***Revised **** Installation Instructions

Transcription

1 IF YOUR ReadyLIFT OFF ROAD SUSPENSION PRODUCT IS MISSING A PART OR HAS A DAMAGED PART, PLEASE CONTACT CUSTOMER SERVICE DIRECTLY. A NEW REPLACEMENT PART WILL BE SENT TO YOU IMMEDIATELY (800) MON-FRI 7AM-5PM PST OR INFO@ReadyLIFT.COM WEBSITE: www. ReadyLIFT.COM **Please retain this document in your vehicle at all times** ReadyLIFT Off Road Suspension Limited Warranty Limited Warranty details for ReadyLIFT Off Road Suspension. The ReadyLIFT Off Road Suspension Limited Lifetime Warranty covers defective materials or defective workmanship for the life of the product to the original purchaser and only on the original vehicle which the product was installed. The ReadyLIFT Off Road Suspension Limited Lifetime Warranty excludes the following wearable items: bushings, bushing sleeves, bump stops, top-out stops, spherical bearings (uniballs), heim joints (rod ends), and misalignment spacers (upper control arm and steering). These items are considered wear items and are covered for 90 days from the original purchase date, therefore these items will not be considered defective because of wear. Wear is subject to use of product, use of vehicle, driving conditions, weather conditions, cleanliness of product/components, and maintenance/up-keep. The degree of wear and overall lifetime of each wear item is subject to afore mentioned conditions and circumstances. ReadyLIFT Off Road Suspension will only warranty wear items in the case of workmanship and defects for the period of 90 days following the date of purchase. Please note that all products should be inspected by a professional technician before installing any part/kit onto the vehicle. In addition, all products should be installed by a qualified technician. Please contact ReadyLIFT Off Road Suspension if there is any question as to the quality of workmanship of each component or its installation procedure. Contact ReadyLIFT Off Road Suspension directly about any potentially defective parts prior to removing any parts from the vehicle. If it appears that the part is warrantable, you will be given an RGA number and asked to return the part freight prepaid. If the part is found to be warrantable, at the sole discretion of ReadyLIFT Off Road Suspension, it will be repaired or replaced and returned to you. The limited warranty expressed by ReadyLIFT Off Road Suspension supersedes that of any claims made by authorized and unauthorized dealers of ReadyLIFT Off Road Suspension products.

2 Please read Instructions thoroughly and completely before beginning installation. Installation by a certified mechanic is recommended. ReadyLIFT Off Road Suspension is NOT responsible for any damage or failure resulting from improper installation. Safety Warning: Suspension systems or components that enhance the on and off-road performance of your vehicle may cause it to handle differently than it did from the factory. Extreme care must be used to prevent loss of control or vehicle rollover during abrupt maneuvers. Always operate your vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions. Failure to drive safely may result in serious injury or death to driver and passengers. Driver and passengers must ALWAYS wear your seat belts, avoid quick sharp turns and other sudden maneuvers. ReadyLIFT Off Road Suspension does not recommend the combined use of suspension lifts, body lifts, or other lifting devices. You should never operate your vehicle under the influence of alcohol or drugs. Constant maintenance is required to keep your vehicle safe. Thoroughly inspect your vehicle before and after every off-road use. It is the responsibility of the retailer and/or the installer to review all state and local laws, with the end user of this product, related to bumper height laws and the lifting of their vehicle before the purchase and installation of any ReadyLIFT products. It is the responsibility of the driver/s to check their surrounding area for obstructions, people, and animals before moving the vehicle. All raised vehicles have increased blind spots and damage, injury and/or death can occur if these instructions are not followed. Installation Warning: All steps and procedures described in these instructions were performed while the vehicle was properly supported on a two post vehicle lift with safety jacks. Use caution during all disassembly and assembly steps to insure suspension components are not over extended causing damage to any vehicle components and parts included in this kit. Included instructions are guidelines only for recommended procedures and are not meant to be definitive. Installer is responsible to insure a safe and controllable vehicle after performing modifications. ReadyLIFT Off Road Suspension recommends the use of an OE Service Manual for model/year of vehicle when disassembly and assembly of factory and related components. Unless otherwise specified, tighten all bolts and fasteners to standard torque specifications listed within the OE Service Manual, or as referenced in the torque specification list provided in these instructions. Suspension components that use rubber or urethane bushings should be tightened with the vehicle at normal ride height. This will prevent premature wear or failure of the bushing and maintain ride comfort. Larger tire and wheel combinations may increase leverage on suspension, steering, and related components. Due to payload options and initial ride height variances, the amount of lift is a base figure. Final ride height dimensions may vary in accordance to original vehicle ride height. Always measure the vehicle ride height prior to beginning installation. Vehicle ride height chart Driver Front: Driver Rear: Pass. Front: Pass. Rear: Bolt Size Millimeters Torque Specs in FT/LB Metric Grade 8.8 Metric Grade 10.9 Bolt Size SAE Torque Specs in FT/LB Grade 5 Grade 8 6mm 6 8 8mm mm mm mm mm mm / / / / / / /

