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Unlocking Peak Off-Road Performance with the TOTAL CHAOS Long Travel Kit

Long travel suspension systems are a cornerstone for serious off-road enthusiasts looking to push their vehicle’s capabilities beyond factory limits. A key upgrade in this realm is the Total Chaos Long Travel Kit. Designed to significantly enhance vehicle dynamics in challenging terrain, these kits are engineered for increased wheel travel, improved stability, and superior durability, transforming a capable off-road vehicle into an extraordinary one ready for the toughest adventures.

Why Upgrade to a Long Travel Kit?

Wider suspension geometry fundamentally changes how a vehicle handles off-road obstacles. By increasing wheel travel, the suspension can articulate further, keeping tires in contact with the ground over uneven surfaces and maintaining traction. A wider track width, typically achieved with long travel kits that extend the control arms, also dramatically improves the vehicle’s cornering stability, both on and off-road. For many popular truck platforms, 2-inch long travel kits offer an optimal balance, allowing for significant performance gains while often permitting the use of stock fenders, minimizing the need for extensive body modifications. The Expedition Series from TOTAL CHAOS, for example, goes further, providing an additional 2 inches of ground clearance compared to their Standard Series kit, further enhancing capability over obstacles. Long travel systems are ultimately about maximizing ride quality, component strength, and overall performance tailored for demanding off-road adventures, potentially offering customization through features like dual shocks for fine-tuned dampening.

Key Features of the TOTAL CHAOS Long Travel Kit

The design and components of a high-quality long travel kit are crucial for performance and reliability. TOTAL CHAOS kits feature extended 4130 chromoly upper and lower control arms. These bolt directly into the factory control arm mounting locations but increase the track width by 2 inches per side, contributing to enhanced stability. With this setup, vehicles equipped with 4WD can achieve approximately 11.5 inches of wheel travel.

A significant upgrade is the use of 1-inch uniballs for the upper and lower ball joints, replacing weaker factory components for increased strength and allowing greater articulation. TOTAL CHAOS utilizes 1-inch I.D. uniballs with a heat-treated stainless steel ball and race, providing superior corrosion resistance and durability. A military-grade PTFE woven fabric liner around the uniball helps minimize noise during operation.

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Urethane bushings are employed in the upper and lower control arms. Compared to stock rubber bushings, urethane dramatically reduces deflection, resulting in a tighter, more responsive feel and improved handling on trails. All pivot points are equipped with zerk fittings, simplifying lubrication and maintenance.

The Expedition Series incorporates Billet CNC machined uniball cups integrated into the boxed lower arm design. This not only increases strength but also helps retain the factory turning radius. The lower arms themselves are internally gusseted and fully boxed for maximum durability, and they include provisions for dual shocks. Integrated steering stop tabs ensure that the factory turning angle is maintained without requiring modifications to the OEM ball joint cradles. As mentioned, the Expedition Series also provides 2 inches more ground clearance than the Standard Series.

TOTAL CHAOS specific 2.5-inch long travel coilover shocks are designed to bolt directly into the factory coil bucket location. It’s important to note that standard extended travel shocks are typically too short and will not work correctly with this system. The inclusion of dual shock tabs allows for the installation of a TC-specific external bypass shock. This enables additional dampening control and maximizes tunability, allowing users to customize their ride quality based on vehicle weight and specific terrain conditions.

Adjustable limit strap clevises are supplied to properly manage suspension droop and prevent components from overextending. These are adjustable, allowing for necessary adjustments over time as limit straps naturally stretch.

The kit includes essential components like DOT-approved stainless steel braided brake lines, which resist expansion under pressure, ensuring consistent braking performance. Custom 17-4 stainless hi-misalignment spacers and Grade 8 mounting hardware are also part of the package, providing robust and precise fitment.

For 4WD vehicles, custom TOTAL CHAOS extended axles are required (sold separately). These are machined from 4340 steel and are designed to reuse the factory inner and outer CV joints, preserving the vehicle’s 4WD capability.

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The quality of the components is paramount for off-road reliability. These kits are hand-crafted in the U.S.A. and feature a durable 3-stage powder coat process that includes a clear coat for a long-lasting finish. It’s crucial to note that these long travel kits are NOT COMPATIBLE with 4-7 inch spindle/drop bracket lifts, as they are designed to work with specific long-travel shock lengths and suspension geometries. If you’re heading out on an extensive trip, perhaps planning visits to multiple destinations like a flying j dealer — mega travel plaza breezewood photos, ensuring your vehicle’s suspension is up to the task is key.

Detailed view of the components included in the TOTAL CHAOS long travel kitDetailed view of the components included in the TOTAL CHAOS long travel kit

Wheel, Tire, and Shock Information

Selecting appropriate wheels and tires is essential to complement a long travel kit and maximize performance while avoiding clearance issues. Recommended specifications include:

  • 16″ Wheel: 16″ x 8″ with 4.5″ backspace, typically paired with a 285/75R16 tire.
  • 17″ Wheel: 17″ x 8.5″ with 4.75″ backspace, commonly used with a 285/70R17 tire.

Specific shock absorbers are required to function correctly with the extended travel offered by the kit. For example, TOTAL CHAOS lists compatible 2.5″ long travel coilover shocks (e.g., PART #: KNG-TC5119-03-A, often available with adjusters) and external bypass shocks (e.g., PART#: KNG-TC1119-34) designed to integrate seamlessly with their control arms and mounting locations.

Conclusion

The Total Chaos Long Travel Kit represents a significant upgrade for off-road enthusiasts seeking maximum performance, durability, and tunability from their vehicle’s suspension. With features like extended chromoly control arms, heavy-duty uniballs, urethane bushings, dual shock capability, and increased ground clearance, these kits are built to handle aggressive terrain and provide a superior ride quality over rough surfaces. Understanding the specific components and compatibility requirements is key to unlocking the full potential of this high-performance suspension system for your next off-road adventure.

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