INSTALLATION GUIDE KPC 4LBO-C51

Transcription

1 INSTALLATION GUIDE KPC 4LBO-C1 Bolt-On 4-Link Kit Chevrolet and GMC C10 Pickup Description: Bolt-on, urethane-bushed 4-link rear suspension for Chevrolet and GMC C10 pickup. Includes bolt-on frame- and axle-brackets, driveline crossmember notch, adjustablelength suspension links, urethane end bushings, and mounting hardware. 1

2 2 THICK OLY CKUP UP 1 /16 THICK, BOLT-ON 4-LINK, GM PICKUP Chris Alston's CHASSISWORKS INC YOUNGER CREEK DRIVE SACRAMENTO, CA 9828 (916) FAX KPC 4LBO-C1 /27/09 DWG: LBO-C1 2

3 ITEM QTY PART NO. DESCRIPTION AXLE MOUNT WELDMENT #60, 4-LINK, DRIVER SLEEVE, POLY BUSHING, /4 x.0 x S-C WASHER, 1/2 SAE, ZINC PLATED, 1/2 ID x 1 1/16 OD x /2 THICK C.00Y HEX BOLT, 1/2-1 x, GRADE 8, YELLOW ZINC C LOCKNUT 1/2-1, GRADE, NYLON INSERT, CLEAR ZINC POLYURETHANE BUSHING 1.6 x.70 x LINK BAR WELDMENT, OAL, /4-16 x 90 $, 1.2 ID POLY POLY EYE WELDMENT, /4-16 x 1 1/4 BORE RC JAM NUT, /4-16 RIGHT, CLEAR ZINC AXLE MOUNT WELDMENT #61, 4-LINK, PSGR, W/PANHARD TAB NOTCH WELDMENT, DRIVELINE, 7-80 GM PICKUP U-BOLT, AXLE TUBE, 9/16-18 x.00 x S-Y FLAT WASHER, 9/16 SAE, HARDENED Y LOCKNUT, 9/16-18, GRADE 8, NYLON INSERT, YELLOW ZINC FRAME MOUNT WELDMENT #2, 4-LINK, DRIVER, 7-87 GM PICKUP FRAME MOUNT WELDMENT #, 4-LINK, PSGR, 7-87 GM PICKUP C1.2Y HEX BOLT, 1/2-1 x 1 1/4, GRADE 8, YELLOW ZINC S-C WASHER, /8 SAE, ZINC PLATED, 1/2 ID x 1/16 OD x 1/16 THICK, C1.00Y 16 HEX BOLT, /8-16 x 1, GRADE 8, YELLOW ZINC C LOCKNUT /8-16, GRADE, NYLON INSERT, CLEAR ZINC DESCRIPTION BOLT-ON 4-LINK, GM PICKUP Chris Alston's CHASSISWORKS INC YOUNGER CREEK DRIVE SACRAMENTO, CA 9828 (916) FAX PART NO. KPC 4LBO-C1 /27/09 DWG: LBO-C1 1

4 PARTS LIST KPC 4LBO-C1 - Bolt-on 4-Link Suspension, 7-87 C10 Qty Part Number Description Link bar weldment OAL x /4-16 RH x bore poly housing link frame mount driver side weldment link frame mount passenger side weldment link axle mount driver side weldment link axle mount passenger side weldment with panhard bar tab Driveline notch weldment 7-87 GM truck LBOC1 - Hardware Bag Qty Part Number Description Y Bolt /8-16 x 1 hex head cap screw C1.2Y Bolt 1/2-1 x 1-1/4 hex head cap screw C.00Y Bolt 1/2-1 x hex head cap screw C Locknut /8-16 nylon insert C Locknut 1/2-1 nylon insert RC Jam nut /4-16 RH Grade, clear zinc S-Y Washer 9/16 hardened SAE flat Y Locknut 9/16-18 nylon insert Grade NE8, yellow zinc Sleeve 1/2 ID x /4 OD x 1-/4 long Poly bushing.7 bore x.87 OAL U-bolt 9/16-18 x -/4 long for round tube /2OZ Poly lube 1/2 oz. cup S-C Washer /8 SAE flat, plated S-C Washer 1/2 SAE flat, plated Poly eye /4-16 RH weldment 4

5 1. Raise the truck and support with jack stands placed under the frame, between the cab and forward leaf-spring mounting brackets. 2. Remove all stock suspension components. The leaf springs must be unbolted from the axle housing.. The front leaf-spring mounting brackets must be removed by taking out the factory rivets. INSTRUCTIONS 4. Remove each rivet head using a cutting torch or by using a cutoff wheel to grind a deep X into the heads of the rivets, and then removing the rivet head with an air chisel.. Once the rivet heads are removed, a round-tip air-hammer tool can be used to drive the rivets clear of the bracket and frame. 6. Use a 1/2 drill bit to enlarge the top and bottom holes at each side of where the bracket was mounted.

