F1540 - nexpart.de
Contents
1. 1 Passenger Side Axle Pivot Brkt F1540LB 1 9 16 3 1 2 Bolt 96312 ton tentare 1 9 16 Locknut 96 56 don n cra Fette bos 1 9 16 Flat washers W96S 10 1 2 x 1 1 2 Bolts 12112CHHC sese 2 1 2 55 tette 2 1 2 Fla Washers VV ZI seater 4 Front Coil Springs 206 2 Bumpstop Extensions BS35 esses 4 1 4 x 1 5 1 14100 25 tec ca retten ncs 4 1 4 Locknuts N14QOL esses nennen tnnt 4 1 4 Flat washers W14F 16 Rear Add A Leafs R21508 esses 2 3 8 Center pins 380412 2 3 8 Center pin nuts N39F S 2 Hendricks clips 4pcs 2 FRONT INSTALLATION 1 Park vehicle on hard level surface Chock wheels 2 Raise front of vehicle Support vehicle at frame rails 3 Disconnect anti sway bar at frame On 92 96 pickup applications disconnect anti sway bar and skid pan from frame 4 Disconnect radius arm brackets from frame by removing rivets and bolts NOTE2. P ELE Es T m Lo 2265 Crosswind Drive Prescott AZ 86301 928 636 3175 F1540 1980 1996 F150 amp Bronco 4WD 4 Suspension Lift INSTALLATION INSTRUCTIONS A N WARNING 1 Read and understand all instructions warnings and cautions in these instructions your owner s manual and related service manualsbefore the installation or use of this product DO NOT install or use this product if there is anything you do not understand in these instructions or related materials 2 Certain Trail Master products are intended to improve off road performance Modifying your vehicle for off road use may result in the vehicle handling differently than a factory equipped vehicle Use of oversize tires suspension lifts body lifts and other suspension modifications may raise your vehicle s center of gravity resulting in an increased tendency for the vehicle to pitch and roll during sudden turns or abrupt maneuvers Extreme care must be used to prevent loss of control or vehicle roll over Failure to drive your modified vehicle safely may result in serious injury or death Drive at reduced speeds to ensure your ability to maintain control of the vehicle under all driving conditions Always wear seat belts 3 DO NOT combine suspension lifts body lifts or other lift devices Combined use of lifts may result in unsafe and or unexpected handling characteristics see enclosed product safety WARNING label
3. 4 Many states now have laws restricting vehicle modifications such as lift bumper height or other alterations Consult your state vehicle equipment laws to determine if the installation of this kit or other modifications are permitted 5 The use of larger than OE tire and wheel combinations may reduce the effectiveness of the braking system including ABS equipped and increase the amount of pedal pressure necessary to obtain a given braking distance with normal stops and increase the stopping distance in a panic stop Drive at reduced speeds and allow for extra stopping distance while driving a vehicle WARNING equipped with larger than OE tires Discuss this issue with your tire and wheel dealer before installing larger tires and do not use tire and or wheel combinations that compromise safe braking performance 6 Supplied in this kit is a safety WARNING label Install this label inside the cab of the vehicle where it will be highly visible to all operators of the vehicle N CAUTION 1 Proper installation of Trail Master products requires knowledge of recommended procedures for disassembly assembly of OE vehicles and components i e steering tie rods control arms brake calipers etc Access to OE shop manuals and special tools is required Attempting to install this kit without knowledge of these procedures may affect the safety of your vehicle and or the performance of these components Trail Master strongly reco
4. Form No IF1540
