Looking to build out an expedition vehicle and need your wisdom! Suspension, tires, & more!

Long story short, I recently picked up a 2000 AC 4x4 sr5 with 100k miles. I took it in for the frame recall immediately, and sure enough I'm getting a brand new frame and rack and pinion for my 21 year old Tundra. As a result, the dealer is fine with me providing replacement parts to be swapped onto the new frame while they're at it.

I bought this truck to be outfitted for two people to travel and live out of for weeks or months at a time. I hope to have a DIY slide in camper (well below payload capacity) built by this time next year or sooner. It's NOT my DD.

My goals for this build are:

• Improve suspension for rough roads and trails (not running the Baja in this thing)
• Keep MPG (especially highway) as high as possible
• Do this as economically (cheap) as possible

What I need help on is the following:

1) Considering my long term plans, are 5100s all around + diff drop + 1.5" progressive AAL still the recommended 'budget' option for a 1-2" lift? Should I order and put the AAL on now or wait until I get the camper built? I also plan to add airbags once that is complete. Picture of my current Wheelers Offroad cart attached.

2) I'm currently looking at going with 235/85r16 on all 5 stock wheels. Most likely Discoverer AT3 or similar. I need something that will give me good MPG and be quiet/safe on the road for 90% of the driving while being fairly capable offroad. I know pizza cutters like this will make for a harsher ride, (since they are all load E,) but unless it's REALLY bad I think I'll live with it just fine. I am NOT an agressive driver.

3) Can someone point me to the best brake upgrade that will still work on the stock 16s? I know I read something about an LW13 swap or something, but ideally it would be an upgrade I could get the dealer to throw on while they are down there. If not I could always do it myself after.

4) If you have any other highly recommended budget mods, let me know!

Thanks in advance.

 

Before we go recommended parts, this gonna be a travel in the states kinda of deal or we talking abroad rig? Parts availability would be a concern for me if I was I your shoes

second 235s aren’t really gaining much over factory off-road package 265s. I would consider 255s if I wanted pizza cutters personally

 

You're wise to go with Load Range E tires. Logging/dirt roads are notorius for slicing tires. If you do any research on driving the Al-Can, Trans Labrador, or similar... everyone recommends 10 ply tires.