Installation Instructions

Transcription

1 Steering kit for Samurai Cross Over Steering Kits (SKU# SST-SSOTS) Installation Instructions CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. Suggested Tools: Twin Post Lift (Optional)! or Floor Jack and 2 Safety Stands (Optional) Metric Sockets: 14 & 17 mm Standard Sockets: 1/2 & 9/16 Ratchet Metric Combination Wrench: 17 mm Standard Combination Wrenches: 1/2 & 9/16 For additional copies of these and other instructions go to: and click on the Instructions tab.

2 Lifting and Supporting the Vehicle Note: Lifting the vehicle is optional. It simply makes the job a little easier. This job could be done with the vehicle on the ground. Lifting Option 1 Lift and support the vehicle on a twin post, frame contact, lift. Front Positioning Rear Positioning

3 Lifting Option 2 Lift the front of the vehicle with a floor jack and support it on safety stands. Front Floor Jack Steering Parts Identification Pin Top Flat Washer Pin Bottom Bushing Pin Top Bushing Steering Bolt Pin Bottom Flat Washer Pin Lock Washer Passenger End Driver End Sleeve Stay Pin Nut Lock Washer Nut

4 Removing the *OEM Steering *Original Equipment Manufacturer Step 1 Hold the stabilizer bolt using a 17 mm open end wrench and loosen the stabilizer nut using a 17 mm socket. Step 2 Remove the nut and lock washer. Step 3 Remove the stabilizer bolt. Note 1: It may be necessary to turn the steering wheel to position the pitman arm such that the bolt can be removed. Step 4 Remove the stabilizer from the stabilizer stay by pulling it toward the front of the vehicle. Note 2: Keep this bolt, lock washer and nut. These items will be used to connect the new stabilizer.

5 Step 5 Loosen the stabilizer pin nut using a 14 mm socket. Step 6 Remove the pin nut, lock washer and flat washer. Step 7 Remove the bottom bushing and stabilizer. Step 8 Remove the upper bushing and flat washer.

6 Parts Identification Tie Rod Bracket (2) Tie Rod U-Bolt (2) Telescoping End Steering Non-Telescoping End Axle Bracket Tie Rod U-Bolt Washers (4) Differential U-Bolt Tie Rod U-Bolt Nuts (4) Bushing Washer (4) Differential U- Bolt Nuts (2) Differential U-Bolt Washer (2) Nut (2) Bushings (4) Installing the Steering Step 9 Position the axle bracket and U-Bolt as shown. Step 10 Install the U-bolt washers and nuts. Tighten the nuts finger tight for now.

7 Shoulder Step 11 Install one stabilizer washer and bushing on the non-telescoping end of the stabilizer. Note: The shoulder of the bushing always goes toward the bracket, away from the washer. Step 12 Insert the stabilizer through the axle bracket as shown. Install the second bushing with the shoulder toward the bracket. Step 13 Apply Permatex Red Threadlocker (or equivalent) to the stabilizer threads. Step 14 Install the nut.

8 Step 15 Using a 9/16 wrench tighten the nut until the bushings begin to bulge. Then tighten the nut an additional 3 full turn. Step 16 Position the (2) Tie Rod U-Bolts and the Tie Rod Bracket as shown. Step 17 Install the (4) washers and nuts. Leave the nuts finger tight for now. Step 18 Install a washer and bushing on the telescoping end of the stabilizer. Note: Be sure the shoulder of the bushing is facing away from the washer.

9 Step 19 Position the stabilizer into the Tie Rod Bracket. Step 20 Install the bushing and washer on the stabilizer as shown. Note: Be sure the bushing shoulder is facing the bracket, away from the washer. Step 21 Apply Permatex Red Threadlocker (or equivalent) to the stabilizer threads. Step 22 Install the stabilizer nut.

10 Step 23 Using a 9/16 wrench, tighten the stabilizer nut until the bushings begin to bulge. Then tighten the nut an additional 3 full turns. Step 24 Move the front wheels all the way toward the driver side as if you were making a left hand turn. Axle Bracket 1/2 Step 25 Slide the axle bracket as far toward the driver side as possible. Telescope the stabilizer rod and tie rod bracket out 1/2 from the body of stabilizer. Step 26 Tighten the tie rod U-bolts using a 1/2 socket. The torque spec is 12 ft. lbs.

11 Step 27 Tighten the axle bracket U-Bolt Nuts using a 9/16 socket. The torque spec is 15 ft. lbs. Step 28 While watching the stabilizer and associated brackets, have an assistant turn the steering from full left to full right and then back to full left again. If the stabilizer or brackets contact (or come close to) other vehicle parts, loosen the U-Bolt clamps and adjust the stabilizer until the steering moves freely in all steering positions. Don t forget to r e t i g h t e n t h e U - b o l t n u t s a f t e r completing this adjustment. Tech Tip The suggested stabilizer position shown above may reduce the risk of damage to the steering stabilizer. Congratulations!! You have successfully installed a steering stabilizer. We hope these instructions have been helpful. If you have suggestions on how we can improve our instructions or our products we welcome your input. Please us at sales@lowrangeoffroad.com or call us at

12 As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at M-F 7:30am-5:30pm MST. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 11/08/13 Copyright 2013 Low Range Off-Road, LC All Rights Reserved