Installation Instructions

Transcription

1 Instructions Created by an: Toyota Tacoma BTB Front Coilovers by Low Range Off Road SKU# TAC-SP-05CO-BTB-650 Diff Drop Kit (SKU# LR-2GDDK) Instructions included Installation Instructions Revised SKU# LR-2GDDK Replace the wheel assembly, lower the vehicle and measure the ride height on both sides as before. If the ride height is within.5 of each other you are finished. If not, repeat the adjustment procedure illustrated above. Differential Drop Kit Sold Separately CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. For additional copies of these and other instructions go to: and click on the Tech and Instructions tab. Suggested Tools: Standard Screwdriver Twin Post Lift (or Floor Jack) Transmission Jack (or 2 Jack Stands) Allen Socket: 5 mm Sockets: 10,12,14,17,19, 21 & 22mm Ratchet Combination Wrenches: 10,14,17,19 & 21 mm Brass Hammer 1/4X8 Punch Ball Peen Hammer Permatex Red Thread-locker 1/2 Dr. Torque Wrench: up to 150 ft. lbs. Pry Bar (24 ) Optional Tools Impact wrench, 1/2 Drive Impact Sockets: 10,14,17,19 & 21 mm

2 Caution: This vehicle will require a professional wheel alignment after this lift kit has been installed. Failure to have this vehicle professionally aligned could result in poor vehicle stability, handling, and braking; as well as excessive tire tread wear. Further, certain aspects of this installation can be dangerous. Therefore, we recommend that a trained professional technician install this kit. General Note The photographs for these instructions were taken with the vehicle placed on a twin post lift. However, this job could be done with a floor jack and jack stands. We also used power tools but, manual tools could be substituted and work reasonably well. Step 1 Lift the vehicle on a twin post lift. or Lift the front of the vehicle with a floor jack and support it with (2) jack stands. Refer to Figure A for proper floor jack and jack stand positioning. Figure A

3 Suspension System Components - Shock and Stabilizer Strut Mount Nuts (3) Upper Control Arm Upper Control Arm Steering Knuckle FORWARD Coil Spring Strut Assembly Shock Absorber Lower Strut Mounting Bolt Stabilizer Bar Stabilizer Link

4 Suspension System Components - Lower Control Arm Front Lower Control Arm Bushing & Adjustment Cam Assembly Rear Lower Control Arm Bushing & Adjustment Cam Assembly Lower Ball Joint Lower Control Arm Ball Joint Attachment Ball Joint Attachment Bolts FORWARD

5 Suspension System Components-Upper Control Arm, Steering Knuckle and Wheel Speed Sensor Wiring Upper Control Arm Upper Control Arm Bushing Bolt Upper Sensor Wire Bracket Bolt Upper Control Arm Bushing Lower Sensor Wire Bracket Bolt Wheel Speed Sensor Wire Steering Knuckle FORWARD Lower Control Arm

6 Step 2 Remove the wheel assembly by removing the (6) lug nuts using a 21 mm socket. Step 3 Disconnect the upper and lower sensor wire bracket using 10 mm box end wrench. Step 4 Disconnect the brake line bracket using a 10 mm box end wrench. Step 5 Disconnect the stabilizer link from the stabilizer bar using a 17 mm socket.

7 Step 6 Disconnect the stabilizer link form the steering knuckle using a 17 mm socket and set the link aside. Step 7 LOOSEN the locking NUT on the rear lower control arm bushing using a 19 mm socket, but do not remove it. Nut Bolt Step 8 LOOSEN the locking BOLT on the front lower control arm bushing using a 19mm box end wrench, but do not remove it. Step 9 Hold the upper control arm bolt with a 19 mm box end wrench and loosen the upper control arm nut using a 19 mm socket. Note: Just loosen the nut. Do not remove it.

8 Step 10 Remove the ball joint attachment bolts using a 19 mm socket. Step 11 Remove the lower strut mount nut using a 19 mm Socket. Note: It may be necessary to hold the bolt with a 19 mm wrench. Step 12 Tap the bolt out using a brass hammer. Note: It may be necessary to finish driving the bolt out using a punch. Step 13 Swing the lower control arm down out of the way. Caution: Once the bolt is removed the lower control arm will swing down.

