Installation Instructions 2” Body Lift 1998-2003 S
Contents
1. range If any steering bind is detected follow the instructions below to correct the angle 1 Remove the negative battery cable then the positive battery cable This is necessary to ensure that the air bag does not deploy while working around the steering column Remove the lower plastic dash panel from under the steering column Four studs mount the steering column to the under side of the dash Locate the two vertical studs near the instrument panel and the two horizontal studs near the firewall Remove the four retaining nuts and lower the steering column to the floor Do not disconnect any wire harnesses Do not disconnect the steering column from the steering shaft The flange holes that mount to the horizontal studs near the firewall need to be elongated for adjustment Using a hand file or power grinding tool oblong the holes up to the edge of the mark that was left by the washer Reattach the steering column to the dash with the OE nuts Before the hardware is tightened pull down on the column so that the horizontal studs are at the top of the newly slotted holes Tighten the nuts securely Check that the steering shaft boot at the firewall is in its proper location Reconnect the positive then negative battery cables Page 112. 9228 Installation Instructions 2 Body Lift 1998 2003 S Series Blazer 2 4wd ZR 2 A SUSPENSION READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE SAFETY WARNING BDS Suspension Co recommends this system be installed by a professional technician In addition to these instructions professional knowledge of disas sembly reassembly procedures and post installation checks must be known PRODUCT SAFETY WARNING Certain BDS Suspension 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 Extreme care must be used to prevent loss of control or ve hicle rollover Failure to drive your modified vehicle safely may result in serious injury or death BDS Sus pension Co does not recommend the combined use of suspension lifts body lifts or other lifting devices You should never operate your modified vehicle under the influence of alcohol or drugs Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving condi tions Always wear your seat belt PRE INSTALLATION NOTES 1 Special literature required OE Service Manual for model year of vehicle Refer to manual for proper disassembly reassembly procedures of OE and related components 2 Adhere to recommendations when replacement fa
3. frame rail Fig 18 FIG 18 25 Remove the wire harness from the plastic retaining clip on the driver s side frame rail Fig 22 22 Remove the bolt clip mounting the oil cooler lines to the passenger s side of the engine oil pan Fig 19 Remove the lines from the pan Page 7 REAR REAR BUMPER 26 Remove the fuel filler cap to access the three screws mounting the filler neck to the plastic body shroud Fig 23 Remove the three screws to allow the filler neck to fall through the shroud while lifting the bed 28 Disconnect the main license plate light wire harness connector at the frame Fig 24 29 Remove the 4 bolts or 5 with some hitch options mounting each of the rear bumper brackets to the frame Remove the bumper from the vehicle LIFT 30 Do a thorough visual check of all wires hoses etc to ensure that everything has adequate slack for 2 of lift 31 Loosen but do not remove all of the body mount bolts There are five body mounts on each side of the vehicle 32 Remove the passenger s side mounting bolts Using a hy draulic jack and block of wood slowly lift the passenger s side of the cab high enough to place the 2 tall x 3 wide spacers on the frame body mounts While lifting continue to watch for hoses wires etc that may be overextending 33 Install 12mm x 140mm bolts and 7 16 USS washer in conjunction with the OE washer and bushings in the main cab mounts Install
4. rear mount ing holes in the core support may need to be drilled out slightly to accept the new 3 8 hardware Attach the OE filter bracket to the relocation brackets with the OE shoulder bolts Tighten the four bolts securely Install the front plastic air scoop to the core support in the original location using the OE plastic fasteners Set four 2 x 2 body blocks on the four front bumper mounting points Fig 35 Set the front bumper up to the mounts and mark where the front valance needs to be trimmed to clear the frame The valance may not require trimming in some cases After the bumper is properly trimmed mount the bumper to the spacers and the frame with 10mm x 80mm bolts and 3 8 USS washer through the bumper spacers and 76 TT 78 79 80 81 82 thread into the original nut tabs on the frame Leave hardware loose Install the side bumper brackets to the bumper using the OE bolts Install the new side bumper relocation bracket to the frame through the lower OE hole Mount the outside bumper bracket to the relocation bracket through the upper most mounting hole with a 3 8 x 1 bolt nut and two 3 8 USS washers Fig 36 Mark the OE side bracket to drill a hole through to match the middle hole of the relocation bracket and outside OE mounting hole on the frame Drill a 7 16 hole at the mark Install the brackets to the frame with the OE bolts in the lower two holes and