5. Longer replacement radius arms and pivot relocation brackets are available Order 88042 5 Remover radius arm brackets from radius arms 6 Install Trail Master radius arm brackets on radius arms Retain using OE bushings washers and nuts DO TIGHTEN AT THIS TIME Fig 2 7 Position radius arms brackets on frame Retain brackets to frame using 7 16 x 1 1 4 bolts washers and nuts provided in existing holes Snug up fasteners to align brackets with frame Fig 2 T TTE zero ti m net i i 4 E P 4 T F m 1 3 Lr a pan Le E ie yy m rr a LE Fig 2 8 Using radius arm bracket holes as guides drill additional 7 16 holes in frame Fig 1 WARNING Use caution when drilling to avoid damage to lines wires 9 Install remaining 7 16 x 1 1 4 bolts washers and nuts in new holes 10 Torque all radius arm bracket bolts to 501 5 11 Support front axles with hydraulic jacks Remove front shock absorbers 12 Remove clips retaining coil springs to frame Fig 4 Fig 4 13 Lower axles Disengage coil springs from frame pockets 14 Remove nuts and cup washers retaining coil springs to axles Remove springs Fig 3 15 Install replacement coil springs on axles Retain using OE cup washers DO NOT TIGHTEN AT THIS TIME Fig 3 11 as mp tt emma err LR DIEI I 16 Raise axles and engage coil springs i
6. ERO etic ntesque GU 171 5 Sg EASTENELDO suni 301 5 116 14 1 501 5 1110 20 551 5 12 13 FASTENERBS 751 5 ie tale 65 801 5 96 FASTENERS xau th Eq oq canes 110 LBS 9 16 GRADE 8 FASTENERS 170 LBS S TO US BOL dose eet tiendra icis 75 90 LBS S B JE ASTENEI eoi eb 150 LBS 28 U BOLTO ETE ER 85 110 LBS JA FASTENERS 5252 nob 17515 PARTS LIST Driver Side Anti Sway Bar Brkt XJSB DO 1 Passenger Side Anti Sway Brkt XJSB PO 1 3 8 1 1 4 Bolts 38114 C HHOQ 4 3 8 Locknuts N38CL rores etaient a 4 3 8 Flat washers W56F esses 8 Driver Side Radius Arm Brkt DB80OL 1 Passenger Side Radius Arm Brkt DB80OR 1 7 16 x 1 1 4 Bolts 76114CHH0O 12 OGCKMUES INTO asso eus ee pata tt eh eoo in ecu teet 12 7 16 Flat washers W38F eese 24 9 16 18 High Nut N96FH nennen 8 9 16 18 x 3 1 4 x 11 5 8 Round 963141158R 4 Driver Side Axle Pivot Brkt F1540SB
7. Retain this and all information regarding your altered vehicle for future reference Thank you for choosing Trail Master Forquestions contact our Technical Assistance Department at 928 636 3175 TRAIL MASTER 8042 SUSPENSION SYSTEM COMPONENT LAYOUT qv 81950308 FRONT OF VEHICLE Longer than stack arms allow for higher rear maunt point providing increased ground clearance over stock length arms with mount point lowering brackets Bent arm design combined with mount relocation brackets which move rear mounts inboard allow for use of larger tires and deeper wheel backspacing without the tire arm rubbing common with stock and other aftermarket radius arms Includes 8017 caster adjustment poly bushing kit TRAIL MASTER 8017 FORD RADIUS ARM CAM BUSHING KIT COMPONENT LAYOUT Mount point up caster decreased Mount point down i caster increased OF VEHICLE 7 ee ac n Replaces bushings in both factory and lifted applications Rotational positioning of cam bushings increases caster adjustment range by allowing vertical adjustment of radius arm rear mount paint STOIHSA 40 LNOHJ 902 NI 861151696 fe PA 7 08 LOOAV I LNANOdNOD ws WALSAS NOISN3dSfS 08814 H3 lSVIN 1 1 2265 Crosswind Drive Prescott AZ 86301 928 636 3175 www trailmastersuspension com Master 1992 Rev 1 96 9 99 8 02 5 03 Printed in U S A
8. all or maintain components may cause serious damage and will void your warranty Fig 7 25 Remove compression limiters from frame rails 26 Install compression limiters on relocation brackets 8535 Retain using OE fasteners and 1 4 flat washers Fig 10 27 Install compression limiter relocation brackets on frame Retain using 1 4 x 1 bolts washers and nuts Torque 1 4 fasteners to 10 LBS Fig 10 i EO Fig 8 REAR INSTALLATION 1 Refer to System Installation Manual and OE Service Manual for proper procedures when installing or replacing U bolts 2 Raise rear of vehicle Support vehicle at frame 3 Remove rear wheels and tires 28 Position anti sway bar relocation brackets on frame Offset 4 Support rear axle in bracket goes toward rear of vehicle Retain using OE hardware Slide bracket forward as far as possible Torque 5 Remover rear shock absorbers fasteners to OE specifications Fig 9 6 Remove U bolts 29 Position anti sway bar under relocation brackets Retain using 3 8 x 1 1 4 bolts washers and nuts Slide bar to front of 7 Lower axle away from springs slotted holes Torque 3 8 fasteners to 30 LBS Fig 9 8 Clamp OE spring packs securely 9 Remove the center bolts 10 Remove spring clips 11 Slowly release clamps relieving pressure from spring packs 12 Clamp spring pack together 13 Install new center pin from bottom up through all leaves 4 Retain using nut suppli
