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.
Toyota Pickup/4Runner 1979-1995 Applications
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 should extend 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 71 ft/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 6.6-13.2 lbs of force to move it without the felt and rubber wiper installed. 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 67 ft/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 re-torque knuckle stud nuts after 100 miles of driving and again every 5,000 miles.