3 This Bill of Materials represents the component contents of this kit. All hardware is of the highest grade and the components are manufactured to exacting specifications for a trouble free installation. Use the attached torque specifications chart when final tightening of the nuts and bolts are done. Box Front Cross Member Rear Cross Member Hardware, F&R Cross Members 1 Bolt, 5/8 11 x 5.5", Hex Head, Grade 8 2 Bolt, 5/8 11 x 4.5", Hex Head, Grade 8 2 Washer, 5/8", Flat 8 Nut, 5/8 11, C Lock, Grade Instructions Front Differential Skid Plate Front Skid Plate Hardware 1 Bolt, 3/8 16 x 1", Hex Head, Grade 8 6 Washer, 3/8", Flat 6 Box UCA Drop Assembly, Driver UCA Drop Assembly, Passenger Hardware, UCA Drop Down Brkt 1 Bolt, M x 80mm, Hex Head, Washer, 14mm, Flat 6 Nut, M14 2.0, C Lock 4 Box Diff Drop, Passenger Side Diff Drop, Driver Side Steering Ext Assembly Kit 1 Steering Extension Shaft 1 Universal Joint, Inc Set Screw & Jamb nut 1 Rod End, 3/4" x 3/4" Steering Brkt, Driver Side Steering Brkt, Passenger Side Sway Bar Drop Down Brackets Brake line Bracket, Front Rear Brake line Drop Bracket Rear E Brake Drop Bracket Bump stop Drop Kit, Rear Hardware, Diff Drop & Steering 1 Bolt, 1/2 13 x 1.75", Hex Head, Grade 8 2 Washer, 1/2", Flat 4 Nut, 1/2 13, C Lock, Grade 8 2 Bolt, 9/16 13 x 1.75", Hex Head, Grade 8 2 Washer, 9/16", Flat 6 Box 3 Continued Nut, 9/16 12, C Lock, Grade 8 2 Bolt, 9/16 18 x 6.0" Grade 8 1 Bolt, 1/4 28 x 1/4", SS Allen, Grade 8 1 Nut, 9/16 18, C lock Grade 8 1 Bolt, M x 140mm Hex Head, Washer, M12 Flat DO NOT USE SEE BELOW Hardware, Sway Bar Drop Brcket 1 Bolt, 7/16 14 x 1.50", Hex Head, Grade 8 4 Washer, 7/16", Flat 8 Nut, 7/16 14, C Lock, Grade Hardware, Brake line Brackets 1 Bolt, 1/4 20 x.75", Hex Head, Grade 8 4 Washer, 1/4", Flat 8 Nut, 1/4 20, C Lock, Grade 8 4 Bolt, 3/8 16 x 1", Hex Head, Grade 8 1 Washer, 3/8", Flat 2 Nut, 3/8 16, C Lock, Grade 8 1 Bolt, M x 100mm, SH Allen, Washer, Rear Bump stop Extension 2 ADDUDEM PACK (BOX 3) Hardware, Diff Drop & Steering 1 Bolt, 1/2 13 x 1.0", Hex Head, Grade 8 1 Washer, 1/2", Flat 2 Nut, 1/2 13, C Lock, Grade 8 1 Bolt, M x 170mm Hex Head, Washer, M16, Flat 6mm Thick 2 Washer, M12, Flat 5mm Thick USE THIS ONE W/ M12 Bolt 1 Safety Warning Before you start installation: ReadyLIFT Off Road Suspension highly recommends that the installation of this product be performed by a professional mechanic with experience working on and installing suspension products. Professional knowledge and skill will typically yield the best installation results. If you need an installer in your area, please contact ReadyLIFT Suspension customer service to find one of our Pro Grade Dealers. Notes: Installation by a professional mechanic is highly recommended. A Factory GM Service Manual for your specific Year / Make / Model is highly recommended for reference during installation. Installation requires cutting and welding of the vehicle frame. Vehicles with a two piece rear driveline may require a carrier bearing drop support bracket, call technical assistance for details. Vehicles achieving more than 5 of rear lift may require rear driveline modifications, call technical assistance for details. All lifted vehicles may require additional driveline modifications and or balancing. A four wheel vehicle alignment will need to be performed after installation of this product. Speedometer / Computer recalibration is required if changing +/ 10% from factory tire diameter. Use of a Vehicle Hoist will greatly reduce installation time. Vehicle must be in excellent operating condition. Repair or replace any and all worn or damaged components prior to installation. 3

