Installed the RadFlo Coilovers and Total Chaos Arms today....KDSS is a P.I.T.A!!

[dtt255]

Well the subject tells it all. After spending 10 hours in 100 degree heat, I am too tierd to write the whole process and post the pics, but here is a pic of the coilovers and arms installed.

I will edit this later with all the details.

About the KDSS system....it is going to be something that I am going to have to learn to like....especially if I plan on working on this LC.

After we got everything installed the truck was leaning heavily to the passenger side. The whole truck, not just the front or rear.

After going on to TIS (toyota's service system) it seems that we needed to BLEED the KDSS system before putting all the new stuff on and then before we take the LC off the jack, we need to re-tighten the KDSS bleed valves.

I have to talk to Toyota on Monday. There is something seriously wrong with that. Does this mean that I cannot jack the truck up and rotate my own tires without bleeding he KDSS system???

In another words, only by BLEEDING the KDSS system, can the suspension be basically 'reset' to re-stabilize itself.

That does not sound correct, Toyota cannot be THAT STUPID!

Well anyway, I have to get some sleep after I try and convince the wife that I love her more then the LC. (shhhhhh don't tell her the truth!

 

[uzj100]

How does it ride now? How does it handle? Pictures? Is this a lift or just new shocks?

 

[macneill]

We need way more pix please!

 

[dtt255]

Ok, here we go.

Pretty simple basic operation.

EDIT: Please see the link with the document attached below by bjowett for how to set the KDSS system BEFORE this install!

First remove the wheels.

Then remove the 4 bolts on top of the shock and one on the bottom.
Make sure that you watch out for the brake line (black) and skid control cable (purple).
We had to use a large screw driver and a mallet to get the actual bolt out of the bottom part of the shock.

Please keep in mind that all these bolts are VERY SNUG and most likely will need to be hammered out. Obviously the best way to do this is to place the nut on back on the end of the screw and hit nut with the hammer. This saves the ends of the actual bolt.

Now once all the bolts are out, the fun starts!!

You have to disconnect this small arm:

This is what connects the sway/KDSS system to the wheel. It is PAIN to try and get out....but just work it and it will happen.

We had to use several jacks to lift the sway bar and lower arm to get them to line up so that we could get it out easily and back in.

Here is another pic of an arm that connects the KDSS system to the lower control arm:

We had to pull out the bottom of the shock by having once of us pull on it, while the other stands on the lower arm to make sure it was fully lowered.

Now the one things that would make this TONS easier is having a lift. Once it is up on the lift everything will be fully lowered by gravity and make things MUCH easier. Plus it is almost a requirement....you will see why in a bit....

Here is a pic of the OLD and then the NEW Coilover:

Notice in this pic that the shock is gone but the control are is still attached. To remove the control arm, you must disconnect the arm from the spindle. To do this, simply hit a the control arm ball joint from UNDER where it connects to the spindle. We had to give it a good 3 hard taps and it popped right out.

WARNING: Keep your face out of the wheel well when doing this!! The arm is under UPWARDS pressure and will snap UPWARDS after you disconnect it from the spindle.

Once you are done with this, just remove the nut from the old control arm and tap the other end of the bolt with a hammer and screwdriver to get it to come out. I had to grab the bolt from inside the engine bay to get it out. It was hitting wire looms and other stuff we could not move from inside the wheel well.

Here is a pic of the OLD and NEW control arms....HUGE difference!

Then put the new control arms in the way the instructions say to. You will need to make sure that you have SUPERLUBE Teflon Grease. I found some at Ace Hardware.
The arms were supposed to come with some grease, but did not. I had to drive 50 miles each direction to go get some.

Grease it up the way the instructions say, this is very important. Plus make sure you use teflon grease as anything else will eat through the poly-urethane bushings over time, and that is not good.

Total Chaos suggests that after 500 miles you check everything and re-grease the bushings via the zerks that you install onto them.

To get the new coilover in, just put the top in first...line up the holes then push down HARD on the lower arm and slip the lower part into the lower arm. Install all the new bolts on top and then you re-use the original on the bottom.

I am making it sound WAY to easy....but it is simply force that you need to push it back in.

Make sure you tighten things up per the FACTORY spec torque or what the new instructions say. If anyone needs help with those numbers, just PM me!

Some things you need to take note of, is WHICH way you want the reservoir to go. The best area we found was behind the shock sleeve and upside down. We secured it by drilling holes on the plastic backing and using 4 zip ties (three around the reservoir and one around the hose at the base of the tank.) It won't be moving at all.
We tried other places, but the wheels were way to close to the reservoir and were just didn't want to take any chances.

Obviously I will be checking everything often to make sure it stays where it is.

I have to give Glenn a call at Radflo and tell him that they need to figure out a mounting solution to this.

Here was our final solution:

Ok now that as the drivers side.

The passenger side is almost the exact same thing BUT the arm that connects the sway/KDSS bars to the lower arm is different. Same size, but a bolt with an allen wrench slot in the middle of it. Same PITA to remove!

EDIT: Please see the link with the document attached below by bjowett for how to set the KDSS system BEFORE this install!
That was the whole thing. About the problem we had at the end...I will go into in my next post. This one is too long already!

 

[dtt255]

Well here is the second part.

