Toyota and off roading go hand in hand. Toyota pickups are one of the most popular vehicles for off road use and consequently a lot of companies produce suspension accessories to accommodate the needs of Toyota owners. With the introduction of the all-new 2007 Tundra it was only a matter of time before suspension companies would develop lift and travel enhancing kits to allow Tundra owners to personalize their trucks.
Pro Comp Suspension is known for their wide range of truck suspension products and it was no surprise to learn that they were the very first company to spend the necessary time to properly develop a true suspension lift kit for the Tundra. This isn't a leveling kit, but rather a true six-inch suspension lift that increases ground clearance while being tough enough to take most off road experiences a new Tundra owner would put this truck through.
The kit comes as a Stage I and Stage II set up. The difference between the two is the Stage II kit includes the new Pro Comp MX 2.75 coil-over shocks in place of a stock coil over spacer found in the Stage I kit. The Stage II rear also includes the MX6 shocks Axle traction bars are optional equipment. New MX6 2.0R reservoir shocks will be available as optional equipment in January 2008.
The kit concept is similar to that of most late model trucks. Pro Comp engineers used their vast knowledge of designing strong, user-friendly suspension systems to come up with a system that is overall similar to that used throughout the industry on IFS-equipped trucks. The kit is comprised of a pair of new cross members that lowers the front differential while also lowering the lower control arms. The upper control arm remains in the stock locations. A new steering knuckle (spindle) compensates for the increased distance between the control arms while correctly positioning the axles and hub assemblies for correct geometry.
The actual amount of lift is divided between the new cross member geometry and the use of either the stock coil over spacer or in the case of the Stage II kit which we will illustrate the installation of, a trick new MX 2.75 coil over. The MX coil-over features a taller coil and is designed specifically for this kit.
Pro Comp recommends the use of 35x12.50 tires with this set up. Factory 17-inch wheels cannot be used. Wheels must be a minimum of 18-inches in diameter and no wider than 9 inches. Backspacing is critical with the Tundra suspensions. This system requires that 18 inch wheels have maximum backspacing of 5.5 inches and 6 inches for 20-inch wheels.
The system is a complete bolt on installation with one exception. In order for the front driveshaft exiting the differential to clear the factory cross member that resides behind the front differential, the cross member must be notched. The directions clearly illustrate to how achieve this modification. The new rear cross member basically takes the structural place of the stock cross member.
With the proper tools, installation time is between 6-8 hours. In the following steps we will disclose the major steps involved with this installation procedure as an overview. This conversion took place at Pro Comp's engineering depart in order to gain the most insight from how to properly install this kit. This is not meant to be an instruction guide, but rather an informative look into what a person can expect to take place during the installation. It is recommended that Tundra owners seek the expertise of a qualified technician or suspension shop to have the Pro Comp Suspension system installed.
It should also be noted that the new Tundra's feature a unique active suspension and traction monitoring system. The truck has yaw sensors that pay close attention to the position of the body and suspension as well as the alignment and wheel speeds. It is important to have the truck properly aligned immediately after installing the kit. Driving the truck without aligning the suspension can trigger onboard warnings and problem displays which are only correctable by having a Toyota dealer reset the sensors and onboard calibration by plugging into the computer.
PRO COMP SUSPENSION
2360 BOSWELL RD.
CHULA VISTA, CA 91914
619-216-1444
 Pictured here is the Pro Comp Suspension Stage II 2007 Toyota Tundra six-inch suspension lift system featuring new one-piece cross members, extended steering knuckles, new MX 2.75 coil over shocks, front compression struts, MX6 rear shocks, rear suspension lift blocks, add-a-leaf and all necessary hardware. Stainless steel front skid plates and rear traction bars are optional equipment that can be included with this kit. |  Here we see the stock 2007 Tundra Double Cab 4wd which will be transformed into a great looking off road truck via the Pro Comp Suspension kit. |  With the truck secured on a lift at the Pro Comp facility, Frankie who also happens to be the engineer that designed the Pro Comp Tundra kit, begins the disassembly process on the front suspension which will include removing the stock knuckles, lower control arms and struts. |
 The factory coil over strut is removed. For Stage I kits the factory coil over will be reinstalled with an upper spacer while Stage II kits get an all-new coil over. |  Both lower control arms are unbolted and removed. |  It is important to note the factory alignment cam bolts in the lower control arms can be easily damaged during disassembly if care is not taken. These cams are expensive to replace to be sure to lubricate the sleeve to aid in removing it from the control arm. |
 Since the front differential will have to be dropped out of the truck, the first step towards doing so is to unbolt the front driveshaft from the differential and remove it. |  With the front differential properly supported Frank unbolts the differential mounts. |  Once unbolted from the cross member, the differential assembly is carted out from under the vehicle. |
 Next we tackle the job of modifying the rear differential cross member. Frank positions the Pro Comp rear differential cross member which will bolt into the where the lower control arms were mounted to determine the area that needs to be cut out on the factory cross member. |  A paint pen is used to scribe the exact area that needs to be removed from the factory cross member. This determination is based on the width of the notch in the new cross member which precisely illustrates how much area needs to be removed. |  After using a cutting wheel to cut out the section, this is what you should expect to see. In Franks hand is the section that was removed from the cross member. |
