Expeditionr

Based on Toyota’s advertising campaign, one would assume that the FJ Cruiser not only commutes well, but that it also performs quite well in light to medium off-road environments. But let’s face it, ads are designed to sell a product. Because of this, it can be difficult at times to separate fact from fiction. From my own experience, I can attest to the FJ’s on-road capabilities. As my primary mode of transport to and from work, I find it’s road performance to be quite mannerly, combining the functionality I require with all of the creature comforts I’ve come to expect from a Toyota vehicle.

As of early 2009, with the exception of the occasional snow storm or foray into the field behind the house, my FJ had not yet seen any real dedicated off-road use. But that all changed in April, 2009, at the FJ Northeasters Run at Rausch Creek Off-Road Park in Tremont, Pennsylvania.  As both a driver and casual observer (watching all the other FJs on the trail), I witnessed the FJ’s off-road handling first hand and can now attest to the truth behind Toyota’s ads. In my case, I stuck with green- or blue-rated trails and despite a few more challenging obstacles, the FJ handled beautifully with absolutely no issues. Upon returning to the trail head, however, we discovered that others had not been so lucky.  A few of the more courageous folks had ventured into some of the black- and purple-rated areas, in near-stock configuration, only to discover that large boulders when combined with a stock FJ is almost always a recipe for carnage.

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As a dedicated BFGoodrich tire guy for almost ten years, I was surprised to see such a loyal following in the FJ forums for Nitto brand tires, specifically their all-terrain series tire known as the Terra Grappler. The positive feedback for this tire and rating for its performance under the FJ was so overwhelming that I decided to take a chance and branch away from BFG. With the new rear suspension on the way, I decided nothing would complement it better than a new set of shoes. Plus, with the suspension raised three inches higher than stock, the original tire size was going to look somewhat dwarfish. So I decided to upgrade the tire size in the process. After calling around to various tire shops, I finally got a smokin’ deal on five brand new Nitto Terra Grapplers in a size of 295/70R17 and an appointment to get them installed.  For those who may have missed my previous post, I had recently ordered the remaining pieces of a Stage One suspension from Icon Vehicle Dynamics.  So two new springs and shocks, five new tires and one alignment later, I was driving home in a lifted, but very smooth-riding FJ Cruiser.

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One of the more prominent issues I noticed early on when driving the FJ Cruiser was that any stops other than those that were completely controlled (slow and steady), resulted in noticeable nose diving. I was also interested in eliminating the forward rake as a result of the front suspension being positioned much lower than the rear. I’d like to point out that I initially went with stock size BFGoodrich tires in order to maintain some semblance of mileage and avoid having to immediately lift the FJ to accommodate a larger size tire. But after almost a year of driving and nose diving, I decided to finally fix the problem and upgrade some parts in the process.

Based on a good past experience as well as overly-positive input from FJ Cruiser forum members, my first decision was to upgrade my front suspension using 2.5″ racing coil-overs manufactured by Donahoe Racing (DR). It should be noted that Donahoe Racing has since been sold to Icon Vehicle Dynamics (IVD) or Icon as they have now become known in the forums. Icon’s engineering and design of the products is identical to the original product and their reputation for producing quality parts has become very well established in a very short period of time. Even though my first revision coil-overs were DR, for the sake of this post and any future posts, I’ll be referring to the company as Icon, Icon Vehicle Dynamics or IVD since I’m sure anyone looking for this product will want to reference the current company rather than the previous manufacturer.

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Perhaps before I dive into the modding madness, I should provide some details regarding the FJ’s stock capabilities and features.  Targeted at the 20- to 30-year-old off-roading demographic, the FJ was designed with ruggedness in mind. Even though the exterior shell of the FJ Cruiser is brand new, many of the underlying components are based on slightly modified versions of other existing product lines. Some may see this approach as cobbling, a vehicle designed in true Frankenstein fashion. But in my opinion, Toyota’s approach to designing and eventually producing the FJ Cruiser prototype was pure genius. Rather than rely on newly designed and therefore untested parts, Toyota dug into their existing product lines in order to determine which parts were proven to be the most reliable over long-term testing. By piecing together the strongest and most reliable parts, Toyota was able to produce not only a quality vehicle, but one which contained many of the best features from other vehicles.

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