4 Front Disassembly: ***Important*** Check kit contents with Bill of Materials to ensure that all parts are included prior to starting installation. Kit components and hardware are of high grade and specification, do not substitute or modify components or hardware. Contact ReadyLIFT Suspension customer service with any questions that you may have. ***Important*** Read and study this manual prior to installation, and familiarize yourself with the kit components and procedures. If you are not confident in your abilities or tools, do not perform the installation and refer to one of our Pro Grade Installers. 1. Park the vehicle on a clean, flat surface and block the rear wheels for safety. Engage the parking brake. 2. Record stock vehicle ride height measurements on both the front and the rear, this will provide and guideline on vehicle rake and lift height. Measure from the center of the wheel up to the bottom edge of the fender well opening and record on chart provided on pg Disconnect the vehicle power source at the ground terminal on the battery. ***2014 and newer models equipped with EPAS (Electronic Power Assist Steering), disconnect the power steering control module connector to avoid arching of the contacts in the internal power relay from a hammer blow or impact wrench. ***Very Important *** 4. Lock Steering Wheel in straight forward position with the column lock or steering wheel locking device. ***Rotating the steering wheel while disconnected from the vehicle rack & pinion may cause damage to the steering column and / or internal clock spring. 5. Raise the front of the vehicle and support with jack stands at each frame rail behind the lower control arms. 6. Remove the front wheels. 7. Remove all factory skid plates and hardware. On models with Electronic Power Steering, you will have to unclip the wiring harness from the skid plate. (Fig 1) (Fig 2) 8. Remove the brake caliper anchor bracket bolts and remove the caliper from the knuckle (Fig 1). Hang the caliper out of the way using a S Hook or suitable strap. Do Not let the caliper hang by the brake hose. 9. Remove the brake rotor by removing the Torx bolt (Fig 2). ***Note Mark all components to their corresponding side of removal (driver / passenger) in order to aid re installation. (Fig 3a) (Fig 3b) (Fig 3c) (Fig 4) 10. Disconnect the brake and ABS line brackets from the control arm pocket, the upper control arm and steering knuckle (Fig 3a, 3b, 3c). 11. Remove the ABS Sensor and Line from the steering knuckle. (Fig 4). 4

5 (Fig 5) (Fig 6) (Fig 7) (Fig 8) (Fig 9) ***Revised **** Installation Instructions Disconnect the tie rod ends from the steering knuckles (Fig 5). Remove and retain the mounting nuts. Utilizing a ball joint pulling tool or suitable device, disconnect the tie rod end from the steering knuckle. Take care not to strike the tie rod end. 13. Disconnect the sway bar links from the sway bar and the lower control arms (Fig 6). Retain hardware and sway bar links. 14. Remove the four sway bar mounting nuts and remove the sway bar from the vehicle (Fig 7). Retain hardware. 15. Carefully remove the hub dust cap to expose the axle shaft nut (Fig 8). Remove the axle shaft nut. Retain the cap and nut, they will be reinstalled later. 16. Loosen the upper and lower ball joint nuts (Fig 9) and leave finger tight. 17. Utilizing a Ball Joint Pulling Tool or suitable device, separate the knuckle from the upper and lower ball joints to dislodge the joints from the knuckle. Remove the steering knuckle from the vehicle. 18. Loosen but do not remove the three strut assembly mounting nuts at the frame (Fig 10). (Fig 10) (Fig 11) (Fig 12) (Fig 13) (Fig 14) 19. Loosen the nuts from the strut to lower control arm mounting bolts (Fig 11). Remove all remaining hardware to Remove the strut assembly from the vehicle. 20. Mark the struts to distinguish between driver and passenger side. 21. Remove the bolts that attach the CV axle to the differential housing, remove CV axle assembly (Fig 12). 22. Remove the upper control arm cam bolts from the frame and remove the upper control arms from the vehicle (Fig 13). 23. Remove the lower control arm mounting bolts and remove the lower control arms from the chassis. Retain hardware (Fig 14). 24. With the steering wheel locked in the straight forward position, use a paint marker or similar device to mark a line from the steering column intermediate shaft to the rack Note Orientation and pinion input shaft, notating the relationship of the components (Fig 15). (Fig 15) 5