6 7. Bolt the driver side front 4-link bracket to the frame using 1/2-1 x 1-1/4 hex bolts, flat washers and lock nuts. There should be flat washers under the bolt head and locknut. Torque to 4 lb-ft. 8. Insert two poly bushings into each 4-link eye. 9. Apply poly lube to the inside of the poly bushings and outside of the steel sleeves. 10. Press the steel sleeves into the poly bushings until they are centered. 11. Use a /4-16 tap and die to chase the threads of the poly eyes and 4-link bars. 12. Thread the /4-16 jam nuts onto the threaded eyes until there are 4- threads remaining between the jam nut and the shoulder. 1. Apply a small amount of anti-seize to the male threads and screw it into the link bar until the jam nut contacts the tube. 14. The center-to-center length of the link bar must measure 22-/4 before installing. 22-/4 6

7 1. Remove the OEM lower shock mount brackets from the axle housing. REMOVE TABS 16. Set the axle housing under the frame and support it on jack stands. 17. These are the 4-link axle brackets. The passenger-side mount has the panhard bar mounting tab. PASSENGER DRIVER 18. Loosely bolt the 4-link bracket to the axle housing using the U-bolts, hardened washers, and locknuts. 19. Rotate the bracket to seat the large tab at the front of the bracket against the leaf-spring pad. 20. Tighten the U-bolts evenly to 60 lb-ft. ROTATE BRACKET UPWARD TO SEAT TAB 7

8 21. Install the 4-link bars with the adjustable eyes closest to the axle housing. Use the 1/2-1 x hex bolts, flat washers, and locknuts. There should be a flat washer under each bolt head and locknut. Torque to 4 lb-ft. 22. Repeat procedure for the passenger side of the truck. 2. Set the driveline notch weldment onto the crossmember closest to the axle housing. 24. Measure from the frame rail to the edge of the driveline notch to verify it is centered between the frame rails. 2. Once centered, clamp the notch securely to the crossmember. 26. Drill the /8 holes through the top of the crossmember, using the notch as a guide. There is one hole at each end of the notch. 8

9 27. Bolt the notch weldment to the crossmember using /8-16 x 1 hex bolts, flat washers, and locknuts. 28. Drill the remaining eight holes through the front and back of the crossmember using the notch weldment as a guide. 29. Use a scribe to mark a cut line along the inside edge of the notch weldment. Extend the lines across the front and rear lips of the crossmember. 0. Use a sawzall or cutoff wheel to remove the center of the OEM crossmember. 1. Smooth any sharp edges using a disc sander or grinding wheel. 9

10 2. Bolt the notch weldment to the crossmember using /8-16 X 1 hex bolts, flat washers, and locknuts. Torque to lb-ft.. Move the axle housing through its full range of travel to check for and correct any binding or clearance issues. WARRANTY NOTICE: There are NO WARRANTIES, either expressed or implied. Neither the seller nor manufacturer will be liable for any loss, damage or injury, direct or indirect, arising from the use or inability to determine the appropriate use of any products. Before any attempt at installation, all drawings and/or instruction sheets should be completely reviewed to determine the suitability of the product for its intended use. In this connection, the user assumes all responsibility and risk. We reserve the right to change specification without notice. Further, Chris Alston s Chassisworks, Inc., makes NO GUARANTEE in reference to any specific class legality of any component. ALL PRODUCTS ARE INTENDED FOR RACING AND OFF-ROAD USE AND MAY NOT BE LEGALLY USED ON THE HIGHWAY. The products offered for sale are true race-car components and, in all cases, require some fabrication skill. NO PRODUCT OR SERVICE IS DESIGNED OR INTENDED TO PREVENT INJURY OR DEATH. KP Components A Chris Alston s Chassisworks Inc., Brand 8661 Younger Creek Drive Sacramento, CA 9828 Technical Support: KPtech@cachassisworks.com LBOC1 REV 11/2/09 10