| Metal
fabrication and welding skills are needed to install
this kit. If you are unsure about your ability
to install this kit seek professional help. Installing
this or any other off-road modification may change
the way your vehicle handles and performs. Vehicles
modified for off-road use are less stable and
may not be suitable for use on the street. First
time install time runs about 8 hours.
If your installing this kit on a solid axle
converted 1986 to 1995 truck or 4Runner please
skip steering box mounting step as your truck
is already equipped with an IFS steering box.
Steering
Box Mounting
Remove
stock steering box, steering arms, front axle
anti wrap bar. Unbolt or cut off with a torch
the factory push-pull steering box mount. Obtain
an IFS steering box from a 1986-1995 4wheel
drive Pickup or 4Runner (note 2wd steering box
will not work). Install pitman arm onto
steering box and snug down the sector shaft
nut. Place steering box on frame rail and slide
forward until it contacts body mount. Rotate
the steering box back so that the steering shaft
going up to the steering wheel is nearly straight.
Check to make sure the pitman arm will not contact
the frame as it turns left and right.
Place
the upper steering box mount onto the frame.
Using the box as a template mark the two lower
mount holes. Drill out the frame holes and install
the provided tubes into the frame. Tubes are
wider than the frame. The excess length should
stick out on the inside of the frame rail. The
outside of the frame rail where the steering
box mounts should be flush. Weld sleeves and
upper mount into place on both the inside and
outside of the frame. Make sure box mounting
surface is flat, grind off excess weld if necessary.
Bolt on steering box, steering shaft and power
steering hoses. Your truck's original hoses
will screw into the fittings on the IFS box.
If the steering shaft from the steering wheel
is not long enough to reach the steering box
it may it be necessary to lengthen the shaft.
This can be done by removing the shear pin
in the steering shaft.
We
recommend adding a plate to the inside of the
frame rail after the IFS kit mount is installed.
This plate shoudl entend forward and behind
the two steering box mount holes that go through
the frame.
Installing
High Steer Crossover Steering
It
is recommended you paint your steering arms
to keep them from rusting. When you paint, do
not paint the bottom, machined surface that
bolts onto knuckle. Remove factory steering
arms from solid axle. Keep original shims that
are under the stock arms. Install new arms using
original shims. The arm with one hole
goes on the left side (driver side) and the
arm with two holes goes on the right side of
truck (passenger). Knuckle stud bolts should
be torqued to 80 foot/lbs. Using a pull scale
attached to the steering arm check the resistance
of the knuckle. With the axle installed and
the tie rod removed the knuckle should require
12-15 lbs of force to move it. If the knuckle
is too tight or too loose it may be necessary
to change the knuckle bearings and/or shims
to bring it into spec.
Next
install left and right tie rod ends into the
tie rod and drag link. One end of each rod is
left hand threaded and the other end is right
threaded. Note the grove machined into the left
end of the rod. The longer rod is the tie rod.
Install the tie rod so one end is attached to
the only hole in the left side steering arm.
Attach the other end in the rear hole of the
right side steering arm.
If
you have not all ready done so, install the
provided pitman arm onto the IFS steering box
using the match marks on the pitman arm and
steering box. If you have a factory IFS steering
box it may be necessary to use a pitman arm
puller to remove the stock arm.
Install
one end of the drag link into the pitman arm.
Install the other end into the forward hold
on the right hand steering arm. Tighten all
four FJ80 rod end castle nuts to 80-100 foot/lbs
and install cotter keys for safety.
With
truck on the ground, Torque the sector shaft
nut on the steering box to 95 foot/lbs.
A
steering stabilizer is recommended if used at
speeds above 25 mph.
Recheck
all hardware and retorque knuckle stud nuts
after 100 miles of driving and again every 5,000
miles. |