 With the factory cross member modified the two new drop down cross member sections are lifted into place and secured. |  The kit provides new bolts to securing the cross member to what were the lower control arm mounts. Included with these bolts are cam block off plates that are timed by having the bolt hole off center. This allows the installer to center the cross member properly while taking into consideration any manufacturer off sets in geometry. By rotating the square cam the position of the bolt and consequently the positioning of the cross member can be adjusted. |  The factory bump stop bolts into its new lower location while bump stop reinforcement brackets are installed onto the cross member and stock bump stop frame mount. |
 Once the proper positioning of the cross member and the bump stop bracket assemblies have been determined, all of the hardware are permanently tightened. |  To make installing the new differential mount brackets easier, they are installed onto the differential before sliding the diff back up into the frame. |  With the differential mounts installed, the axle assembly is carefully lifted back into the frame and between the two new cross members. Both front differential mounts are then guided into their mounting positions on the front cross member and secured with the provided hardware. |
 For the rear the differential will need to be pivoted and in some cases the rear cross member bolt loosened so the cross member can be pivoted enough to allow the differential mount to slide into the inner mount bracket on the cross member. |  With both cross members and the differential secured, next comes the installation of the rear bump stop reinforcement bracket onto the cross member and factory bump stop frame mount. |  With all of the cross member brackets and the differential installations finalized, all of the mounting hardware is permanently tightened. |
 Since the differential is now extended away from the frame, new longer vacuum and vent lines are installed. These hoses are provided with the kit. |  Here is a good look at the Pro Comp cross members installed. Production units will have a black powder coated finish. |  From underneath we can show you a better look at why the factory rear cross member had to be notched and how the new Pro Comp cross member has been designed to accomplish this while addressing the strength requirements. |
 While the new cross member ties in strongly to the frame rails, additional support is provided by drilling three holes into the factory cross member, then installing the provided nut plate into the cross member in order to bolt the center portion of the new cross member to the old one. |  |  The new Tundras have exceptional turning radius which gives the driver the ability to make those sharp u-turns. But when installing larger tires such as the 35x12.50 size tires recommended for this kit, the turning sweep is can be just a little too much which can result in the tires rubbing if turned full lock. To tackle this Pro Comp provides a ΒΌ-inch thick steering stop plate that is machined to fit into the factory steering stop on the lower ball joint bracket. This plate must be welded to the steering stop. Even with the plate installed the Tundra still has an amazing turning radius while keeping the tires from rubbing at full lock. |
 As previously mentioned, the control arm alignment cam bolts can be easily damaged if care is not taken when removing or installing them. Before mounting the lower control arms to the cross member, the cam bolts are generously lubricated with bearing grease which will make installing them safer and easier. |  The factory control arm bolts and cam bolts are installed to secure the control arms to the cross member. |  On the left is the new Pro Comp MX 2.75 coil over strut assembly featuring a thick threaded body for spring height adjustment along with CNC machined lower mount. You will notice compared to the stock strut on the right there is a significant height difference. Part of the lift height of the Pro Comp Stage II kit comes from the new coil over dimensions. The Stage I kit uses a spacer that mounts to the top of the factory coil over. The MX 2.75 coil over has this distance covered in the design of the unit. |
 A pivoting upper coil over mount CNC milled from billet aluminum is attached to the top of the coil over to provide the four mounting points that will line up with the factory coil over bolt holes. |  The MX coil over is installed into the coil over frame mount while the nuts are installed, but not tightened. |  The dust seal is removed from the factory steering knuckle and installed onto the new Pro Comp knuckle. |
 |  The beefy body on the Pro Comp MX coil over is wide at the base and consequently a small amount of material inboard of the mount position must be trimmed in order to allow the coil over to have full intended motion and not bind up during full suspension droop. The area that needs to be cut off is marked in yellow paint pen. |  After touching up the area with a little flat black paint to protect the exposed metal from the cutting, the lower coil over mount is installed into the control arm. |
 While most of the suspension components so far have been lowered away from the vehicle are part of the kit design, the same thing occurs with the sway bar to keep the entire suspension geometry working like factory. A sway bar drop bracket is installed into the factory sway bar mount holes in the frame. |  The sway bar mounts are then bolted to the bracket as shown. |  Here is a good look at the difference between the stock steering knuckle on the left and the new extended Pro Comp steering knuckle on the right. The Pro Comp knuckle is much stronger. It is a beefy, heavy components designed to retain the factory geometry while accommodating the lowering the suspension which in turn translates into suspension lift. |
 Here Frank lifts the big Pro Comp steering knuckle into place and secures it to the upper ball joint. |  The axle assembly is then installed through the knuckle while the lower ball joint bracket is secured to the knuckle. |  With the knuckle installed the upper coil over mount hardware are permanently tightened. |
