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Toyota 4Runner 1996-2002 factory workshop and repair manual download

Tools & supplies (minimum)
- Floor jack and 2–4 quality jack stands (rated for vehicle weight)
- Wheel chocks, wheel lug wrench or 19 mm socket
- Impact gun or breaker bar + sockets (10–22 mm common)
- Torque wrench (capable to ~200 ft·lb)
- Spring compressor (coil spring type) or appropriate strut spring compressor for MacPherson strut
- Ratchet, extensions, combination wrenches
- Pry bar, pick, hammer, punch
- Hex/Allen key to hold strut shaft (if required; many struts use 6–8 mm hex)
- Penetrating oil (PB Blaster), wire brush
- Bungee cords or zip ties to hang brake caliper
- Rubber mallet
- Thread locker and anti-seize
- Replacement bolts/nuts (recommended), new washers if supplied
- Work gloves, safety glasses

Replacement parts commonly required
- Lowering springs or complete lowering struts/coilovers (front and rear matched)
- Shorter/lowered shocks or shock absorbers rated for lowered ride height (if not using matched strut assemblies)
- New top mounts/strut bearings (recommended if old)
- New sway bar end-links (if worn or to avoid bind)
- New bump stops or shortened bump stop adapters (to prevent shock/spring damage)
- Spring isolators/seats if damaged
- New hardware (many kits recommend replacing specific bolts/nuts)
- Alignment (camber/caster) parts if needed (cam bolts, caster plates)

Safety precautions (READ BEFORE START)
- Work on a flat, level surface. Never rely on a jack alone — always use jack stands.
- Chock opposite wheels. Block the wheels on the ground before lifting.
- Compressed springs store lethal energy. Use a proper spring compressor and stand to the side, wear eye protection, and do not use improvised methods.
- Support the knuckle/axle with a jack or stand before separating suspension components.
- Follow kit manufacturer instructions first — this is a general procedure for coil-spring/strut systems.
- Get a professional 4-wheel alignment after installation.

General notes before starting
- Identify whether your 4Runner is coil-spring front/rear or uses a different rear setup (most 4Runners use coil springs; some model variations or lift-equipped trucks vary). Install method differs if leaf packs or aftermarket setups are present.
- Most lowering kits replace both front and rear springs or provide matched struts/shocks. Do not mix stock shocks with much-lower springs — that causes poor damping and premature failure.
- Record ride height and corner weights if you care about symmetry.

Step-by-step — Front (strut with coil spring)
1. Prep
- Park on level ground, chock rear wheels, loosen front lug nuts slightly.
- Raise front with floor jack, place jack stands under frame/subframe. Remove front wheels.

2. Disconnect components
- Remove sway bar end-link upper nut and separate end-link from strut (support sway bar with bungee).
- Unclip brake line and ABS sensor wire from strut/brake backing plate; do not let caliper hang by lines. Hang caliper with bungee.
- Remove two lower strut-to-knuckle bolts (usually large, e.g., 17–19 mm/22 mm). Support the knuckle with a jack so it won’t drop.

3. Remove strut assembly
- Open hood. Remove the three upper strut tower nuts (often 12–14 mm) while holding strut shaft with hex or an assistant to prevent rotation.
- Lower strut assembly out of vehicle.

4. Compress spring and swap or install new components
- Securely mount spring in compressor, compress slowly and evenly until tension is relieved on top nut.
- Remove top nut and upper mount. Remove old spring and isolators.
- Install lowering spring or new strut assembly per kit orientation (shorter end up/down as instructed). Replace upper mount if provided.
- If installing a complete lowering strut, no spring compressor is needed—follow manufacturer assembly.

5. Reinstall strut assembly
- Insert strut back into tower, loosely install upper nuts (do not torque fully until weight on wheels unless manufacturer says otherwise).
- Reconnect lower bolts to knuckle, torque both upper and lower fasteners to factory specs (consult manual).
- Reattach sway bar link, brake line bracket, ABS wire.

