How to Install the Marlin Crawler RCLT HD Long Travel Suspension on a 3rd Gen Toyota Tacoma

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Why Upgrade to the RCLT HD?

If you’re serious about off-road performance and rock crawling, the Marlin Crawler RCLT HD is a game-changing upgrade for your 3rd Gen Toyota Tacoma. This heavy-duty long travel independent front suspension (IFS) system is engineered for strength, durability, and control — even in the toughest conditions.

Unlike traditional lift kits or LT setups, the RCLT HD features:

  • A fully integrated MarRack steering system
  • Billet steel knuckles with extended steering arms
  • Reinforced UCAs and LCAs with oversized bushings
  • Compatibility with factory geometry and OE+ brakes

Whether you’re building a rock crawler, overland rig, or weekend warrior, this kit delivers serious performance.

What You’ll Need for the Installation

Before starting the RCLT HD installation, make sure you have these tools and supplies on hand:

Essential Tools:

  • Torque wrench (in-lbs and ft-lbs)
  • Hand wrenches: 17mm, 19mm, 21mm, etc.
  • Crowfoot wrench (for torquing tight angles)
  • M10–M35 sockets, 9/16” & 11/16” bits
  • Rubber mallet, dead blow hammer, pry bar
  • Floor jack + jack stands
  • Grease gun (90° fitting recommended)

Lubricants & Extras:

  • Water-resistant grease (marine/silicone-Teflon)
  • Multi-purpose grease
  • Anti-seize thread lubricant
  • Zip ties, gloves, shop towels

Full Step-by-Step Guide: RCLT HD Install on Tacoma

Here’s a breakdown of how to install the RCLT HD on a 3rd Gen Tacoma. You can complete this with basic mechanical knowledge and some patience.

Step 1: Pre-Installation Prep

Flush the Power Steering System

Old fluid can cause premature wear on your new MarRack. Flush and refill with clean power steering fluid.

Remove Factory Suspension & Steering

Take off the following components:

  • Upper & lower control arms
  • Knuckles, CV axles, tie rods
  • Rack and pinion
  • Factory sway bar (optional)

Step 2: Prepare the HD Knuckles

You have two options here:

  • Using New Parts – Install outer oil seals, press hubs, add O-rings, grease the knuckle, and torque the hub bolts to 44 lb-ft.
  • Reusing OEM Parts – Carefully remove and clean hubs from factory knuckles, inspect and grease components, then install them into the new RCLT HD knuckles.

Finally, install the inner oil seals on both knuckles.

Step 3: Assemble Upper Control Arms (UCAs)

  1. Install grease Zerks – Torque to 30 in-lbs
  2. Grease and insert bushings
  3. Install compression sleeves – Lightly tap them in with a mallet

UCAs feature thick ¼” bracing and are designed for max clearance and travel.

Step 4: Assemble Lower Control Arms (LCAs)

  1. Install grease Zerks – Same as UCAs
  2. Grease and install oversized bushings

  3. Install frame-specific compression sleeves:

    • Type III frames: Use thick wall MCSU71521111
    • Type IV frames: Use thin wall MCSU71521112

LCAs are engineered for max durability, impact absorption, and increased approach angle.

Step 5: Install the RCLT HD Components

Install Upper Control Arms

  • Position with the uniball plate facing up and straight leg toward the rear.
  • Grease all bushing faces and torque the factory shock tower bolt to 64 lb-ft.

Grease the Zerks

Use a 90° grease gun and water-resistant grease on all UCA and LCA fittings.

Brake Compatibility Note

Tacomas before 2015 require drilling caliper holes to 9/16” to fit M14 bolts (Toyota part 90105-14198).
Alternatively, upgrade to 2015+ 4Runner/GX460 calipers and rotors for an OEM big brake setup.

Final Steps & Inspection

  • Double-check torque specs on all bolts
  • Fully grease all control arm bushings
  • Align your front suspension
  • Bleed the power steering system if the rack was replaced
  • Test drive and re-check hardware after 50–100 miles

Watch the Full Install

Want to see the whole process in action? Check out our YouTube video with full RCLT HD installation coverage — tools, tips, and trail-tested results.

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