3rd Gen Toyota 4Runner Long Travel Build Guide

Turning a stock 3rd gen Toyota 4Runner into a long-travel off-road machine is exciting—but it’s also easy to waste money if you don’t plan it right.

A 3rd gen Toyota 4Runner long travel build replaces the factory front suspension with extended-travel control arms, longer shocks, and supporting components to gain more wheel travel, better ride quality, and stronger off-road performance. Expect improved desert handling and trail control, but also higher cost, more maintenance, and extra setup work.

What “long travel” really means on a 3rd gen 4Runner

Long travel isn’t just about lifting the truck higher. It’s about allowing the suspension to move farther up and down while keeping tires planted.

On a 3rd gen 4Runner (1996–2002), long travel typically adds:

• +2 to +3.5 inches wider track width
• 10–13 inches of front wheel travel
• Improved high-speed stability and obstacle absorption

This platform is popular because it’s simple, reliable, and built by Toyota, which means parts availability is excellent.

Key components you’ll need for a long travel build

Long travel control arms

Aftermarket upper and lower control arms are the foundation of any long travel setup. They widen the stance and correct suspension geometry.

What to look for:

• Chromoly or boxed steel construction
• Uniball or high-angle ball joints
• Proven weld quality

Extended travel coilovers

Standard shocks won’t cut it. Long travel coilovers are longer and valved for aggressive off-road use.

Common features:

• 2.0 or 2.5-inch shock bodies
• Remote or piggyback reservoirs
• Adjustable compression (optional but useful)

Axles and CV upgrades

With more travel comes more stress. Stock CVs may survive mild use, but hard driving usually requires:

• High-angle CV boots
• Extended or chromoly axles

Skipping this step is one of the fastest ways to break parts on the trail.

Steering and brake considerations

A wider front end changes steering angles.
You may need:

• Extended brake lines
• Steering rack spacers
• Reinforced tie rods

These aren’t “nice to have”—they’re critical for safety.

Rear suspension: don’t ignore it

Many people focus only on the front. That’s a mistake.

A balanced build usually includes:

• Longer rear shocks
• Progressive-rate springs
• Adjustable panhard bar

Matching front and rear performance keeps the truck predictable at speed.

Pros & cons of a 3rd gen 4Runner long travel build

Real-world examples

Weekend desert runner
A lightly built 3rd gen with +2” long travel, 33” tires, and tuned coilovers shines on washboard roads and fast trails. The ride feels smoother than stock, even at higher speeds.

Overland + off-road hybrid
Some owners combine long travel with armor and camping gear. While capable, extra weight reduces suspension performance unless springs and valving are adjusted correctly.

Trail-only build
For rock crawling, long travel helps—but it’s not a magic fix. Gearing, lockers, and driver skill still matter.

FAQs (People Also Ask)

Is long travel worth it on a 3rd gen Toyota 4Runner?

Yes—if you drive off-road often and value ride quality. For light trails, a quality lift may be enough.

How much does a long travel build cost?

Most builds range from $5,000 to $10,000+, depending on shock choice, axles, and labor.

Can I daily drive a long travel 4Runner?

You can, but expect:

• Slightly worse fuel economy
• Wider turning radius
• More frequent inspections and maintenance

Do I need a body lift or cutting?

Often yes. Wider suspension and larger tires usually require trimming or a small body lift.

Final verdict

A 3rd gen Toyota 4Runner long travel build is one of the best upgrades for serious off-road performance. It transforms how the truck handles rough terrain and high-speed trails. However, it’s not a bolt-on budget mod.

If you want comfort, control, and confidence off-road—and you’re willing to invest the time and money—long travel is absolutely worth it. If not, a well-tuned lift might be the smarter move.