Science Serving Sick ToysTM
Extended Front Shock Mount Installation
ESM13 & ESM14
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PLEASE READ all instructions all the way through BEFORE YOU START!
Safety First! Installing A.O.R. Extended Front Shock Mounts requires the use of a cutting torch, grinder and welder. A.O.R. products should only be installed by those knowledgeable and experienced with such equipment and with fabrication for 4x4 suspensions. Your safety depends on it!
IMPORTANT STEP ONE: Have your shocks in hand before you start this installation.
Why? A.O.R.'s Extended Front Shock Mounts are designed for shocks with 13 inches of travel (ESM13) or 14 inches of travel (ESM14). And if you line up 13-inch (or 14-inch or whatever-inch) shocks from several different makers, you'll find some shock bodies are longer and shorter than others. In other words, the collapsed and extended lengths may differ from shock to shock, even when all the shocks are 13-inchers or 14-inchers.
And since shock length is critical to this installation, you'll need to have your shocks first.
NOTE: These photos show the installing ESM14 mounts and Bilstein 14-inch travel 5100 shocks on an '84 4Runner with a 2-inch body lift. HOWEVER, the same procedures and steps apply to ALL Toyota trucks and 4Runners with or without body lifts. Of course, a body lift makes fitment easier.
1. Remove the old shocks and the flexible inner fender skirts that cover the gap above the frame. Then cut off the stock shock brackets as shown. Two important cautions: take care not to cut into the frame with the torch; and be careful not to torch into nearby brake lines or wiring. Note the sheet metal scrap inserted behind the stock mount on the passenger side (arrow) to shield the starter wiring harness.
2. After torching around the top and sides of the stock mount, a hammer tap is usually all that's needed to remove it. Next, torch the smaller gusset as shown, removing it to just above the bottom of the frame. Exact trimming is not necessary. Then it's time to start smoothing out the cutting scars. Note that it's better to have to grind down a few ridges than to have to deal with a butchered frame.
3. Wear proper eye protection when grinding. And keep at it until the frame is smooth and flat. The new shock mounts weld to this surface.
4. The size of the holes you have to cut in the inner fenders depends upon your body lift and the shock bodies you're using. Start by holding the mount vertically against the frame right where the stock mount used to be. Then cut hole just big enough for the mount to poke into the engine bay. Enlarge the hole as necessary to clear the mounts and shocks. CAUTION: Don't cut blind! Have a helper hold wiring and other cut-able stuff out of the way. And have the helper warn you if you're in danger of cutting some bigger component. NOTE: A.O.R.'s Extended Front Shock Mounts should install without forcing you to relocate any underhood components.
5. Clamp the extended mount in approximate place and double-check vertical positioning over the stock lower mount. With the truck on a level surface, measure the distance between the lower and upper bumpstops as shown in photo at left above. Multiply that number by 1.2 (i.e. if measurement is 6": 1.2X6=7.25) Add this number (7.25 in our example) to the COLLAPSED length of your shock (i.e. 27.25" if the collapsed shock length is 20") Adjust mount position on frame until the distance between the lower shock mount eye on the axle and the new mount's upper eye (measured from eye-center to eye-center) equals the collapsed shock length plus the multiplied bumpstop distance (27.25" in our example). NOTE: also check steering clearance under flex: longer-travel shocks may require relocating or adjusting bumpstops.
6. Once you double-check measurements, shock clearance and mount verticality, weld those bad boys on. Weld the whole circumference of the mount, and don't forget the back side along the top edge of the frame.
7. When you've bolted the shocks in and it all looks something like this, you're done!
Happy 'wheeling and thanks
for choosing A.O.R. products!