As the highly anticipated 4th Generation Toyota Tacoma hits the off-road scene, suspension experts at IRONMAN 4X4 are hard at work crafting a suspension system that balances rugged performance with everyday comfort. Leading the charge is Sean Spencer, a suspension development engineer who shares a behind-the-scenes look at how their lift kit and suspension systems are tailored for the next-gen Tacoma.
Starting with the OEM Benchmark
When IRONMAN 4X4 begins developing suspension components for a new vehicle, the process starts with analyzing the OEM suspension setup. Engineers begin by disassembling key components like the front and rear coils and shock absorbers to determine factory spring rates and damping characteristics.
Back at their headquarters in Australia, the team uses specialized equipment to gather dyno curves on the stock suspension. This critical data becomes the baseline for improving the vehicle’s ride and handling characteristics, especially for off-road applications.
“It gives us kind of a benchmark on where to start,” says Spencer.
Enhancing Ride Comfort and Off-Road Performance
Many stock vehicles—including the new Tacoma—tend to have a stiff, almost sporty feel, which might work on pavement but doesn’t always suit overland adventures or long-distance drives. That’s where IRONMAN 4X4 steps in.
By engineering a Tacoma lift kit and performance suspension system, they aim to improve:
- Ride comfort for daily driving
- Off-road compliance over uneven terrain
- Wheel articulation for challenging trails
With extended travel suspension in both the front and rear, the 4th gen Tacoma can better maintain traction and stability, even in rocky or muddy environments. This means smoother climbs and more confidence-inspiring descents, no matter the conditions.
A Game-Changer: Coil-Sprung Rear Suspension
One of the biggest changes in the new Tacoma platform is its switch to a coil-sprung rear suspension, a major shift from previous leaf spring setups. This upgrade significantly improves ride quality, especially when paired with Ironman 4x4’s finely-tuned shocks and coils.
“It’s really great for adding ride comfort and quality,” Spencer notes. “We also have a full box chassis now, which adds rigidity without compromising comfort.”
This added chassis strength gives IRONMAN 4X4 even more flexibility to push the envelope in terms of off-road performance without sacrificing the smooth, daily-driver feel that many Tacoma owners still want.
Fine-Tuned for Every Adventure
At the heart of IRONMAN 4X4’s philosophy is balance—creating a lift kit that offers off-road capability without making sacrifices with on-road comfort and reliability. Designing complete performance suspension systems with this mindset provides confidence with the adventure seeker to take their Tacoma to more remote places, knowing the suspension components will simply do what’s asked of them.
Making design choices such as using large rubber bushings for the shock mounts rather than what other brands choose to use, which are spherical bearings. Rubber bushings ensure high-frequency vibrations are absorbed and not transferred into the chassis. These provide more comfort, last longer, and require much less maintenance over spherical bearings, maintenance that puts more cost burden on the customer.
Carrying The Load
Supporting the weight of the vehicle and any added accessories is the other major part of IRONMAN 4X4’s design process. Customers like to customize and load up their adventure rigs, and the weight from these accessories must be supported properly, otherwise the safety and performance of the suspension is compromised. IRONMAN 4X4 understands the critical importance of managing vehicle weight. The solution is to offer several front and rear spring choices that give the customer options for a perfect ride no matter what they have loaded in the pickup bed.
IRONMAN 4X4 has a range of springs engineered for a stock weight Tacoma, up to fully outfitted adventure trucks, so no matter what toys the customer carries or tows, the suspension is tuned for the task. Supporting the weight properly allows the shocks to keep the vehicle composed and stable.
IRONMAN 4X4 understands that most folks are not racing the Baja 1000 and do not need extremely expensive race-inspired suspension on their Tacoma for their family weekend adventures and then driving the same Tacoma to work on Monday. The needs of customers must be properly met with sensible suspension solutions that provide maximum comfort, performance, and reliability without emptying their wallets.
IRONMAN 4X4 has designed a 4th-gen Toyota Tacoma suspension upgrade that is built to perform and last. Shop all our Gen 4 Tacoma accessories here.