9. ed 14 Clamp pack tightly Torque center pin nut 15 Raise axle Align center bolts with holes in blocks With pins and center bolts fully seated in axle pads and blocks retain axle to springs using U bolts supplied Run up but DO NOT TORQUE U BOLTS AT THIS TIME 16 With axle supported in raised position install recommended rear shock absorbers 17 Install desired wheels and tires Torque lug nuts per OE manual specifications 18 Lower vehicle to ground 19 Torque front and rear U bolts to 85 110 LBS 20 Torque front spring shackle and frame mount bolts to OE specifications 21 Test drive vehicle Note position of steering wheel when vehicle is traveling straight ahead Note steering characteristics of vehicle when bumps or dips are encountered If steering wheel is not centered when vehicle is traveling straight ahead or if vehicle turns sharper toward one direction adjust drag link length If vehicle exhibits bumpsteer or goes left or right when bumps or dips in the road are encountered steering geometry drag link angle must be corrected by installing steering arm SA40 This arm is available separately through your Trail Master dealer 22 With suspension fully extended check driveline universal joint s and C V joint s for binding interference PRODUCT SAFETY LABEL Supplied in kitis a safety warning label Install label inside cab Locate label in a highly visible location to all operators of this vehic
10. le If label becomes lost or damaged contact Trail Master at 928 636 3175 for a replacement WARNING The suspension of this vehicle has been modified to improve off road performance As a result this vehicle may handle differently than factory equipped vehicles Extreme care must be used to prevent loss of control or roll over during sharp turns or abrupt maneuvers Failure to drive this vehicle safely may result in serious injury or death Do not drive this vehicle unless you are familiar with its unique handling characteristics and are confident of your ability to maintain control under all driving conditions Consult the instructions accompanying this product and the vehicle owner s manual for additional product safety warnings Always wear seat belts reduce your speed and drive safely trail master POST INSTALLATION NOTES WARNING 1 Check all fasteners for proper torque before driving the vehicle for the first time with this kit after the first 500 miles after each off road use and during routine vehicle servicing Worn damaged or loose parts can fail suddenly resulting in loss of control of the vehicle and personal injury 2 In ALL steering and suspension positions check to ensure that there is adequate clearance between ALL rotating moving fixed and heated members Ensure adequate clearance around steering components exhaust components brake lines fuel lines fuel tank and electrical wiring 3 Visual
11. ly inspect components for wear or damage after each off road use and during routine vehicle servicing Worn damaged or loose parts can fail suddenly resulting in loss of control of the vehicle and personal injury 4 Trail Master does not recommend a particular tire and wheel combination for use with its products and assumes no responsibility for customer choice of tires and wheels Consult your owner s manual for recommended tire sizes and warnings related to use of oversize tires and wheels In general larger tire and wheel combinations may increase stress and wearon steering components leading to increased maintenance and greater risk of component failure including loss of steering control Property damage or personal injury may result Large tire and wheel combinations may also alter speedometer calibration reduce braking effectiveness and alter vehicle center of gravity height See product safety warnings Check with an experienced off road shop for the tire and wheel combinations that work best on your truck Remember BIGGER isn t necessarily better 5 Trail Master s goal is to provide you with the best system possible for a reasonable cost It must be noted that the components in your Trail Master system do not eliminate OE component weaknesses 6 Perform headlight adjustment 7 Set vehicle alignment within OE specifications The size of rim and tire combinations should be considered when making front end adjustments 8
