering in place in the center position and remove the key. Rotating the wheel will damage the mechanism and will disconnect the airbag, horn and cruise-control system.
Now the real work begins. Start by loosening the driveshaft at the front of the truck and
The stock Toyota crossmember is cut vertically with a Sawzall. Make certain you mark carefully before cutting. You'll want to trim the edges with a small disc grinder. Be certain you have all the right clearances-it took us some time and refitting of parts to get it just right.
The stock Toyota crossmember is cut vertically with a Sawzall. Make certain you mark caref

After the crossmember is cut, it's a good idea to paint the surface with flat black spray paint to prevent rust. Now it's time to install the new front and rear Pro Comp crossmember units.
After the crossmember is cut, it's a good idea to paint the surface with flat black spray
New crossmembers and steering rack mount are now bolted in place and ready for refitting of the Toyota steering rack.
New crossmembers and steering rack mount are now bolted in place and ready for refitting o
Reinstallation of the Tacoma's front A-arms is relatively straightforward. Just be certain that the adjusting cam bolts are correctly reinstalled, as shown.
Reinstallation of the Tacoma's front A-arms is relatively straightforward. Just be certain

The completed assembly shows the new bumpstops incorporated nicely into the front-suspension crossmembers.
The completed assembly shows the new bumpstops incorporated nicely into the front-suspensi
Use of this lift kit dictates a need for longer brake lines. Pro Comp provides new stainless steel lines that fit perfectly.
Use of this lift kit dictates a need for longer brake lines. Pro Comp provides new stainle
Installation of our trick coilover front shocks is straightforward. These trick assemblies feature ride height and pre-load set at the Pro Comp factory. They are ready to install right out of the box.
Installation of our trick coilover front shocks is straightforward. These trick assemblies

The final touch at the front comes when we install the Pro Comp skidplate. Installation is quick and easy, and begins with a simple front mount attached in stock threaded locations. Both the mount and bottom plate are finished in the same powdercoat color to match the rest of the suspension. The front plate is made of good-looking stainless steel.

Rear Suspension

In the rear, a lengthened main brake line must be added to accommodate the additional height provided by the kit's suspension blocks. This kit includes a nice braided stainless-steel line.
In the rear, a lengthened main brake line must be added to accommodate the additional heig
Removal of the stock rear shackle plate and bolts is a simple step, especially if you have access to air tools, as we did.
Removal of the stock rear shackle plate and bolts is a simple step, especially if you have
The Pro Comp kit comes complete with this bracket, which is used to reposition the brake proportioning valve.
The Pro Comp kit comes complete with this bracket, which is used to reposition the brake p

Remove the parking brake line's retaining bracket, flip it over, and reinstall it to provide more clearance.
Remove the parking brake line's retaining bracket, flip it over, and reinstall it to provi
Here we install the new rear spring blocks. Note the longer U-bolts supplied with this kit.
Here we install the new rear spring blocks. Note the longer U-bolts supplied with this kit
Now it's time to install the Pro Comp MX6 adjustable monotube units. They not only look great, but also will help stabilize the rear end on those fast Baja chase roads.
Now it's time to install the Pro Comp MX6 adjustable monotube units. They not only look gr

Here we're getting ready to fit our Pro Comp traction bars. Nicely finished in a sprinkled gray powdercoat, these bars are another great addition to keep our truck working well in the desert.

Project 40th Anniversary Tacoma - Part 1, click here.
Project 40th Anniversary Tacoma - Part 3, click here.
Project 40th Anniversary Tacoma - Part 4, click here.