9 Strut Mount Nuts Step 14 Remove the (3) upper strut mount nuts using a 14 mm socket. Note: The nut closest to the engine may require a box end wrench instead of a socket for removal. Step 15 Guide the strut assembly out the bottom as shown. Step 16 Install the LROR Coil Over Strut assembly back in the same position as the one just removed. Step 17 Install the supplied hardware (See next photograph) and leave the nuts loose for now.

10 Tech Tip Install the flat washer first, then the lock washer, and then the nut. Step 18 Using a large screwdriver, twist the bottom of the strut so it will align with the mounting holes in the lower control arm. Step 19 Swing the lower control arm up, aligning the mounting holes with the bottom of the strut and install the lower shock bolt. Step 20 It may be necessary to tap the bolt into place with a brass hammer. Caution: Be careful to not damage the threads of the bolt.

11 Step 21 Apply Permatex RED threadlock to the bolt as shown. Step 22 Install the nut and torque it to 100 ft. lbs. Step 23 Align the holes in the ball joint bracket with the steering knuckle. Step 24 Apply Permatex RED threadlock to the threads of both bolts.... Note: It may be necessary to use a transmission jack (or a floor jack) to lift up on the lower control arm to install these bolts.

12 Strut Mount Nuts Step and install both bolts. Torque these bolts to 118 ft. lbs. Step 26 Using a criss-cross pattern, progressively tighten, the (3) upper strut mount nuts until 47 ft. lbs. is reached. Note: Use a 17 mm tool on these supplied strut mount nuts. Step 27 Lower and remove the transmission jack (or floor jack) from beneath the passenger side control arm if used. Step 28 Reattach the brake line bracket and bolt. Torque the bolt to 9 ft. lbs.

13 Tech Tip Insure that the bracket tab fits in the hole properly. Step 29 Reattach the top and bottom wheel speed sensor brackets. Torque both bolts to 9 ft. lbs. Stabilizer Link Tech Tip It may be necessary to provide a little more slack to the wheel speed sensor wire. This is done by spreading the bracket with a standard screwdriver and carefully sliding the wire toward you. Insure the wire is secure in the bracket, yet free to move with the front wheel and associated steering and suspension parts. Tech Tip Do NOT install the stabilizer link at this point. That will come later.

14 Step 30 Repeat Steps 2 through 29 on the driver side of the vehicle. After competing these steps come back to Step 31. Step 31 Install the DRIVER SIDE stabilizer link and torque both nuts to 52 ft. lbs. Note: Insure that the longer stabilizer link stud goes (UP) in the steering knuckle and the shorter stud goes (DOWN) in the stabilizer bar when installing this link. Step 32 Install the PASSENGER SIDE stabilizer link and torque both nuts to 52 ft. lbs. Step 33 Install both (driver and passenger side) wheel assemblies and torque the lug nuts to 76 ft. lbs.

15 Step 34 Remove any equipment (transmission jack, jack stands, etc.) left under the vehicle and lower the vehicle to the floor. Final Torquing of Control Arm Bushings Caution: Control Arm Bushings must be tightened with the vehicle s suspension at ride height. This means the full weight of the vehicle must be on the wheels and not supported in any way by a jack, twin post lift or jack stands. Failure to follow these instructions will result in premature failure of the control arm bushings. Step 35 Torque all (4) lower control bushings (2 driver side and 2 passenger side) to 100 ft. lbs. Step 36 Torque the upper control arm bushing nuts, on the driver and passenger side, to 85 ft. lbs.

