Posted on Jun 16, 2026

by Mateo Ianotti

We Fixed the Biggest Issue on the 4th Gen Tacoma

Building long travel suspension on the 4th Gen Toyota Tacoma is still relatively new ground. The truck is newer, the aftermarket is catching up, and the suspension geometry presents challenges that don't have off-the-shelf answers yet. Dirt King tackled this head-on, developing a full rear suspension setup from scratch, testing it in the desert, and tuning it with Down South Motorsports - a team with over 20 years of off-road build experience.

In the video below, Mateo walks through the completed build, gets behind the wheel for the first time since the rebuild, and the Dirt King team works through live valve stack tuning in real desert conditions. It's worth watching in full.

What Changed in the Rear Suspension

The previous iteration of this build went out to King of the Hammers with around nine inches of rear travel. It wasn't enough. The second Mateo hit the whoops at 60 mph, the answer was obvious: the rear couldn't keep up with the front.

The rebuilt setup runs a 2.5x14 inch coilover through a fabricated bed cage, a custom three-link rear geometry, and brings total rear wheel travel to 15 inches - a 67% increase over where it started. Key details from the build:

Three-link rear suspension, smog legal, factory gas tank retained
Coilover mounted through the bed via a low-profile cage - full-size spare still fits
All link pockets gusseted, billet links, full frame plates throughout
Frame notched to extract the last bit of uptravel from the geometry
Shock adjusters fully accessible from the bed

The fabrication quality throughout is thorough. Nothing was left as an afterthought.

How the Tuning Works

The test day with Down South Motorsports is where this video gets genuinely interesting. Suspension tuning at this level isn't adjusting settings on a screen - it's pulling the shocks off the truck, disassembling the rebound valve stack, and physically changing the shim arrangement inside the shock body before reassembling and bleeding out any trapped air.

The team made two tuning passes. First, a clicker adjustment on the reservoir (high-speed damping firmed two clicks) - quick, non-invasive, but not quite what they were looking for. Second, a full valve stack change targeting the mid-to-high speed rebound, which required taking the shocks back to the trailer and reworking the shim stack with Sunny from Down South.

After the valve stack change, the truck was noticeably more planted. Mateo reported more confidence and control at 60 mph, and Mason confirmed the sweet spot for the current tune sits around 60-63 mph - with 70-75 mph territory available for a future revision. Critically, the tune also passed as daily drivable. That's the balance Dirt King is targeting: competitive desert capability without sacrificing road manners.

Mid Travel vs Long Travel: The Real Difference

Mason's comparison at the end of the session is the most useful two-minute answer to this question you'll find. The short version:

Mid travel is right for most Tacoma owners. It handles trails and moderate desert use well, fits within stock body lines, and daily drives easily. If you're out in the desert occasionally and want to push it, mid travel is a well-rounded setup.

Long travel is a different animal. At 70 mph through serious whoops, mid travel simply isn't in the conversation. Long travel unlocks that next level - wider, more aggressive, and capable of speeds a mid-travel truck can't safely reach. Once you've driven one, it's hard to go back.

Final Thoughts

This build shows what's possible when a rear suspension is developed properly rather than bolted on and hoped for. Dirt King went from nine inches of travel to 15, refined the valve stack with 20 years of tuning experience in the room, and produced a truck that hits 70 mph through desert whoops and still daily drives.

If you're planning a suspension build on your 4th Gen Tacoma, browse the Tacoma suspension range at TacomaBeast, or check out the full long travel kits and components selection. The team can help you figure out the right direction for your build.

Frequently Asked Questions

Find quick answers to common questions.

Q: What rear travel does the Dirt King 4th Gen long travel build achieve?

A: 15 inches of wheel travel, up from nine inches in the previous iteration. The gain comes from the 2.5x14 inch coilover and the custom three-link geometry built specifically for the 4th Gen chassis.

Q: Is the long travel setup smog legal?

A: Yes. The three-link design retains the factory gas tank and is confirmed smog legal. Only the filler neck is modified to reach the new bed sides.

Q: Does the bed cage eliminate truck bed storage?

A: Not significantly. Dirt King designed it low-profile, the shock towers are covered with panels, the bed seals cleanly and a full-size spare still fits.

Q: What's the difference between mid travel and long travel suspension?

A: Mid travel is the right choice for most Tacoma owners who want improved off-road capability without major bodywork changes. Long travel goes further: wider stance, more aggressive geometry, and the ability to run at speeds mid-travel setups can't handle. The trade-off is cost, fiberglass, and commitment.

Q: Does this setup daily drive well?

A: Yes. Dirt King's goal throughout development was a valve code that works in the desert and on the road. The production tune is signed off on a standard road course before it becomes final spec.