6 25. Remove the bolt that connects the steering column intermediate shaft to the rack and pinion input shaft coupler. 26. Disconnect the wiring harness and plugs from the Front X member (Fig 16) Support the rack (Fig 16) and pinion unit with a jack or suitable device, remove the four mounting bolts that attach the rack and pinion to the frame and remove the rack and pinion assembly from the vehicle. (Fig 17) ***Use extra caution not to damage any wiring or electronic components. Do not drop, hit, or tamper with the rack and pinion unit. Keep the rack and pinion unit in a safe and secure location until it is time to re install.*** (Fig 17) 27. Remove the four bolts that attach the OEM cross member to the frame at the rear lower control arm pocket and remove the cross member from the vehicle. 28. Remove the driveshaft mounting bolts and disconnect the driveshaft from the differential (Fig 18). Allow the driveshaft to rest out of the way. 29. Unplug the actuator wire and vent tube from the front differential. Remove the wire loom from the attachment points on the front differential. ***Warning*** The front differential is heavy and awkward. It is best removed by two people, or a suitable jacking device. 30. Remove the front differential. Utilizing an appropriate jack, support the differential housing. Remove the differential mounting bolts at frame and remove the differential from the vehicle. Photo of diff mounting hardware L &R side Frame Preparation ***There are several cuts required for parts clearance. It is important to read these instructions carefully as you will be modifying the factory frame in a way that is irreversible. Now that the vehicle is fully disassembled, it is the time to make all of these cuts. It is also important at this time to sand, prep, paint and fit check clearance for all parts that need to be installed in these areas. This will save time and hassle as installation proceeds in the Front End Assembly process, a little extra time and prep will ensure a better Fit and end product. Always double check measurements before cutting.*** Measure Twice Cut Once*** 31. Utilizing a suitable cutting device, remove the factory skid plate mounting brackets from the frame. The Cut line should parallel the front x member profile. (Fig 19a, 19b). Sand, clean and paint exposed metal surface. (Fig 18) (Fig 19a) Fig 19b) 6

7 32. Locate the rear control arm pockets and measure 3 3/8 from the inner edge of the pockets out towards the frame/ outside (Fig 20) of truck. (Fig 20). Mark a vertical cut line on both sides of the frame pocket and connect these lines up and over the top side. 33 A. Using a suitable cutting device, cut the along the line from Step #32 to remove this area from the (Fig 21) vehicle. (Fig21) Round off the bottom corners and sand any sharp edges. Paint any exposed metal surface. 33 B. Once the Rear Pockets have been modified you may need to clearance the front of the pocket to ensure proper fitment of the differential once reinstalled. We recommend sanding the front lip of the Pocket to prevent the CV from contacting the frame. Clearance both Driver and Passenger side. 33 C. Clearancing the frame for Steering extension U Joint. It is important to ensure there is a minimal of 1/4 of clearance around the joint and set screw. Once the steering Extension is installed. We recommend pre grinding before installing the components and modifying as necessary. 7

8 34 A. Using a suitable cutting device, cut the upper control arm bump stop out from the upper control arm mounting pockets as shown (Fig 22). You will need to sand the inside of the pockets flush to ensure proper fitment of the Upper Control Arm Drop Brackets fit properly. Use caution not to remove material from the pockets. 35 B. Once you have removed the lower gusset plate on the upper control arm pockets you want to make grind the gusset plate flush with the chassis. Indicated by the yellow arrow in Fig 23. (Fig 25) (Fig 26) (Fig 22) (Fig 23) 35 A. Using a suitable cutting device, trim the lower plates from the upper control arm pockets (Fig 23) and sand until flush with the frame. Sand and smooth all cut areas flush with the frame and upper control arm pockets. 36. The upper control arm frame pockets must be clean and free of excess material in order to accept the upper control arm drop brackets (p/n driver & pass). (Fig 25) Check for proper fitment at this time (Fig 26), it may be necessary to slightly spread the pockets for fitment. Use a heavy hammer to strike and open up the pockets. 37. Front & Rear Cross Member Fitment. It may be necessary to slightly remove some material in order to fit the new front and rear cross members into the frame. It may also be necessary to spread open the pockets. Check the front (p/n ) and rear (p/n ) for fitment. Use a suitable cutting tool to remove material for fitment. Use a large hammer to strike the factory frame pocket tabs to spread them open to aid in cross member installation. 38. *** Please See Following Pages for Detailed instructions for Rack and Pinion Clearance.*** 8

