Ironman 4x4 Suspension

I have a auto Stethoscope, and you can really hear it with it on the UCA right at the bushing.

when I did my install, I went off their video, which did not have the UCA install, and when he torqued the factory UCA back down, he said to do it super tight, after watching their video on the UCA, he says 85 ft lbs. I wonder if I have it too tight? I’ll loosen it tomorrow, drive up the road, then tighten it again.

 

Dang, this is all such a bummer. I had IM FCP on my 19 Tacoma and was real happy with the product but seems like some issues in their quality control may have plagued them for a bit. Will keep watching

 

Make sure the outer UCA washers are not rubbing against the rubber bushings. If they're curved, they curve outwards away from the bushings so they don't make contact. The washers are there in case a bushing blows to try and keep it all in place.

Happens with Dobinsons UCA's on 4runners

 

I think I have them correct. I wonder if they are slightly over tightened, if the noise is coming from the inner part where the UCA contact the truck

 

If I tighten the UCA ball joint castle but to the exact torque spec, will that mess with my alignment?

I think I torqued them to 60 and I see they are 81

 

That looks correct.

No, it wouldn't affect the alignment. Go ahead and tighten it down all the way, just in case that's what's making the noise.

 

I got a call from a manager at Ironman4x4 this morning. He seems eager to help me out. He wanted to see pictures of my bowed coils and he is going to decide if he wants to have me try installing them, or just send me new ones. Considering the driver's side coil is so bowed that it actually is touching the shock body already (I literally can't slide a piece of paper between the coil and shock) I am thinking he is going to just send new struts.

According to him, they are aware of this issue, but it only seems to be an issue with Tundra struts and while many of them are bowed, he says that it is very few that actually rub, and the rubbing only affects a very small percentage of customers so I don't know if they are working on a fix or not. It just may not be worth it to them to fix it if it only rubs on <1 or 2% of customer orders. But that's just me speculating. I told him about some of the fixes mentioned in this very thread and he seemed intrigued. If that means their QC or assembly procedures will change, I have no idea.

As of right now, I am happy with the customer service I am receiving and with the rest of the kit, which looks very well made and solid. I'm just waiting on a return email from the manager to find out if I am going to install what I have, or wait for a new set of struts.

I'll update with whatever I hear back.

 

I suspect it's a lot more than 1-2%. I mean, look how many people on here have had problems. And we didn't just log in to bitch, we were posting before we ever bought them.

If you could provide pics of both of yours showing how they are set up and where the closest point is, that would help. Mine and everyone I've seen are bowed the same way. The ramp on the lower perch is insufficient to support that end of the coil, so the coil bows towards the high spot on that perch. Like I said earlier, a lift will also tend to make the coil bow outward due to the angle of the top mount not being at quite the correct angle. Plus, another thing going on at the top, is that the spring is kinda ground flat but not quite... there is a fairly large open gap, and where that is positioned will also result in less support and a bow in the coil. The way that IM mounts the springs (with the pigtail and high point of the ramp towards the outside) seems to exacerbate the outward bow (and inward contact) from both ends.

 

I get what you are saying, but also keep in mind that the majority of Tundra owners aren't on this forum or any other. And people who buy these lift kits and there is nothing wrong with them don't then get online and let everybody know about how there was nothing wrong with the kit.

So yeah, while there are 5 or so people here with bowed coils, that is 5 out of how many kits that have been sold? I don't know.

I'm not making excuses or anything or defending Ironman, I'm just pointing out the reality of internet reviews.

 

Pics

 

Can't believe they shipped them like that... the 2nd picture is extreme!

Can't see it directly, but it looks like the close/contact point is opposite the high point of the ramp like all the others. Consistent issue...

 

I got a response from Ironman4x4. They are sending me a new set of struts.

As of right now, I am happy. Hopefully they will send a new set that isn't so severely bowed.

 

Are the struts supposed to be in facing a certain direction?
I noticed on my drivers side, the bottom of the strut is rubbing in the trucks little housing that it sits in.

 

Typically they are showing their stickers towards the outside for marketing...perhaps that's why it is rubbing...

 

I’m confused because looking at a pic of the strut, the bottom mount looks centered with the body, so shouldn’t matter? But idk

 

I agree, don't think there is any offset on any front shock I've seen.

 

I took my UCA off, greased the hell out of it, reinstalled, still making noise. I sprayed white lithium on the lower shock mount and no noise.

may be dumb luck, but I’ll drive it a day or two and check

 

Looks like it's rubbing, and I'd expect that to squeak... but I doubt it was an install issue.

 

The passenger side has a very small spot in the same area, wonder if it’s worth relaxing, or just get the grease gun and squirt a dab in there

 

More news from my ordeal.

The second set of struts they sent me were also very bowed. Even worse than the first set. I called Ironman4x4 and let them know that I was pretty upset with this development and here is what I was told:

I was told that after my last phone call and the pictures I sent (I was on the phone with them for well over an hour talking to management) Ironman4x4 stopped denying there was an issue, and they called in one of their engineer/product development guys to find out what is causing the bowed coils on the Tundras. The customer service agent I was talking to did not know what they found out, but he knows they identified and fixed the issue. They also now have only ONE guy assembling the spring on the shocks, and then inspecting them before packaging and shipping. This particular guy is supposed to be very meticulous and a perfectionist and very experienced. We'll see.