When we got it all done....we noticed that the LC was DRAMATICALLY leaning to the right. The whole LEFT SIDE of the truck was about 5 inches higher then the left.

See here:

Now that is VERY weird as everything we did was on the FRONT not on one side.

Well some of us jumped on the front left bumper trying to stabilize it, etc...nothing.

So I drive it around....otherwise then needing an alignment (which I expected), and being tilted higher on the left side, it was fine.

So we pulled out the manual and read through that section again.

Well it seems that somehow the KDSS system locked up and would not let the LC re-calibrate itself.

This morning at 7AM I am sitting in their service bay and they take her into the building.

I am very lucky that I got a service guy and head tech who used to work at Lexus and have dealt with the AHC on the lexus vehicles and was familiar with these types of issues.

Well they hooked up the computer thingy to my LC and had the computer initiate a re-calibration of the suspension system and it freed everything up and we were all good!
Didn't cost me a thing and only took about an hour!

What exactly caused it, I don't know. I think with us pulling and stepping on the arms, etc. trying to free everything up, that we triggered something.

Here is a AFTER Toyota Service picture:

I took it to a place that specialized is alignments for 4 wheel drive vehicles today. We both agree that it needs about 1/2 inch more lift in front. So he is going to adjust the Radflo's so that they are 1/2 inch higher and then align everything.

Here is a BEFORE lift:

After Lift: (Much better, but I still need to adjust it 1/2" upwards.)

UPDATE after having more responses throughout the thread and with the document that is linked below, it seems that the issues I had were caused by us NOT unlocking the KDSS system before the install.

Something that is relatively simple and easy.

The ONLY issue with all of this is that ALL 4 Wheels need to be completely lifted completely off the ground and allowed to hang to the maximum distance downward BEFORE you do the unlocking of the KDSS system.

For a normal shop this is not an issue, for people at home.....you are going to need a few extra jacks......

 

[macneill]

Looks awesome.

So this is in lieu of an OME?

OME has not indicated they have anything coming out anytime soon.

Glenn from Radflo offered to make some custom ones......I took him up on it.

 

[uzj100]

What are you using for the rear lift? Which springs?

 

[dtt255]

What are you using for the rear lift? Which springs?

Nothing! That is just from the weight of the front that is kicking up the rear!

 

[uzj100]

There has to be rear springs available. What did slee use on the 200 headed to Alaska?

 

[bjowett]

I read something online recently in PDF form that showed how install a lift on a 200 series with the KDSS. It shows how to open a valve in the center control valve for the KDSS before installing the kit, then closing it after. I'm assuming it is to prevent the issue you had..... I'll try to dig it up.

Oh, looks good!

 

[bjowett]

Here it is.....

Catalogue

http://www.kingsprings.com/Version_3_graphics/200 Series Tech Bulletin.doc

 

[dtt255]

Here it is.....

Catalogue

http://www.kingsprings.com/Version_3_graphics/200 Series Tech Bulletin.doc

Where were you Saturday Night!!!!

I guess we are lucky that the crowbar we used to move the sway bar didn't hurt anything

That sounds so much easier then the tech manual instructions!

 

[MutleyFJ62]

dtt255: when we lift these at work, the procedure to level the vehicle is to locate the actual kdss pump, which, on australian models is under the floor pan, just behind the drivers' seat, ensure the vehicle is sitting on flat ground and crack the two bleed nipples on the pressure lines, this lets fluid move internally in the pump and allows everything to return to normal. Interesting to note, up to 10mm difference between left and right in the ride height is considered acceptable from toyota.

 

[ShottsUZJ100]

Do you have a better AFTER pic? It looks the same as before lift. ???

 

[dtt255]

Do you have a better AFTER pic? It looks the same as before lift. ???

We are on a vacation to Utah. When I get home I will take some better shots.....shotts.

 

[chimyz]

Just finished install of my setup...same as DTT255. Thanks to DTT255s help and advise, it took only 4 hrs instead of his 10 .

I have to put a big thanks out to my friend Dave. He was the main wrencher, but we worked through the install together.

The KDSS is not too much of a PITA, as long as you open up the valves to allow fluid to run throughout the system. We also didn't end up with a 5" lean when the install was complete. Everything was nice and level at the end of the install.

I will need an alignment, that will happen later this week. Once I get the rig leveled by adjusting the coilovers, and have some time, I will post pics and comments in a new thread.

Again...Thanks to DTT255 and Dave.

 

[AutoCraft Aus]

KDSS is easy, just undo the valves, and make sure the vehicle is level when you do them up again.

Or,

when you see some one you lknow parked the 200, undo them, lift the car one side a bit, re tighten the valves, and they wont be able to figure out why thier new 200 leans one way all of a sudden

 

[dtt255]

KDSS is easy, just undo the valves, and make sure the vehicle is level when you do them up again.

Or,

when you see some one you lknow parked the 200, undo them, lift the car one side a bit, re tighten the valves, and they wont be able to figure out why thier new 200 leans one way all of a sudden

Now that would be funny....if I didn't do it to myself at first!

 

[dtt255]

Do you have a better AFTER pic? It looks the same as before lift. ???

I just got back from vacation and will be getting it adjusted up on Monday or Tuesday, so I will take more pics before and after that process.

 

[dtt255]

Here is a pic after I got the front raised an inch and the alignment done.

Mucho Bueno!