16 Measuring Ride Height Condition for Ride Height Measurement Vehicle must have been rolled for at least 10 feet to insure the wheels are settled to normal rolling position. Take Measurement Here Vehicle bounced several times in the front. Vehicle on level ground. Both front tires at equal air pressure. Step 37 Measuring Ride Height Hold the tape at true vertical. Center the tape on the wheel assembly. Measure to the bottom of the fender. Measure the ride height at the other wheel in the same EXACT location. Compare the two measurements. The measurements should be within.5 of each other. If they are, you are finished. If they are not, adjust the side that needs to be lowered. Example: If the passenger side is.75 higher than the driver side, lower the passenger side at least.25

17 Adjusting Ride Height Step 38 Lift the vehicle as done before. If you are using a twin post lift be sure to lift on the frame of the vehicle. If you are using a floor jack, be sure to support the vehicle under the frame with jack stands and remove the floor jack. Step 39 Remove the wheel on the side to be adjusted. Step 40 Loosen the allen screw (indicated by the arrow) using a 5 mm allen socket. Step 41 Turn the adjustment sleeve CLOCKWISE using the spanner tool supplied with the kit. Note: 2.5 Turns equals approximately.25 of ride height. So, if you need to lower the ride height.5, you would turn the adjuster sleeve down (clockwise) about 5 turns.

18 Step 42 Tighten the allen screw after adjusting the sleeve. Step 43 Replace the wheel assembly, lower the vehicle and measure the ride height on both sides as before. If the ride height is within.5 of each other you are finished. If not, repeat the adjustment procedure illustrated above. Congratulation!!! You have finished the front lift. It is wise to double check all the fasteners to insure you have not overlooked any of them. We hope these instructions have been helpful. Please feel free to contact us with any questions or concerns you may have. If you are adding the differential drop kit please continue to the next page. Differential Drop Kit Sold Separately Replace the wheel assembly, lower the vehicle and measure the ride height on both sides as before. If the ride height is within.5 of each other you are finished. If not, repeat the SKU# LR-2GDDK

19 Front Differential Components Mount Nut Front Differential Upper Mount Stopper Differential Support - Passenger Side Skid Plate Lower Mount Stopper Mount Bolt Differential Support - Driver Side FORWARD Front Skid Plate Bolts (2) Rear Skid Plate Bolts (2)

20 Installing the Front Differential and Skid Plate Drop Kit Hooks Step 44 Remove the front two skid plate bolts using a 12 mm socket. Step 45 Let the front of the skid plate rest on the (2) hooks. Step 46 While supporting the rear of the skid plate, remove the back (2) bolts using a 12 mm socket. Step 47 Unhook the front of the skid plate, let it drop down, and set the skid plate aside.

21 Step 48 While holding the nut on the driver side support with a 19 mm box end wrench, remove the bolt using a 22 mm socket. Step 49 Repeat the previous step on the passenger side. Note: Keep the large washer. It will be needed later on. Differential Support Differential Support Step 50 Let the passenger side differential support drop down. Step 51 Let the driver side differential support drop down as well.

22 Step 52 Insert the supplied spacer between the passenger side differential mount and the frame and install the supplied hardware according to Figure B. Figure B This illustration shows the positioning of the hardware (supplied and factory) on the differential support. Frame Brace Step 53 Install the supplied nut but leave it loose for now. Tech Tip You may need to pry the driver side differential support away from the frame brace in order for it to drop down enough for the spacer to be installed.

23 Step 54 Insert the supplied spacer between the passenger side differential support and the frame and install the supplied bolt. (see Figure B) Install the supplied nut on the bolt. Step 55 While holding the driver side nut with a 19 mm box end wrench, snug the bolt using a 19 mm socket. Torque the bolt to 101 ft. lbs. Step 56 While holding the passenger side nut with a 19 mm box end wrench, snug the bolt using a 19 mm socket. Torque the bolt to 101 ft. lbs. Step 57 Hook the front of the skid plate as shown.

24 Step 58 Insert the front (2) supplied bolts from the bottom and place the supplied spacers on top of the skid plate as shown. Step 59 While holding the skid plate in place, start the front (2) bolts. Leave them loose for now. Step 60 Insert the rear (2) supplied bolts from the bottom with the supplied spacers on top the skid plate and start them as well. Step 61 After all (4) bolts are started, snug them with a 12 mm socket and then torque them to 20 ft. lbs.

25 Congratulation!!! You have finished the front differential and skid plate drop. It is wise to double check all the fasteners to insure you have not overlooked any of them. We hope these instructions have been helpful. Please feel free to contact us with any questions or concerns you may have.

26 As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at M-F 8am-5pm 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 09/03/15 Copyright 2015 Low Range Off-Road, LC All Rights Reserved