The fifth generation Toyota 4Runner is a fantastic truck/suv for vehicle-based and overland travel

The Gen 5 Toyota 4Runner has earned a reputation as a solid overlanding platform. In the first two years of its evolution, which began in 1984, it sported a one-piece front axle configuration derived from the lovable Hilux pick-up family, before switching to an independent front suspension.

Engines have ranged from the famed 22RE four-cylinder to the 4.7-liter V8 found in some Gen 4 models. The latest iteration of the 4.0 V6 steps up the horsepower a bit from earlier V6 models and remains bolted to an actual, steel, truck-style chassis, something we see less and less of as the soft-bellied unit-body construction vehicles have ventured off pavement. Proponents of the Jeep Grand Cherokee and similar unit-bodied machines argue that their lighter construction offers better ride and fuel economy. Many would suggest that any advantage for the true overlanding enthusiast ends there. Drive both at 150,000 miles and the reason is evident: the 4Runner usually remains tight and rattle-free, and the more pliable ladder frame works in harmony with rugged terrain rather than against it, a willow in the wind, if you will.

Even so, overlanding demands something more than what is usually available from the showroom; it calls for a rig finely tailored to the specific type of driving the owner wants to tackle. Racing against a setting sun, for example, might require driving aggressively down a bumpy backcountry route for miles on end. For this reason, suspension was the first consideration for the build on our 2016 4Runner. We wanted equipment that would not only produce a decent ride over repetitive bumps without fade but would also hold up as well as the iron-tough Toyota on which it would be bolted. Having enjoyed the Icon Stage V suspension on our Tacoma GS, we selected Icon’s aluminum Stage VII enhanced with Timbren Active Off-Road Bumpstops for our latest rig, also to be dubbed GS, or Gelande Strasse, meaning “land and street” in German.

We installed most other components ourselves but the suspension required more time than I was willing to invest, so I returned to our dealer, Fowler Toyota in Norman, Oklahoma, where Master Tech Jordan Smith swapped, torqued, adjusted, Loctited and tested every bolt, nut and strut. With our Trail model lacking the complex KDSS option, we could benefit from the longer travel and simpler design of this suspension upgrade. Seven hundred fifty-pound springs, paired with preload and damping adjustments on the 2.5-inch remote reservoir shocks, cover the gamut of variables we face when speeding along in the rough.

Factory wheels were replaced with Stealth SR8s in matte gunmetal, wrapped in Falken Wildpeak A/T3W P285/70 R17 tires. We chose the Falkens for their aggressive upper sidewalls and offset shoulder blocks which protect the tire against rocks and provide improved traction at the low pressures we sometimes run. We have also found them quiet and, combined with the Icon suspension, handling is incredibly stable on twisty roads. The -10mm offset wheels are designed for off-road applications with a beefed-up rim flange, simulated beadlock pattern and eight concave spokes. If it’s going to be tough it might as well look the part.

Weight is always a factor so we opted for CBI’s aluminum front bumper with full grill protection to ward off branches and wayward deer. A Warn 10-S Zeon winch tucks neatly inside and a pair of Rigid D Series Pro 3”x 3” Driving Beam lights fill the corner ports. These little beauties spread nearly 5,000 lumens through six LEDs, exposing anything in the ditches like a blast from the sun.

Our rear bumper is also CBI but made of steel for its ability to support a single swing-out tire carrier, fold-down table and dual jerry can mount. A Hi-Lift Jack can also be attached to the swing-away system if desired. Again, a pair of Rigid D Series Pro diffused lights are mounted in the rear bumper and act as auxiliary back-up lights.

Installing a rear-mounted spare tire renders the back-up camera null and void. Zero visibility when backing renders the wife a less-than-happy camper, too. We found a tidy solution with RSG Metalworks’ camera relocation harness and mount. Installation was relatively simple for anyone with moderate skills and the resulting improvement in my marriage was well worth the effort. So far, we have not crash-tested the bumper while backing.

Aluminum CBI skid plates cover the chin area, power train and fuel tanks, offering tough, lightweight protection far in excess of factory components, and CBI’s incredibly strong, DOM steel rock rails attach full length to the frame. We chose horizontal over upswept mounting for the rails so they could pull duty as proper steps for rooftop access.

Up top we installed BajaRack’s flat Spy rack with its integral servo for mounting a retractable Rigid 40-inch Radiance light bar. The Radiance bar has independently controlled blue backlighting and a brilliant, penetrating beam that fires over 16,000 lumens more than 1,000 feet down range. BajaRack’s retractable Spy system keeps the main off-road light legal, even in California where showing the face of a powerful non-DOT light might earn you a costly reward from the Highway Patrol, and it allows remote, infinite vertical adjustment. Rigid lights have proven 100% reliable during more than eight years of use on our Tacoma and were a no-brainer for the 4Runner build. We chose Rigid’s diffused D2s for our bumper-mounted back-up lights as well.

We also attached an Eezi Awn Series 2000 2.5-meter awning and BajaRack’s simple, secure axe and shovel mounts to the roof rack. The awning’s spring retraction mechanism makes set-up or take-down a 60-second operation and its 260-gram Teflon-coated Ripstop polyester roof provides 50 square feet of protection from sun or rain. The whole affair is housed in a secure, black anodized aluminum case for longevity.