9 ***Rack and Pinion Clearance Instructions*** It is important to read these instructions carefully as you will be modifying the factory frame in a way that is irreversible. You will need to Drill / Cut two holes to make clearance for lowing the Rack and Pinion. Hole #1 will be a 3 Diameter Hole/ Hole Saw on the Driver Side of chassis for the servo on the Rack and Pinion. The measurements will be taken from center of the lower factory mounting hole of the Rack and Pinion on the Driver side. Hole #1 location is on the Back / Differential side of the front Cross member. First measurement for hole #1 Is to locate the lower mounting hole for the Rack and Pinion on the driver side and measure 3 3/4 from the center of the mounting hole to the left or outside of the driver side of the truck and make a vertical line. (Fig 38.A) Second Measurement for hole #1 Locate the same lower mounting hole for the Rack and pinion and measure 7/8 up from the hole and make a horizontal line towards the outside of vehicle. Both lines should intersect. (Fig 38.B) At the intersection of the 2 lines will be the location for the pilot hole for your 3 hole saw. Center mark and drill a 1/4 Pilot hole for the hole saw. Once your pilot hole is drilled you can continue to Hole saw the section of material out. (Fig 38.C ) Fig 38.A Fig 38.B Fig 38.C 9

10 ***Rack and Pinion Clearance Instructions*** It is important to read these instructions carefully as you will be modifying the factory frame in a way that is irreversible. Hole #2 will be a Diameter of 1 1/2 and is located on the Back / Differential side of the Front Cross member. Hole #2 will be measured from the factory passenger side Lower Control Arm Mount and bottom of chassis. First Measurement for Hole #2 will be 6 1/2 from the Center of the Passenger side Lower Control Arm Mount inboard towards the center of the truck. Make a Vertical Line ( Fig 38.D) Second Measurement for Hole #2 it to measure 1 1/2 up from the bottom of the Chassis on the vertical line created by first measurement. Make a horizontal line at that measurement. (Fig 38.E ) Where the lines two intersect you will need to center punch and drill the pilot hole for the 1 1/2 Hole saw. Once the pilot hole is drilled you can continue to hole saw the material out. Fig 38.D Fig 38. E 10

11 39. Clean and paint all bare metal surfaces utilizing a premium paint to prevent corrosion. Front Installation 40. Steering Extension Assembly This system is equipped with a patent pending rack & pinion steering extension kit. Please follow installation instructions closely and check for all clearances and tolerances along the way. (Fig 27) (Fig 28) 40c. Locate the steering u joint (# ) and steering extension shaft (# ). It is important that the male flats on the extension shaft are oriented perfectly with the female flats on the u joint. (Fig. 29) Insert the splined shaft into the u joint and secure with the supplied (5/16 18 x 7/16 ) set screw and jamb nut as shown and torque to in lbs. It is important to utilize only the 5/16 18 x 7/16 long set screw on the upper half of the u joint as this aids in clearance of the frame. (Fig 30). 40d. *** See next page(12) for detailed information on Steering Extension. ******** 41. Install the upper control arm drop bracket assemblies (p/n driver& passenger) into the upper control arm frame pockets using the supplied ( ) hardware. Install the bolts so the head is inside the strut pocket with bolt threads facing toward ends of vehicle. Do not tighten at this time. (Fig 31) 40a. Find the Steering Extension Drop Bracket (# ) with steering support bracket and install ¾ rod end (# ) into the pinch bung as shown. Set the ¾ rod end at approximately 1 1/4 from the face of Pinch bung to center of the ball. (Approx. 1 full turn out) (Fig 27). Install the 1/4 28 allen bolt into the pinch bung as shown, then tighten down once the rod end is in the horizontal position using a 1/8 allen wrench. 40b. Install Steering Extension Drop Bracket Assembly (# ) into the frame using the supplied hardware. Note: Only mount the top hole of the bracket as the lower will be used to install the steering rack. (Fig 28).Do not tighten set screw into factory back cut in shaft. (Fig 29) (Fig 30) (Fig 31) 42. Install the front cross member (# ) using the OE hardware. Insert the bolts from behind the cross (Fig 32) member with nuts facing the front of the vehicle. Do not tighten at this time. 43. Install the factory rack and pinion unit with the previously installed u joint and steering extension shaft assembly to the front cross member and frame using the supplied M16 bolts/washers in the two driver side holes, and the M12 bolt/washer one passenger side hole (Fig. 32).As you raise the rack and pinion unit, slide the steering extension shaft and u joint assembly through the ¾ rod end attached to the support bracket. Connect the top of the steering extension shaft to the factory sector shaft with the factory pinch bolt, torque to factory specification. At this time, tighten the bolts securing the steering extension drop bracket (# ) and torque to specification. 11