12. mmends that this kit be installed by a certified mechanic with off road experience 2 Use the appropriate tool for the job and be sure that tools are in good condition Failure to use proper tools and or tools in good condition may result in personal injury 3 Always wear safety glasses while installing this kit to avoid eye damage from debris broken tools etc 4 Use Loctite 243 thread locker on all metal fasteners per the manufacturers directions unless otherwise noted in these instructions Failure to use thread locker may result infasteners becoming loose overtime 5 The components included in this kit require regular inspection for wear or damage Periodically check fasteners for proper torque see chart of required torque specifications on next page Worn damaged or loose parts can fail suddenly resulting in loss of control of the vehicle and personal injury PRE INSTALLATION NOTES WARNING 1 Properly block and secure vehicle prior to installation Compare parts included in your system with the enclosed parts list Placing hardware with components before you start may reduce installation time Contact your Trail Master dealer if any parts are missing or appear to be different than those indicated on the parts list PRE INSTALLATION NOTES 1 Pitman arm PA10 is recommended for vehicles with power steering Available separately 2 Radius arm frame support bracket FS84 Available separately is rec
13. n frame pockets Retain using OE clips and bolts Torque spring clip bolts to OE specifications Torque lower spring retaining nuts to OE specifications Fig 4 17 Remove axle pivot bolts 18 Remove driver side axle pivot bracket from the passenger side of the frame OE bracket looks similar to F1540LB 19 Position relocation bracket F1540SB inside OE passenger side axle pivot bracket located on driver side of frame Retain bracket by installing 1 9 16 x 3 1 2 bolt through OE pivot bolt hole Align bracket and snug up bolt Fig 6 Fig 20 Using relocation bracket holes as guides drill 1 2 holes in crossmember 21 Install 1 2 x 1 1 2 bolts washers and nuts in new holes NOTE On 92 96 F150 models with front skid plate skid plate Torque fasteners retaining brackets and anti sway bar mounts to underside of relocation brackets 22 Position axle inside pivot bracket Retain using OE pivot 30 Install Trail Master front shock absorbers bolt and nut DO NOT TORQUE AT THIS TIME Fig 6 23 Position relocation bracket F1540LB on passenger side WAR N G of frame Align bracket with OE mount holes Retain using OE fasteners Torque to OE specifications Fig 7 Compression limiters relocation brackets and correct shock 24 Position driver side axle pivot inside bracket Retain using absorbers must be in place on all vehicles Allowing suspension to over extend or compress by neglecting to inst
14. ommended for all applications 3 On early models cutting may be required for removal of the driver side axle pivot bracket located on the passenger side of the vehicle and or the OE radius arm frame brackets In addition drilling may be required for some all mounting holes when installing the Trail Master radius arm brackets 4 If desired longer tubular replacement radius arms and pivot brackets are available separately Order 88042 5 Forincreased caster adjustability replacement type polyurethane radius arm bushings are available Order 48017 6 Non adjustable polyurethane radius arm bushings are available Order SA35 7 Rear U bolts are included in this system These U bolts are intended for use on pickup applications Due to the addition of an add a leaf to the OE spring pack OE U bolts on pickup trucks will be too short OE Bronco U bolts have adequate length for reuse If desired replacement U bolts for Bronco applications are available separately Order 840051 4 required 8 Recommended Trail Master shock absorbers Front 53460 63460 73460 Rear 52510 62510 72510 For models with factory Quad Suspension Additional front shocks 53490 63490 73490 GLOSSARY OF TERMS TM Trail Master DRV Drivers side of the vehicle PASS Passengers side of the vehicle OE Original equipment SHS Supplemental Restraint System TORQUE SPECIFICATIONS VAFAS TENERS ne estas 10 LBS 0 16 FAST EN
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