Interior protection was added to ward off the crud carried in on boots and jeans. We’ve successfully used Cover King’s aftermarket seat covers on both our Tacoma and 4Runner GS. They fit well, look fine, and eliminate worry when climbing in after sitting on the ground or jumping in sweaty after a hike. Toyota’s thick rubber, factory All-Weather mats protect the floors.

Under the hood we installed ARB’s powerful Twin-Air, 6.2 CFM compressor using a Slee Offroad mount. The installation is tidy, unobtrusive, and accessible. For now we are using only the single quick-disconnect port on top of the unit and, with its incredible volume and pressure capability, we are in no hurry to install a tank.

A pair of Odyssey Group 34 and Group 35 batteries mount in an Off-Grid Engineering dual-battery system. The laser-cut aluminum mounts and NASA-quality wiring harnesses look amazing and inspire confidence. Reliability is paramount when away from cell service and ready access to help and the second battery as back-up or to run house loads is part and parcel to such a build.

Speaking of control and distribution of electrical power, where our Tacoma uses a conglomeration of analog relays and wires soldered to various connections, we stepped up to the gold standard in power distribution systems for overlanders on the 4Runner. Our sPOD Source, eight-connector PDC has brought to light just how far the industry has come with this sort of technology. A programmable flat screen display operates our compressor, lights, servo and our electric fridge and rear cargo area USB and 12V ports. An iPhone app enables remote control of each component through the Bluetooth feature, making it possible to control lights or other devices from our tent or armchair without opening a door. Icons can be created for each device by snapping a photo or we can simply type in the name of each load for easy identification. Perhaps most notable is the customer support from sPOD. A quick phone call brings real-time help for programming or other questions when they pop up. Installation is as simple as it gets.

We added a Tembo Tusk Extreme Duty Flat Fridge/Cargo slide to the cargo area, and to keep food and beverages cold we kept our trusty Engel MT 45 Fridge strapped down with Tembo Tusk’s Fridge and Cargo tie-down system. With U.S.-made, Accuride steel tracks, the slide locks down tight, is easy to operate by pressing a small, yellow lever, and it’s built to last a lifetime.

A custom graphic applied to the rear quarter was created by artist friend and graphics designer George Dotson to identify the second iteration of our GS truck family.

Security is handled by Smith and Wesson but not without adhering to proper safety standards. Our Made-in-Texas, Lock’er Down Console Safe, built from 12-gauge domestic steel, keeps our security measures secure. We chose their four-digit combination lock for simplicity but high-strength Abloy Sentry High Security key and metal-cased electronic lock options are also available.

Our rig was put to the test on the 900-mile Southern California Backcountry Discovery Route right after Overland Expo West in May, 2019. From the incredible Icon Stage VII suspension and Timbren Active Off-Road Bumpstops to the handy RSG Metalworks back-up light relocation kit, every upgrade served its purpose without issue. We took our tire pressures up and down as conditions dictated, never feeling that the wait was too long with ARB’s Twin-Air compressor. The Falken Wildpeak A/T3Ws performed well over rocks and sand and in flash floods as rains hammered Death Valley. They dug into snow better than expected until physics and a bit of foolishness forced us to deploy the Warn Zeon 10-S winch to rescue us from our error. The retractable Spy and Rigid lights pierced the darkness and turned the night into day at the push of a button on the sPOD’s touch screen. My wife even tested the CBI skids a time or two as I mis-spotted her a tad over one rocky section. Our Tembo Tusk fridge slide kept the Engel MT 45 secure and our food stayed cold. We were never at a loss for electrical power with the team of Odyssey batteries and Off-Grid Engineering set-up. Every upgrade proved its worth, while none seemed like overkill or out of place.  The 4Runner GS is finally a wrap and we could not be happier with the result.

Vendor List:

Icon Vehicle Dynamics
http://www.iconvehicledynamics.com
Timbren Industries
https://timbren.com/active-off-road-bumpstops/
Fowler Toyota
https://www.fowlertoyota.com
Stealth
https://www.stealthcustomseries.com/collections/toyota
Falken Tire
https://www.falkentire.com
CBI Offroad
https://cbioffroadfab.com
Warn Industries
https://www.warn.com
Rigid Industries
https://www.rigidindustries.com
RSG Metalworks
https://rsgmetalworks.com
BajaRack
https://www.bajarack.com
Eezi Awn
https://www.equipt1.com/collections/eezi-awn
Cover King
https://www.coverking.com
Slee Offroad
http://www.sleeoffroad.com
ARB 4×4 USA
https://www.arbusa.com
Odyssey Battery
https://www.odysseybattery.com
Off-Grid Engineering
https://www.offgrid4x4.com
sPOD
https://www.4x4spod.com
Tembo Tusk
https://tembotusk.com
Engel
https://www.engelcoolers.com/shop/12-volt-portable-fridge-freezers.html
Lock’er Down
https://www.lockerdown.com
Backcountry Discovery Routes
https://ridebdr.com

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