The underbed crossbar is made from burly 1 1/2", .120-wall steel tubing. The A.O.R. system also features heavy-duty 3"x3"x1/4" frame-mount plates and precision 3/16" shock-mount tabs. The system, product code ESMRCB, is available for $149 through A.O.R.'s secure online ordering at www.aor4x4.com/longtravelshocks.htm.

The photos below show the installation on an '84 4Runner with a 2-inch
body lift and Dana 60 axles. However, the same steps apply to all Toys
listed above.

The first task is to position and tack weld the shock brackets as shown -- approximately one inch inboard from the U-bolts and with the bottom of the bracket level (parallel to the ground) and even with the bottom of the axle tube. Note that the shock tabs angle back slightly. The bracket may need to be repositioned, so it's not finish-welded yet.

NOTE: Stock lower mounts (the ones on the stock U-bolt plate) can't be used with this system, but they don't interfere with positioning the
new A.O.R. lower mounts.

The A.O.R. system is a U-cut-and-weld-it deal. You'll need to trim the crossbar to length. Step one is to measure and mark the center
point between the two shock bosses on the cross bar.

Up under your Toy, you'll need to measure distance between
inside of frame rails just forward of the frame crossmember, taking the
thickness of the mounting plates into consideration.

Setting up a square like this makes it easy to cut the correct angle for mounting the crossbar. The distance from the centerpoint of the crossbar (arrow) to right-angle of the square should be exactly HALF the total measurement between the frame rails (minus the two plate widths).

Double-check your measurements and make sure the main crossbar shaft is parallel with the bottom side of the square. Then mark and trim the crossbar ends as shown above. A chop saw works best, but a hacksaw works, too. Note that the cuts will be at an angle relative to the open end of the bar.

Positioning the mounting plates depends on your truck's body lift and the particular shocks you're mounting. The A.O.R. system provides a good bit of latitude to accommodate different shocks. A.O.R. recommends to bolt the shocks on and trial-fit the crossbar as shown above.

NOTE: The mounting plate's diagonal positioning. Most welders prefer this
position to reduce stress on the frame. When shock angles and clearance
are satisfactory, the crossbar is tacked into place.

There's no
finish-weld at this point! In some cases, non-stock exhaust routing may
need to be adjusted for clearance.
aor-shkmt7. Finish-welding is done only after shock angles have been
checked and you're sure there's no excessive bindup in bushings or Heim joints.

Here's an upper mounting plate and crossbar end after welding and painting.

Here's the finished installation that ramped 1000+ with
A.O.R.'s 5-inch-lift springs, extended shackles and Bilstein 14-inch-travel 7100s.

Advanced Off-Road Research (A.O.R.)
725-B West Grand Avenue
Grand Junction, CO 81501
970-263-4300
aor@gjct.net
www.aor4x4.com