 Next comes the installation of the factory wheel hubs onto the steering knuckles. There is an O-ring on the back side where the hub attaches to the knuckle. It is important to make sure this O-ring is properly in place when installing the hubs. |  The brake rotors are now installed. The factory brake backing plates are not to be reinstalled. |  The factory ABS sensor is secured to the knuckle. |
 With the suspension which includes the brakes moving away from the frame, new brake line bracket extensions are installed to reposition the brake line. |  Pro Comp specifies that in order to provide extra clearance for the larger tires, the tie rod ends need to be removed and swapped from side to side. |  Here is a great look at the almost complete Pro Comp Tundra six inch suspension system. |
 Before the front suspension itself can be considered finished, all mounting hardware is checked along with securing the CV nut to the recommended 275 ft/lbs. torque. |  With any IFS drop down-type lift kit it is important to give the system as much lateral support as possible. This kit includes compression bars which extend off of the rear cross member to brackets that use factory holes in the transmission cross member. The holes have to opened up with a drill, then the bracket can be installed as shown. |  Attach the urethane bushing-equipped compression bars to the front cross member, then to the rear brackets and secure. |
 Here is a better look at the compression bars installed. |  Like any lift kit, the drive shaft angle has to be taken into consideration. While under the truck we took the opportunity to install the provided carrier bearing spacers. |  The Pro Comp Tundra six-inch suspension system fits and looks really good on the Tundra. This angle gives you an idea of what the system looks like. For this installation the Pro Comp parts were powder coated silver so they would show and be easily identifiable. The production parts will come powder coated black. |
 Optional equipment for this system are the popular Pro Comp stainless steel skid plates, one for the front and one as a protector that connects between the front and rear cross members. |  The final product has a mean look that works good and drives great. |  REAR-The rear will be lifted six inches to match the front. The first step to address is removing the brake lines from the axle housing mounting bracket in order to let the rear end down later in the installation. |
 The rear shock is removed and discarded. MX6 shocks will replace the stock versions. |  With the axle properly supported, the u-bolts and axle pads are removed. |  The emergency brake cable bracket is unbolted from the axle housing. An extension bracket will be installed later. |
 The rear end housing is lowered enough to allow for the installation of the add-a-leaf which installs between the spring pack and the overload. |  The new spring pack center bolt is reinstalled to secure the new leaf to the spring assembly. |  The lift block is installed with the pin offset towards the front of the vehicle. |
 New longer u-bolts are then installed and the block and leaf spring assemblies permanently tightened. |  The brake lines previously removed from the charcoal canister bracket and rear end housing brackets are attached to new extended brackets that mount on the same canister brackets at the top. This moves the lines down appropriately with the lift while providing a secure mount just like the stock application. |  The Stage II kit comes with MX6 shocks. For this installation Pro Comp wanted to show off their new MX 2.0R aluminum body reservoir shock that will be available by January 2008. |
 The shocks use the factory mounting locations. |  With the axle moving further away from the frame, it is necessary to install the emergency brake cable extension bracket that attaches to the axle housing and the factory e-brake cable bracket as shown. |  With the rear suspension complete, the next move is to disassemble the factory tires. The reason this has to be done is because the Tundra wheels have tire pressure sensors mounted inside the wheels that have to be removed and placed into the new wheels in order for the TPS and VSC systems to function properly. |
 Here is what the TPS looks like. It is part of the valve stem assembly. Care should be taken when dismounting the tire to not damage the sensor. |  With the new Pro Comp 20x9 6066 wheels and 35/12.50 Pro Comp Xtreme M/T tires mounted up, Frank installs the combination onto the Tundra. You cannot use the factory lug nuts with these wheels. |  An option for this kit is a trick double tube traction bar set up that is easy to install and helps to reduce axle wrap along with still allowing suspension articulation. The axle mount was installed under the lift block. |
 The front mount bracket for the traction bars installs onto the frame. The bolt holes must be drilled into the frame. The easiest way to do this is to attach the traction bar to the axle then attach the front bracket to the traction bar and position it on the frame with the truck at ride height, then mark and drill the new holes. |  The bracket mounts on both the outside flange as well as underneath to provide maximum strength. |  Here is quick look at the traction bar installed. |
 Last and something that is very important is the alignment. The Pro Comp suspension system has been engineered to allow for the truck to be aligned back to within factory specifications. It is important to align the suspension before driving the truck otherwise the onboard sensors will pick up that something is wrong and flash codes that will possibly require the Toyota dealer to turn off via reflashing the computer. |  So what does the kit do for the Tundra? Well here is a look at our 2007 project Tundra after all of the work was complete. Needless to say, the kit really makes gives the Tundra a mean appearance along with a commanding view of the road and increased ground clearance for off roading. Those beefy Pro Comp Xtreme M/T tires and 6066 wheels definitely compliment the appearance. The new MX 2.75 coil overs provide a solid yet very controlled ride quality that really dampens most bumps and dips. It is obvious great care was taken to design the spring rate and valving of these coil overs. | |
