Toyota Surf / 4Runner 1996–2002 Body Lift Installation Guide
This guide covers fitting Flatout Offroad’s 2-inch / 50mm body lift kit to a 1996–2002 Toyota Hilux Surf or 4Runner (third generation).
Read all steps before starting. With mechanical knowledge and suitable tools, this kit can be installed at home or fitted by a 4WD workshop.
Kit contents: 10 body lift blocks, the required fasteners and a steering shaft extension.
Installation time: Allow 4–7 hours with two people. If you’ve installed a body lift before, expect around 4 hours. For your first installation, allow closer to 7 hours.
You can view the 1996 - 2002 Surf and 4Runner body lift kit here
Toyota Surf / 4Runner 1996-2002 Gen 3 Body Lift Instructions
Before you start
Have suitable sockets and spanners, a torque wrench, penetrating oil, trim tools, wheel chocks, and lifting and support equipment rated for the work. Never work beneath a body supported only by a jack.
These vehicles are getting older, so seized fasteners are common. A few days before installation, apply penetrating oil to accessible body mount fasteners and the steering shaft connection where the extension will be fitted. This can make disassembly easier on the day.
For more information about the lift blocks and splined steering extension used in this kit, read our What makes a quality body lift guide.
1. Park and secure the vehicle
Park your 3rd Gen 4Runner or Surf on firm, level ground with the front wheels and steering wheel straight ahead. Apply the parking brake and chock the wheels securely.
Disconnect the battery, starting with the negative terminal. Keep disconnected terminals isolated. Where a vehicle has more than one battery, isolate the system appropriately.
2. Remove the front bumper and expose the mounts
Remove the front bumper as required to access the front body mounts. Disconnect any attached wiring like fog lights, before moving the bumper away.
Inside the vehicle, carefully remove the door-sill trims and front kick panels needed to lift the carpet. Locate the plastic body mount access covers beneath the carpet / trim you have removed and take them out. If you have been doing a bit of 4wding often these pockets will be full of dirt and grit, so this is a good time to clean them all out.
Identify every body mount before proceeding. On early model 4Runners and Surfs there is 8 body mounts, in later models 1997 and later you will be looking for 10 mounts. Keep the fasteners and washers organized by position.
3. Remove the gear-lever surrounds
Remove the console trims and lever surrounds. This needs to be done so you can inspect clearance around the transmission and transfer-case levers during and after the lift.
4. Prepare the steering and check connecting components
Keep the steering wheel secured in its centered position. Mark the steering joint alignment before disconnecting the joint specified in the image at the bottom of this page. Do not rotate the steering wheel while the shaft is disconnected. This joint can be difficult to separate so I recommend hitting it with penetrating oil the day before you plan on undoing it!
Check the radiator, fan and shroud before lifting. Remove the detachable lower shroud section before you start lifting the body.
5. Loosen the body mount bolts
Loosen all body mount bolts, then remove the bolts from one side only. Leave the opposite side loosely engaged to help retain body alignment, with enough movement for the lift. It is easiest if you have someone holding a spanner on top while you go round loosening them from the bottom.
If you are doing this body lift without a vehicle hoist it is very important you do not remove all body mount bolts at once.
6. Raise one side of the body
Using suitable equipment, raise one side of the body slowly. Only lift the body enough to fit the spacers supplied in the kit. The supplied spacers go between the body and the body bushes.
Lift the body slow and Inspect everything running between the body, chassis and engine. Check engine bay and underneath the vehicle for any wiring, earth straps, battery cables, brake pipes, hoses, fuel filler and breather hoses that can get pinched or pulled during the lift.
Usually there is not a lot that needs done with these vehicles but you still need to check and take care. If the body resists, tilts unexpectedly or pulls a component tight, stop and find the cause. Do not use extra lifting force to overcome an obstruction.
7. Fit the spacers and longer bolts
Fit each spacer in between the body and the existing body mount assembly. Keep the factory bushes in place.
Install the correct longer bolts at each position. Reuse the factory washers and retain their original orientation. To remove the factory washers from the original bolt heads, the best way to do this is to find a deep socket that can fit over the bolt head and then hit the back of the socket with a hammer or mallet. The washers should pop off the factory bolt heads. Re-use all these washers in the positions they came from with the new bolts supplied with the body lift kit.
Lower the body carefully onto the spacers, checking that everything seats squarely. Start the nuts by hand and leave the fasteners loose enough to allow alignment while completing the other side.
8. Repeat on the opposite side and align the body
Repeat the lifting and spacer installation process on the other side. Keep the installed side loosely secured while doing so.
Once all spacers are fitted, check that the body sits evenly on the chassis and every spacer, bush and washer is correctly seated. Tighten the body mount hardware.
9. Complete the steering extension installation
Fit the supplied steering shaft extension in the location specified in the image below. This is where it is designed to fit, it will not fit anywhere else on the vehicle.
Check the steering through its full range. There should be no binding, interference or abnormal free play. If there is any binding do not drive the vehicle until this is resolved.
10. Check gear selection
For manual vehicles, check both gear and transfer-case levers. Occasionally the sound deadening around the shifter entries into the cab can obstruct the shifters full range of motion - trim this as required to get free movement of the selectors.
For an automatic vehicle, check that the selector positions correspond correctly with the transmission, D still selects drive etc. Verify Park, the start-inhibit function and reverse-light operation. Sometimes the selection can be slightly off, if so - you can adjust the shift linkage from underneath the vehicle. These is lots of room to do so now as you've got the body lift installed.
If there is any obstruction with Manual or Automatic vehicles, do not force a lever into gear. Identify what is restricting movement.
11. Refit components and complete the final checks
Refit the radiator/shroud components and any other parts you have removed for the lift. Check fan clearance, hoses and wiring before starting the engine. Refit the bumper using the appropriate brackets, then replace the body mount access covers, carpet, trims and console surrounds.
Before driving, confirm:
- All body mount and steering fasteners are tightened.
- Spacers, bushes and washers are seated correctly.
- Steering operates correctly without binding or abnormal free play.
- Gearbox and transfer-case selection are correct.
- No hoses, pipes, wiring or earth straps are stretched, trapped or rubbing.
- The fan, radiator and shroud have adequate clearance.
- Bumpers and any brackets are secure.
Reconnect the battery once the installation checks are complete. Carry out controlled stationary operational checks, followed by a cautious test in a suitable area once the vehicle is safe to be driven. Stop immediately if steering, shifting, noise or vibration is abnormal.
Recheck the installation and fasteners. Confirm any road-use inspection or certification requirements that apply where the vehicle will be used.
Need help with your installation?
If you are unsure about a fitting detail, contact Flatout Offroad before continuing.
Have a useful fitting tip or a clear installation photo? Send it through so we can keep improving this guide for future customers.