12 Revision page added. Install the passengers side steering rack support bracket to the frame and to the upper rack mounting hole. Use the provided 1/2x13x1 grade 8 bolt, washers and stover nut to attach the bracket to the frame. Attach the bracket to the steering rack using the factory bolt. 12

13 **Important Information for Steering** 40d. The steering extension shaft and u joint must now be installed on the steering rack prior to installation of the rack & pinion unit. The steering extension u joint has a tight fit, so it is recommended that you install it to the rack prior to installing the rack & pinion to vehicle, this will aid the installation of this assembly. There are two (2) set screws (5/16 18 x 5/8 ) on the lower portion of the u joint, one to lock side load to the flats, and one to lock fore & aft of the rack & pinion input shaft at the cut out where the original pinch bolt was (Fig 40d 1). Set Screw Attachment Points Properly orientate the set screws and press the u joint onto the rack & pinion input shaft using the lower half of the u joint. Ensure that the top of the rack & pinion input shaft is flush with u joint (Fig 40d 2) Fig 40d-2 Depending on the production date of the vehicle, you may need to lightly sand the steering shaft on the rack and pinion to make the ReadyLIFT U joint fit. The amount of material needed to be removed is minimal. We recommend an air sander with no greater than 120 grit to remove the material. Fig 40d-1 If you are not able to press it on or do not have access to a press, you may gently tap the u joint onto the shaft using a soft hammer by tapping gently on the ears of the lower portion of the u joint. (Fig 40d 3 and Fig 40d 4) It does not take much to get the u joint onto the shaft. ***DO NOT PRESS OR STRIKE THE TOP OF THE ENTIRE U JOINT ASSEMBLY AS DAMAGE MAY OCCUR TO THE TRUNION BEARINGS. DO NOT STRIKE OR PLACE TOO MUCH FORCE ON THE RACK & PINION INPUT SHAFT OR UNIT AS DAMAGE MAY OCCUR. Apply thread locker to both set screws and torque to in. lbs. Secure with the supplied jamb nuts. Fig 40d - 3 Fig 40d

14 43a. At this point in time it is important to turn the wheel full left & full right to ensure the steering is smooth and free of restrictions. (If there is any tight spots the Heim will need to be adjusted in or out to free up the rotation of the steering shaft.) *** Do not Turn the steering wheel while disconnected from Rack and pinion. Over Rotation will result in Damage to steering column and Safety Systems.*** 44. Install both the Driver Side Differential Drop Bracket (p/n ) and the Passenger Side Differential Drop Bracket (p/n ) onto the existing factory mounts utilizing the factory hardware, do not tighten at this time. (Fig 34) (Fig 34) (Fig 35) (Fig 36) 45. Install the front differential onto the previously installed differential drop brackets utilizing the supplied hardware. Tighten all differential mounting hardware at this time starting with the top factory hardware, and moving down to the supplied hardware. Torque to specification. (Fig 35) Re attach the vent tube and the 4wd actuator plug. 46. Re attach the front drive shaft to the front differential utilizing the previously removed factory hardware. 47. Install the Rear Cross Member (p/n ) into the frame pockets utilizing the factory hardware. The bolts will go through the upper control arm drop bracket support, the frame of the vehicle and the cross member. (Fig 36) Do not tighten at this time. (Fig 37) 48. Install the factory upper control arms into the upper control arm drop down brackets utilizing the factory cam eccentrics and bolts. Be sure to remove the factory alignment insert before alignment cam installation. (Fig 37). Do not tighten at this time. 49. Install the factory lower control arms into the front and rear cross members utilizing the supplied hardware. (Fig 38) Do not tighten at this time. (Fig 38) 50. Install the supplied Sway Bar Drop Down Bracket (p/n ) onto the frame utilizing the factory hardware. Do not tighten at this time. Attach the sway bar to the bottom of the drop down brackets utilizing the supplied hardware. Starting at the top factory bolts, torque to factory specification. Torque the supplied bolts to 60ft lbs. (Fig 39) (Fig 39) (Fig 40) 51. Install the CV Axles to the front differential utilizing the stock hardware previously removed, torque to factory specifications (Fig 40). 14

