JC,
I think what is going on here is that ARB would like you to use their shackles and they also don't want you to run 4" longer shackles front and rear. Poser, it's been a while and I know that Man-it-ant Free sells longer shackles but I thought that ARB only sold one length for the 40??? 20 or 25mm longer than stock? Is there a new one out? I'd like to know for myself! I know they make anti-inversions but I thought for only 81 and newer FJ40. I am no expert, please school me.
Before they sold anti inversion shackles (for 81 and newer), they sold a small metal plate that you welded onto the frame prevent the shackle from inverting.
I bought a set of their springs back in the early to mid 90's when I first heard about them and they wound up on my friend's truck. They inverted badly at Tellico but ARB sent him a new set under warranty and the metal plates. This is why I think they want you to run what they sell. So they can better stand behind it when and if you have a problem. If you had home made, crappy or some whacky double shackle, they can't warranty it as easily. Same applies to a spring over or a shackle reversal, that is not what they designed the springs for - if you run them in that configuration and have a problem, it's your problem not theirs...if you run as a part of their whole system and have a problem then they will stand behind it.
I'd have to agree with IGE about the Ubolts. You should get new ones, true a bolt stretches every time that you put torque onto it but then gets shorter with out tension (racers and the aerospace industry often measure stretch vs. torque). It is amazing how metal fatigued they can be on old trucks - they just snap when you try to take them off were as newer ones will just flex like a torsion bar when you try to take them off. Listen to how loud the snap is when you cut them off and then should speak to how much tension they are under!
I'd say you can run slightly longer shackles no problem though, I'd never had any trouble but I don't wheel that hard.
-Stumbaugh