That all being said, this all happened AFTER my replacement set was shipped to me. So once again they are sending me a new set and this time I was promised they will be within spec.

Of course, this is just what the customer service guy told me. Do I believe him? I'd like to, but I have little reason to believe or disbelieve him other than the fact that he freely admitted that Ironman4x4 was previously denying an issue existed when it clearly did. That does make me think the story might be at least partially true. A company being honest about a mistake can go a long way. I guess I'll find out in another week or so when my new, new, struts get here and see what the coils look like.

I do not have to return any of the 4 struts they have already sent me and I was told they are mine to do whatever I want with. I might just try buying or renting a spring compressor and seeing if I can fix the bowed springs myself and then maybe sell them. If the springs were straight they are still perfectly good and high quality struts.

I really hope they did fix this issue. I do think that Ironman4x4 makes some smart design choices and I know they are very popular over seas and especially in Australia. They are big competitors to OME down under.

 

Sounds like they are taking good care of you. Can't believe they are just letting you keep the 4 that you have! Even with the ubiquitous 25% off deal the shocks sans springs are $300 each... and at least that part is ok. The springs are probably ok as well.

We need to know what the fix is, too... because many people are assembling these themselves. Did you take detailed photos by any chance? I have my theories, but not a lot of samples to go on...

 

I am assuming it is just an assembly issue with lining the spring up properly on the spring perches, judging by the fact that they have one guy now assembling them. I did ask the customer service guy to find out exactly what the fix was and email me, but so far I haven't gotten that email. I suspect he probably forgot. Which I understand. I forget shit like that at work all the time.

But yeah, if nothing else, their customer service is top-notch. I was actually planning on a big fight if they wanted me to ship those struts back, and an even bigger fight if they wanted me to pay for return shipping. But when I asked them, they didn't even hesitate to tell me I didn't have to send them back. I guess they know, they messed up, so it is their responsibility to make it right and the customer shouldn't have to be part of that process.

That customer service is what is keeping me from demanding a full refund. But if the third set shows up bowed, that is exactly what I will be doing. Fool me once, shame on you, fool me twice, shame on me, fool me a third time, its war.

As far as pics, I posted them in this thread. I haven't take any pics of the new set, but suffice to say, they were actually worse. I also haven't tried fixing the other 2 sets yet. I am just waiting for the third set to arrive in usable condition and be on my truck and working before I do anything else.

 

@Kur YOU SIR are one VERY GRACIOUS sumbitch!! GOD BLESS YOU MAN!!

You either are or have worked in customer service!! I did too, and every now and again a good booger like you comes along, and you think to yourself "damn we're f'ing this customer, I gotta make this right."

If they don't send you good struts...I'll go to their store and moon 'em for you!

OH NOW I REALIZE what this is really all about...you're one of the last of a breed that has...patience.

So forget about what I said if you can about customer service...I really meant their service sucks!! How long has this shit been going on?!?!? Since mid-2021, right?

Adieu kind sir!

 

It hasn't been going on that long for me. For me it's been 3 weeks. And yeah, I do have a lot of patients. I'd rather work with them to solve the problem so everybody can win rather than just throwing a tantrum. But there are always limits to everything. This is their last chance with me to make it right.

 

Yep. That's pretty much the conclusions I came to in my research and why I chose to go with Ironman4x4.

Now if only they can get me a straight set of coils....

 

My first set on my Tacoma years ago was the same way. They destroyed the shock after a few weeks (the bend wasn't as noticeable as yours from the factory). The second set was amazing, and the 3rd set was foam cell pros and there wasn't a single issue with them.

 

While the foam cell technology is pretty good in theory and generally in application as well but it is very concerning they are shipping these out with the coils like that. We’re not talking one set being shipped out like that. Multiple people are receiving them that way and multiple people have received replacements that were just as bowed or even more.
If they honestly believe that is an acceptable way to assemble a coilover (which they appear to be backing off of now) one has to question their knowledge about things.
If they don’t believe it is acceptable but they are still shipping them out like that then one has to wonder what other corners are being cut.
Ironman ended up being my 2nd choice a couple years back. At this point I am glad it ended up that way.
Glad for the most part they are taking care of it but not a chance I would put a bowed spring like that on my truck hoping it will work and know I will likely have to tear the truck down again.

 

As I pointed out in my comment the other day, Ironman4x4 has finally decided to recognize there is an issue and has taken steps to fix it. At least, that is what I was told by their customer service rep and their manager. I'm still waiting for my new set of FCPs to arrive before I verify that this information is accurate or not.

All I know for sure right now is that at least two of their employees fully admit that there has been an ongoing issue. And that is at least a step in the right direction.

 

So are they only recognizing the problem because they are being called on the carpet and they were good with shipping these out KNOWING it was a problem but did not care?

Or did they really think that these were fine and it took some random folks on a forum to get a company that arguably specializes in suspension components to realize this is not acceptable?

Both are problematic granted the 1st being far more egregious.

EoTech did that years ago knowing their product was faulty yet still delivered 10s of thousands to our military and law enforcement folks.
I haven’t bought an EoTech since and likely never will.