15 52. Obtain the appropriate upper strut spacers (5.0,5.75 or 6.5 Lift Height ) and match the driver side spacer to the driver side strut and the passenger side spacer to the passenger strut. Install the spacer to the strut utilizing OE hardware and torque to factory specification. Fig. C 54b. Re install the factory brake rotor and caliper utilizing the previously removed factory hardware, torque to factory specification. (Fig 42) 55. Reinstall the outer tie rod end to the factory steering knuckle and torque to factory specification. (Fig 43) (Fig. A) (Depending on Production Dates the Driver Side Spacer can be Identified by Either (Fig. A or Fig. B) The Passenger side will either be Blank or Have a P etched into the top Plate. (Fig. E) ) (Fig C) (Fig. B) (Fig. E) 53. Install the strut assembly into the upper frame mount utilizing supplied hardware and attach to the lower control arm utilizing the previously removed factory hardware. 54a. Install the factory steering knuckles into the upper and lower control arms utilizing previously removed factory hardware, toque to specification (Fig 41a, 41b). Install the CV drive axles into the steering knuckles during this procedure and torque the axle nut to factory specification. (Fig 42) (Fig 43) (Fig 44) 56. Install the Front Brake Line Support Bracket (p/n ) onto the Upper Control Arm Drop Bracket Bolt, The Bracket is being used as a washer and only utilizes 1 Washer per bolt, do not tighten (Fig 44). Attach the factory brake line bracket assembly to the Front Brake line Support Bracket (p/n ). Align the bracket vertically in order to allow the brake line to have slack at full suspension droop and starting at the top bolt, torque to 120ft lbs. Torque all remaining Upper Control Arm Drop Bracket to frame hardware to 120ft lbs. at this time. 57. Re attach the ABS line to its original connection point. Reattach the brake line and ABS wire assembly back onto the control arm, steering knuckle and hub assembly utilizing the previously removed factory hardware (Fig 44a, 44b). Torque to factory specification. (Fig 44a) (Fig 44b) (Fig 41a) (Fig 41b) 15

16 ***Revised **** Installation Instructions Rear Installation: 58. Install the front differential skid plate to the front and rear cross members. It is necessary to cut the lower flange from the front differential for skid (Fig 45a) plate clearance. Mark a cut line just above the large hole, and just below the small hole at an angle as indicated (Fig 45a, 45b, 45c, 45d). Install the skid plate utilizing the supplied 3/8 hardware and torque to 35ft. lbs. 59. Tighten Front & Rear Cross Member to frame bolts and torque to 165ft. lbs. (Fig 45b) Tighten and double check all upper control drop brackets, differential drop brackets, and steering bolts at this time for tightness and proper (Fig 45c) torque. Do not tighten the upper and lower control arm pivot points at this time, this will be performed with the vehicle on the ground at ride height in order to prevent the bushings from binding or being pinched. (Fig 45d) 60. Install the wheels and tires and lower the vehicle to the ground. 61. Lower the vehicle to the ground, jounce the suspension up and down a few times, and tighten the upper (120 ft. lbs.) & lower (175ft lbs.) control arms to the specified torque. 62. Re check that all hardware is tight and of proper torque value prior to vehicle operation. 63. If driving the vehicle to an alignment shop, adjust the toe prior to vehicle operation. 80. Block the front wheels and raise the rear of the vehicle. Place jack stands under the frame rails ahead of the spring hangers. Gently support the center housing of the rear differential utilizing a suitable floor jack. (Fig 46) 81. Remove the wheels. 82. The parking brake cable must be relocated. Disconnect the factory rear emergency brake line support bracket from the inner frame rail and install it onto the supplied (p/n ) rear E Brake Drop Bracket and bolt into place using the previously removed and newly supplied hardware. (Fig 46) 83. Unbolt the factory hard (Fig 47) line mounting bracket from the top of the frame. Note: You can access these bolts from the outside of the frame inside the inner fender well (Fig 47). Gently pull down on the bracket and hard lines and install supplied (p/n ) and attach to the factory bracket utilizing the supplied 3/8 bolts, nuts, and washers and torque to 35ft. lbs. Re attach assembly to the top of the vehicle frame (Fig 48) utilizing the previously removed factory hardware and torque to specification (Fig 48). Note: It is best to perform the rear installation on one side at a time. (Fig 49) 84. Remove the factory rear shocks and discard, they will not be used. Extended length shocks are required with this system. 85. Remove the passenger s side u bolts and discard, they will not be reused. (Fig 49) 16

