Crossover Steering Conversion Frame Mounting Kit

Crossover Steering Conversion Frame Mounting Kit (ORS-ST001)

NOTICE TO INSTALLER: Fully read and understand these instructions for starting. This will make the job easier and faster. We promise!

This part is designed in conjunction with a crossover steering conversion. These instructions were written for the frame modification during this conversion. There are additional procedures to be done and parts to be installed. It is the installer’s responsibility to install the proper parts on the vehicle. This kit is designed for use with a steering gear from an 86-95 Toyota 4×4 or 4Runner, often referred to as an IFS steering gear. There are many parts available for this conversion through ORS and other manufacturers. ORS recommends the use of new “hi-steer” steering arms, a new heavy-duty tie rod and draglink, new heavy-duty rod ends, and the proper pitman arm or pitman arm insert to securely fasten the drag link.

This modification and product is intended for off road use only.

The installation of this product requires fabrication. We recommend that the installer is competent with fabrication processes such as welding, cutting, and grinding. A poor installation of this product can lead to a frame and/or steering failure.

  1. Center the steering system of the vehicle, making sure that the tires are pointing straight forward and the steering wheel is centered.
  2. Remove the key and lock the steering wheel in place.
  3. Remove the torque rod and discard. This is the rod that connects the inside of the frame to the axle housing.
  4. Disconnect the drag link from the pitman arm and set the drag link out of the way.
  5. Remove the steering shaft and hydraulic lines/hoses from the steering gear. Remove the steering gear from the vehicle and discard.
  6. Move the steering shaft and hydraulic lines/hoses out of the way. Plug the lines/hoses so that they are not leaking fluid.
  7. Remove the mounting plate from the frame and discard. If necessary, clean the frame rail around the steering gear mounting area.
  8. Using a torch or cutting tool, remove the torque rod mount from the inside of the frame. Use a grinder or sander to smooth the frame surface. Be careful not to damage the frame.
  9. This kit comes with 2 steering plates. The plate with larger holes is placed on the inside of the frame. The plate with smaller holes is placed on the outside of the frame.
  10. Place the outer plate on the frame rail. Position it so that the straight edge is about 1.5″ from the rear edge of the front body mount. Clamp the outside of the plate to hold it in place.
  11. Place the IFS steering gear on the outside of the frame rail against the outer plate. While holding the gear in place, check to see if gear is in proper place. It is recommended to place the steering gear as high as possible for leaf spring clearance. When doing so be sure that the pitman arm will clear the frame during movement from side to side.
  12. At this point it is also recommended to check for steering setup clearance. With the vehicle at ride, be sure that the suspension components all clear each other. Be sure that the steering gear is far enough forward so that the drag link does not strike the tie rod. Fully cycle the suspension to be sure that all these components clear in all conditions. Keep in mind any future modifications, such as moving the axle forward.
  13. Move the steering gear and frame plate around on the frame until the ideal location is found.
  14. If the steering gear is in the proper place, mark the outer steering plate’s position on the frame. Separately mark the outline of the steering plate on the frame. Remove the outer plate and steering gear.
  15. Using a sanding tool, sand along the outline marks on the frame to provide a clean welding surface. “Mirror” the same marks on the inside of the frame and remove paint accordingly. Remove only enough paint to provide a good weld. Be sure not to remove the marks that reference the outer plate’s proper position.
  16. We recommend applying a thin coat of paint to the rear of each plate before installation to help prevent rust in the future. Be sure not to paint too much as this can cause a defective weld. Be sure to keep the paint away from the edges.
  17. Using the reference marks, place the outer plate against the frame in the same position. Firmly tack-weld the outer plate in place.
  18. Using a 1/2″ transfer punch, mark the center of the 2 holes that lay against the frame rail. Drill 2 1/2″ holes to match the plate through the outside frame rail only.
  19. Carefully measure the location of the inner plate on the inner frame rail. This plate should be placed directly on the other side of the frame from the outer plate. It should be placed so that the 3 holes from both plates line up perfectly on a plane perpendicular to that of the outer frame rail. Take great care in aligning the 2 plates perfectly, this will greatly help in installation.
  20. Clamp the inner plate in place. If the inner frame rail is concave, use the clamp to form the plate to the shape of the frame.
  21. Be sure that the inner plate is in the proper location. Firmly tack-weld the inner plate in place.
  22. Using the holes in the plate as a guide, cut or drill holes in the frame to match the 2 lower holes in the inner plate.
  23. Slide the provided sleeves through the inner plate until they bottom out on the outer frame rail or outer plate. There are 2 different lengths provided. Arrange the sleeves so that the amount protruding from the inner plate is relatively the same for all sleeves.
  24. Drill out the 3 mounting holes in the steering gear to 1/2″.
  25. Using the provided hardware, mount the steering gear on the frame with the sleeves in place. The washer and nut should be used on the inside of the frame. There are 2 lengths of bolts provided, use the longer bolt where appropriate. Tighten the 3 mounting bolts.
  26. Double check all clearances, making sure the steering gear location will work in every condition.
  27. Weld the sleeves to the inner frame plate. Be sure that both frame plates are firmly tack-welded to the frame at this point.
  28. Remove the steering gear and hardware.
  29. Fully weld both plates into place. We recommend using approx. 2″-3″ beads around the outside of the plates. Place approx. 1″ gaps between each weld. Weld the upper sleeve to the inside of the outer frame plate. It is also recommended to weld a small piece to steel between the upper sleeve and the top of the frame. This will add some additional strength to the setup.
  30. Once the frame has cooled, apply primer and paint to all bare metal surfaces.
  31. Install the steering gear using the provided hardware. The washer and nut should be installed on the inside of the frame. Tighten the mounting hardware.
  32. Count the revolutions in the steering gear and be sure that the gear is rotated to the center position.
  33. Install the drag link at the pitman arm and tighten the hardware.
  34. Install and tighten the hydraulic lines/hoses. The lines/hoses from the original steering setup usually work well with the new steering gear. The return and pressure ports are oriented the same on the IFS gear as they were on the original steering gear.
  35. The steering shaft may be the wrong length at this point. A local salvage yard may have a selection of early Toyota (79-95) steering shafts, so the appropriate length can be found. The existing steering shaft can also be modified.
  36. To lengthen the existing shaft, drill out the two “fill” holes using a smaller drill bit. These holes can be found along the larger part of the steering shaft. They will appear to be filled with a white plastic substance. Once these holes are drilled out, tap the steering shaft with a hammer and brass drift until it breaks free. At this point, the steering shaft can be lengthened by sliding the 2 pieces apart. Be sure not to lengthen the shaft so far that failure is possible. Once the desired length is achieved, place a small tack weld between the two pieces to retain rigidity and length.
  37. Install the steering shaft. Be sure that the steering gear and steering shaft are referenced to each other properly. Tighten the steering shaft hardware.
  38. Start vehicle and check for leaks.
  39. After a short period of driving, check the torque on the steering gear mounting bolts and check for leaks.
  40. Congratulations!