WARNING DO NOT EXCEED THE MANUFACTURER S RECOMMENDED GROSS VEHICLE WEIGHT RATING (GVWR). As in any suspension installation, it is the installer s responsibility to assure a correct installation. The installer is also responsible for providing adequate clearances between vehicle components such as axles, shocks, exhaust and mechanical linkages to ensure a safe and reliable installation. Instructions: 1. Remove truck bed. Use care to insure that the OEM lighting wire harness connectors, fuel filler neck and grounding straps are disconnected prior to lifting the bed from its mounts. 2. Chalk front tires to ensure truck does not roll. 3. Jack rear of truck up and secure with jack stands. Duplicate on both sides. Remove wheels, shocks, leaf springs, gas tank, gas tank cross member, charcoal canister and mounts. 4. Measure and draw your cut line as shown. Cut both sides on the line and pull rear half away from the frame.
5. After you cut the rear half off, the notches will slide on from the rear of the truck towards the front. You will need to make sure you sand/grind all the undercoating and dirt from the frame where the new notches will go. Lift the rear of the notch up and down as you push it toward the cab. The notches will be tight and will probably need some tapping with a rubber mallet to get them into position. You will see on the drawing that there are several holes that will line up with existing holes on the frame. Once you have these holes lined up, bolt the notches on and then use the other holes as a template to drill out the remaining holes. 6. Then install the front gas tank cross member. They will bolt on top of the notches and through the frame. 7. Install the rear bag link cross member inside the frame rails. In the center of this cross member there are 2 tank mounting tabs, these need to point towards the cab when the cross member is installed. 8. Install the top cross member between the two notches.
9. Remove the differential cover and drain the fluid, lower the differential mount onto the axle with a slight angle towards the back. If you try and install it from the bottom it will give you trouble but from the top it should go right on. It is required to install a differential gasket between the diff. mount, the diff. and the diff. cover and the diff. mount. Next install the axle mounts onto the axle where the leaf springs were installed. Hand tighten the u bolts until the rest of the axle assembly is installed. Once all the pieces are installed go back through and tighten all the hardware. 10. Once you have the frame rails, cross members, and axle assembly installed then position the axle underneath the frame sections.
11. Install the lower link with the urethane bushing connecting to the frame and the heim joint installed under the axle. Since all the links are fully adjustable you can center your wheels when the truck is layed out. 12. Install the bushings and sleeves into the gas tank cross member. These install from the inside of the tube out. The heim joint on the upper wishbone link will then fit in between with washers on both sides of the heim. The long 5/8" bolt will run inside the tube that is welded to the front cross member, all the way through to the other.
13. Attach the wishbone to the differential bracket. 14. Install the bag links to the rear bag link cross member towards the axle.
15. Next connect the bag links to the axle with the 3/4" heim joints. The adjustment holes on the lift bar axle mounts are for customers with smaller diameter tires than 30. By moving the heim joint to one of the higher holes will allow the truck to lift more since it will compress the bag more when laid out. They also affect the angle between the heims and the forward lower link bars at ride height. At ride height the angle between the heims and these lower link bars should be as close to 90 degrees as possible without going over. If it is over the truck will be fine it might just have more of a tendency to wheel hop. 16. Install the bags with a 3/8 bolt going through the bottom of the bag link and install them to the bag mounts on the rear frame sections.
17. Next install the shocks from the axle up to the top cross member. It is easiest to install them on the cross member first and then down to the axle. 18. Cycle the suspension, adjust the length of the links and pinion angle and check for driveshaft clearance on the cab. After this you can install all the factory parts i.e. gas tank, charcoal canister.