6. Repeat other side, reinstall wheels, lower car to ground
- Tighten lug nuts to spec with vehicle on ground.

Step-by-step — Rear (coil-spring rear)
1. Prep
- Chock front wheels, loosen rear lug nuts, raise rear and support on jack stands under frame. Remove rear wheels.

2. Disconnect components
- Remove shock(s) lower nut and upper nuts as applicable (support axle with floor jack).
- If the kit replaces springs, remove any sway bar links and parking brake cable brackets that attach to differential/axle.

3. Remove spring
- Lower the axle with floor jack slowly to unload the coil spring.
- Remove spring isolator and spring from perch. If spring is under tension, use a spring compressor or support axle adequately.

4. Install lowering spring/spacers
- Place new lowering spring into perch with correct orientation and new isolators.
- If using coil spring spacers, insert per kit instructions between spring and seat; ensure full contact and fasten any retaining hardware.

5. Reinstall shocks and components
- Reinstall shocks (use shocks valved for lowered height or coilovers as supplied). Torque all fasteners to spec.
- Repeat for other side.

6. Lower vehicle onto wheels, torque lugs
- Lower vehicle, torque lug nuts to spec.

If kit is coilovers (front/rear)
- Follow coilover manufacturer assembly instructions: install assemblies into strut towers, bolt lower mounts to knuckles/axle, set initial ride height (threaded body) to recommended setting, tighten locking collars, torque all hardware.

How each tool is used (key operations)
- Floor jack/jack stands: lift and securely hold vehicle; never work on jack alone.
- Spring compressor: clamps onto coil spring at two points, compress evenly using threaded rod to relieve top nut tension so spring can be removed/installed. Compress until free play on top nut is gone, then remove top nut carefully. Release slowly.
- Impact/breaker bar: remove tight fasteners (lower strut bolts, control arm bolts); breaker bar for initial break loose if rusted.
- Torque wrench: final tightening to factory torque — critical for safety and alignment.
- Pry bar/hammer/punch: to persuade stubborn knuckle or shock mounting bolts; use penetrating oil first.
- Hex/Allen to hold strut shaft: prevents shaft from spinning while removing top nut.

Common pitfalls & how to avoid them
- Not replacing shocks: stock shocks are valved for stock spring rates/lengths — install shocks suited for lowered height or coilovers. Otherwise you’ll get poor handling and shock damage.
- Incorrect spring orientation or missing isolators: ensure top/bottom isolators are installed and spring seats are clean. Mis-orientation causes noise and seat wear.
- Reusing stretched/damaged hardware: replace lower strut bolts, nuts, and any rubber mounts showing wear.
- Failing to support knuckle/axle: dropping the knuckle unsafely can damage brake lines/ABS sensors and injure you.
- Spring compressor misuse: never stand directly over a compressed spring; use high-quality compressors and compress evenly.
- Not checking bump stop clearance: lowered cars may need shorter bump stops or limiters to prevent over-compression of shocks.
- Uneven drop front vs rear: match front and rear lowering amounts to avoid extreme geometry issues.
- Not getting alignment: lower ride height changes camber/caster; driveability and tire wear will suffer without a 4-wheel alignment.
- Ignoring swaybar link length: shortened geometry may bind stock links — replace with adjustable/to-fit links if necessary.

Final checks & break-in
- Tighten all fasteners to factory torque specs (consult Toyota service manual for your model/year).
- Verify brake lines/ABS wires have slack at full droop; ensure nothing rubs.
- Recheck lug nuts after short drive.
- Perform a professional 4-wheel alignment immediately.
- Test drive slowly to listen for noises and check handling. Re-torque hardware after 100–200 miles.

Notes on specifications
- Specific bolt torques and exact procedures vary by model year. Use the Toyota factory service manual or kit instructions for torque values and any model-specific steps. When in doubt, use OEM specs.

Done.
rteeqp73

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