Project 2005 Nissan Nismo Frontier - Four Wheeler Magazine

Our Nismo Frontier has gathered a sizable fan base in the last two years. Reader feedback is never without praise for our midsize project and its bolt-on nature. However, we're often questioned about which suspension system we installed under our Nismo. Unfortunately our response is not always what people expect, let alone want to hear. You see, when we were in the market for a lift kit, the Frontier platform was new from the ground up, and suspension options were extremely limited. This was a royal pain in the rear for us because we wanted to improve the stock setup. So instead of getting mad about it, we converted our frustration into progress, volunteering our truck as a guinea pig to a select few aftermarket suspension manufacturers, hoping to jumpstart our favorite midsize platform in that particular area of upgrades.

First, we dropped the vehicle off at Calmini of Bakersfield, California. Calmini specializes in the import market and jumped at the opportunity to mock up an affordable cosmetic drop-bracket-style lift kit for us. The kit Calmini prototyped, although not intended to drastically improve trail performance, did raise the vehicle 5 inches, which allowed fitment of 33-inch tires. Along with the improvement in ride height came an additional inch of ground clearance, thanks to an intelligently designed lower front crossmember.

Moab's Kane Creek Trail was no match for our Nismo Frontier. Here Four WHeeler Publisher Steve VonSeggern creeps cautiously across one of the several creek crossings along the route.
Moab's Kane Creek Trail was no match for our Nismo Frontier. Here Four WHeeler Publisher S
This is the new Calmini drop-bracket suspension lift for Frontiers. You'll notice it comes with taller knuckles to help accommodate a 5-inch increase in overall ride height.
This is the new Calmini drop-bracket suspension lift for Frontiers. You'll notice it comes
We're going to skip to the main course because space is tight. What you're looking at here is the driver-side rearmost front crossmember mount. This is where the lower A-arm bolts up, as well as where the rear of the front differential is attached to the frame. In this photo, the metal bracket has been marked with a silver pencil. This is where the Calmini kit requires that installers cut out a small piece to allow fitment of the new dropped crossmember. This is the only major "can't-go-back" portion of the Calmini kit.
We're going to skip to the main course because space is tight. What you're looking at here

Next, we dropped our project off with the capable designers of Total Chaos Fabrication of Corona, California. Total Chaos is well known for building high-quality long-travel suspension systems for desert racers and prerunners. After about a week with these go-fast experts, a new tubular upper control arm was refined and fit-tested on our truck.

Finally, we decided to consult our friends in the R&D department at Light Racing for a much needed "mobility improvement session." These guys are all about secondary suspension (air bumps), and the products they build are second to none. Our session resulted in a new application for Light Racing's sweet new Compact Jounce shock line. We like Jounce Shocks because they allow increased speed and mobility by removing the harshness from a bottom-out event. Light Racing's engineers used our truck to design, fabricate, and test a set of mounting brackets for the new system.

The results of all our time and energy are significant to Frontier owners because now there are actually a few suspension options available for public consumption.

Here again you can see where the OE bracket was cut (arrow). Notice how the new (blue) crossmembers drop the differential down from the factory location. This is typical with drop-bracket lift kits. As you might imagine, these lowered mounting points increase leverage on the framerails. (This is why we don't recommend drop-bracket kits for the go-fast crowd.) To combat the added leverage, Calmini uses aft-braces (not shown) that help distribute stress loads back to the factory transmission crossmember. These braces work fine for everyday driving scenarios, but don't expect this arrangement to hold up in the Baja 1000.
Here again you can see where the OE bracket was cut (arrow). Notice how the new (blue) cro
This picture illustrates how Calmini achieves lift using the OE Bilstein strut. Notice the blue piece between the top of the strut and the factory coil bucket. It has a similar effect to walking on stilts, i.e., no actual increase in wheel travel, just elevation change.
This picture illustrates how Calmini achieves lift using the OE Bilstein strut. Notice the
Here, the technicians are installing the large front differential skidplate supplied with the suspension lift. This rigid piece of 1/4-inch steel substantially stiffens the front drop-down assembly while protecting the vulnerable aluminum front differential at the same time. It comes powdercoated blue, as does the rest of the kit's bracketry.
Here, the technicians are installing the large front differential skidplate supplied with

The rear of the Calmini kit utilizes a 2-inch lift block and new U-bolts to achieve a 2-inch increase in ride height. The new Calmini monotube gas shock is a sure improvement over stock, but is in no way designed for high-heat, fast desert driving.
The rear of the Calmini kit utilizes a 2-inch lift block and new U-bolts to achieve a 2-in
We wanted to improve on Nissan's factory ride quality, so we contacted Deaver Spring Manufacturing of Santa Ana, California. Deaver builds a soft-riding minipack that replaces the OE overload leaf with a three-leaf progressive add-in pack. The design helps eliminate ride harshness by distributing ride forces over a larger spring surface area. The kit raises rear vehicle ride height by 2.5 inches and comes complete with all necessary mounting hardware. This modification improved ride quality significantly. The only downside to this setup is that the design diminishes payload capacity by about half, which means you can't tow or haul as heavy a load as before. For our purposes, this sacrifice was well worth it.
We wanted to improve on Nissan's factory ride quality, so we contacted Deaver Spring Manuf
Altogether, it only took Deaver's technicians about 30 minutes to install both minipacks in our Frontier. Deaver removed the 2-inch Calmini lift block in addition to the stock overload leaves. This gave our truck a level stance front to rear.
Altogether, it only took Deaver's technicians about 30 minutes to install both minipacks i