17 86. Lower the axle and remove the OE lift block and discard, it will not be reused. 87. If installing an optional add a leaf to the spring pack, perform this procedure at this time by following the instructions included with your add a leaf kit. If you are not installing an add a leaf kit, proceed to step Select the appropriate rear MultiLIFT rear block kit. Install the new provided lift block so that the short end of the tapered block points toward the front of the vehicle. (Fig 50) (Fig 51) (Fig 52) 89. Raise the axle and block up to the spring while aligning the center pins. Fasten the spring and block assembly with the provided u bolts, high nuts and washers. Snug the u bolts firmly, they will be torqued with the weight of the vehicle on the springs. (Fig 50) 90. Repeat installation procedure on the driver s side of the vehicle. 91. Locate and remove the rear factory bump stop (Fig 51). Utilizing the supplied (p/n ) Bump Stop Drop Down Spacer, install the supplied longer bolt up through the factory bushing and drop down spacer and reattach to the frame. (Fig. 52) 92. Install the extended length shock absorbers with the OE hardware. Torque to 60 ft lbs. 93. Check all brake lines, hoses, and wires for proper slack and clearance while suspension is at full droop. Adjust as necessary. 95. Jounce the Front & Rear of the vehicle to settle the suspension. 96. Torque the u bolts to 130 ft lbs. Some Final Checks 104. Check all hardware for proper torque specifications Torque lug nuts to wheel manufacturer specifications Check tire air pressure to manufacturer specifications A complete four wheel vehicle alignment is necessary Re adjust headlights to compensate for increased ride height Cycle Steering from lock to lock and check for any interference of wheels, tires, brake lines, hoses, wires, etc. and ensure adequate clearance throughout the suspension cycle Install all warning tags and decals as directed: Rear view mirror hanging warning card Hang from rear view mirror to warn new driver of vehicle modification. Lifted Truck Warning Decal Apply decal to upper left hand corner of the inside of the windshield facing the driver Give all installation instructions, warranty information, and all remaining literature to the end user and keep with vehicle records Re Check all hardware for proper torque value after 500 miles, and then periodically at each service interval thereafter. 17

18 Final Checks & Adjustments Post Installation Warnings: Once the vehicle is lowered to the ground, check all parts which have rubber or urethane components to insure proper torque. Torque wheels to factory specs. Move vehicle backwards and forwards a short distance to allow suspension components to adjust. Turn the front wheels completely left then right and verify adequate tire, wheel, brake line, and ABS wire clearance. Test and inspect steering, brake and suspension components for tightness and proper operation. Inspect brakes hoses and ABS lines for adequate slack at full extension. Failure to perform the post inspection checks may result in vehicle component damage and/or personal injury or death to driver and/ or passengers. Test drive vehicle and re-check the torque of all fasteners and re-torque wheels on vehicle. Re-adjust headlamps. Vehicle Handling Warning: Vehicles with larger tires and wheels will handle differently than stock vehicles. Take time to familiarize yourself with the handling of your vehicle. Wheel Alignment/Headlamp Adjustment: It is necessary to have a proper and professional wheel alignment performed by a certified alignment technician. Align the vehicle to factory specifications. It is recommended that your vehicle alignment be checked after any off-road driving. In addition to your vehicle alignment, for your safety and others, it is necessary to check and adjust your vehicle headlamps for proper aim and alignment Vehicle Re-Torque and Safety Inspection: Upon completion of all services and adjustments performed on your vehicle, and within 50 miles of driving, check to ensure all fasteners and hardware are properly torqued to specification as noted in the vehicles factory service manual or the torque chart included. 18