Up front, some minor fender trimming was necessary to prevent tire rub while turning during suspension compression. A non-Nismo Frontier may require even more fender trimming because the stock ride height is about 1/4 inch less than a Nismo-spec truck. As you can see, the necessary trimming was pretty minimal with the Toyo Open Country Mud-Terrain tires we installed. It's worth noting that different wheel backspacing may also affect tire clearance, so we recommend asking retailers for advice before cutting.
Up front, some minor fender trimming was necessary to prevent tire rub while turning durin
We installed a sweet-looking set of 18x8 American Racing "Fuel" wheels. These wheels are air-sensor-compliant and feature gloss-black painted spokes. The tires we picked were the extremely tough Baja-proven Toyo Open Country MT in a 33x12.50R18. With a 10-ply rating, these tires should provide a surplus of puncture-free service miles.
We installed a sweet-looking set of 18x8 American Racing "Fuel" wheels. These wheels are a
Our friends at Light Racing of Catheys Valley, California, designed, built, and installed the Compact Jounce shock kit you see here. We had them install this system after the prototype Calmini lift was removed and the original OE suspension parts were reinstalled. This way, Light Racing could prototype the system and ensure fitment on both lifted and non-lifted Frontiers. As you can see, the front kit is pretty simple, consisting of two main parts; the jounce shock with upper mount, and the lower A-arm contact pad.
Our friends at Light Racing of Catheys Valley, California, designed, built, and installed

The rear Jounce Shock kit is equally simple to the front. A frame-mounted bracket houses the jounce Shock canister, while a lower contact pad, secured to the top of the axlehousing, provides a sizable flat contact patch setup to accommodate the axle's range of movement.
The rear Jounce Shock kit is equally simple to the front. A frame-mounted bracket houses t
Here you can see our Project Frontier restored back to its stock suspension, tires, and wheels. The only difference now is that the Jounce Shocks are absorbing the force from this small jump at Light Racing's R& D facility. Now, the truck lands smooth every time and we never get a harsh shock or loud bang associated with a bottom out. Instead, the Compact Jounce Shocks are absorbing the energy in a controlled manner.
Here you can see our Project Frontier restored back to its stock suspension, tires, and wh
This is a stock '05 Nismo Frontier that we borrowed from our friends at Antioch Nissan in Antioch, California. We brought this truck along to demonstrate the differences between a stock and Jounce Shock-equipped truck. We ran each truck over the same jump at the same speed. We first ran our Jounce Shock-equipped Project Frontier, and after four successful landings we were satisfied with the results. Next we hit the jump with the stock truck you see here. This was the third jump of our test session. Just as the shutter of our camera snapped closed, the stock driver-side front Bilstein Nismo-spec strut experienced a catastrophic failure. The shock simply wasn't designed to handle the force of the jump. Something had to give.
This is a stock '05 Nismo Frontier that we borrowed from our friends at Antioch Nissan in

We pulled off the driver-side front tire to inspect the failure. Shock oil was everywhere, indicating complete destruction and an end to our day's test session.
We pulled off the driver-side front tire to inspect the failure. Shock oil was everywhere,
Upon closer inspection, we found the swaged end cap, now separated from the shock body, had simply popped off, bending the shock body in the process. Residual damage was also found on the shock's cast-steel piston. Needless to say, we proved the worthiness of the Jounce Shocks with this carnage. Our Project Frontier, having survived the test, was good to go for another round, thanks to the Jounce Shocks.
Upon closer inspection, we found the swaged end cap, now separated from the shock body, ha
This shot shows the dome-shaped contact pad Light Racing uses on the front of the Frontier kit. The shape of this pad is very important to help align the Jounce Shock during impact.
This shot shows the dome-shaped contact pad Light Racing uses on the front of the Frontier

The Total Chaos UCA kit comes complete with high-misalignment spacers, urethane bushings, inner sleeves, bumpstop pads, and Grade-8 hardware. We like these because they solve two important issues and feature user-serviceable 1-inch uniballs.

The Total Chaos UCA kit comes complete with high-misalignment spacers, urethane bushings,

2005 Nissan Nismo Frontier Upper Control Arm

This is the new tubular upper control arm (UCA) by Total Chaos. These arms are designed as a bolt-on system that eliminates the factory ball joint and provides a 1-inch Teflon-lined uniball instead. We can't quite figure out why, but all '05-and-up Nissan Frontiers have a weird problem where the factory upper control arms contact the coil bucket during full droop. The contact is often amplified when aftermarket coil spacers are installed. These new tubular arms incorporate urethane droop stops, which contact the coil bucket instead of the arm, thus eliminating the problem. These arms also add caster, which will aid in vehicle cornering and overall handling, both on- and off-pavement. They also assist in correcting alignment issues when aftermarket lifts are installed. These arms are manufactured using 4130 chromoly tubing and come powdercoated silver with an additional layer of clearcoat. In some cases, these arms will actually allow for slight gains in wheel travel. The system is 100 percent bolt-on and requires no drilling or welding. The arms can be installed on any Frontier, Xterra, or Pathfinder. Zerk fittings are included to lubricate the urethane bushings and inner sleeves while bolted on the vehicle.

SOURCES
Deaver Spring	Total Chaos Fabrication 951-737-9682 http://www.chaosfab.com
Calmini Products	Light Racing Div. of Specialty Products Company www.lightracing.com
American Racing 1275 Davis Rd., Suite 300 Elgin IL 60123 8-00/-321-5489 3-10/-635-7806 www.americanracing.com	Toyo Tires 6261 Katella Avenue, Suite 2B Cypress CA 90630 8-00/-678-3250 www.toyo.com