5. rest on the frame rails Note A flat head screw driver may be required to release the lower fan shroud retaining clips Page 5 14 Remove the nut retaining the ground strap at the 17 4wd only Remove the two bolts mounting the battery passenger s side firewall and remove the wire from the tray to the core support and remove the battery tray from stud Fig 12 the vehicle Fig 14 an iho MEDE Bg a SE 15 Remove the four screws mounting the air filter housing cover and remove the cover Remove the intake hose from the throttle body and allow the intake hose assem bly to rest on the engine during lifting 18 4wd only Remove the two sheet metal screws and bracket mounting the positive battery cable terminal box to the core support Fig 15 16 4wd only Remove the battery retaining clamp and re move the battery from the vehicle Fig 13 19 4wd only Remove the two bolts mounting the front axle actuator to the passenger s side inner fender The bolts are accessed from inside the wheel well Fig 15 16 Page 6 UNDER BODY FRAME RAILS 23 Remove the bolt mounting the brake lines to the driver s side shock mount Fig 20 20 Remove the bolt mounting the ground strap s to the passenger s side frame rail Fig 17 24 Remove the brake line from the plastic retaining clip on the driver s side frame rail Fig 21 21 Remove the wire harness from the plastic clip on the passenger s side
6. wire to the frame with the OE bolt Install the filler cap Tighten all hose clamps securely UNDER BODY FRAME RAILS 57 58 Install the short end of the provided L shaped ground strap relocation to the passengers side frame rail with the OE bolt Fig 29 Attach the ground strap s to the bracket with a x bolt nut and two SAE washers Check all brake lines wire harnesses etc to see that they are not rubbing on any abrasive surfaces Use pro vided zip ties to secure lines were needed FRONT UNDER HOOD 59 60 61 62 63 64 4wd only Measure and mark 7 to the inside of the posi tive battery cable terminal box bracket mounting holes on the passenger s side core support Fig 15 Drill a 1 8 hole at each of the marks 4wd only Mount the terminal box bracket to the new holes with the OE mounting screws 4wd only Measure and mark 7 to the inside of the axle actuator mounting holes on the inner fender Fig 16 Drill a 3 8 hole at each mark 4wd only Mount the axle actuator to the inner fender us ing the new holes and the OE mounting bolts 4wd only Install the battery tray to the original mounting holes using the original mounting bolts 4wd only Install the battery on the battery tray and secure with the OE retaining bracket Do not attach the battery cables at this time Page 9 65 Install the provided ground strap extension on the ground stud at the passen
7. a 12mm x 140mm bolt with large 72 washer in the front core support mount from the top down and fasten with the OE bushing washer and r tia Fig 25 Leave all hardware loose at this time age 34 Repeat lift procedure on driver s side of the vehicle Note 4 door models have two more body mounts than 2 door models If installing on 2 door 2 blocks and bolts will be extra 35 If necessary adjust the body so it is square on the frame and tighten all mounting bolts securely Use Loctite on all mounting hardware REAR REAR BUMPER 44 Remove the license plate from the rear bumper 45 Remove the top plastic cover from the rear bumper by squeezing the plastic clips and pushing them out of the holes Fig 26 46 Remove the eight bolts and the bumper brackets from the rear bumper Fig 27 47 47b 48 49 50 51 52 93 54 55 56 Install the new rear bumper brackets with the OE hard ware and four 12mm nuts with four 7 16 USS washers to replace the welded nuts on the upper OE bracket mounts Do not tighten at this time The bottom corner of the rear frame horns must be trimmed to make clearance for the relocated bumper Measure from the back edge of the frame 1 5 8 and mark Measure up from the bottom of the frame 1 1 2 and mark Cut out the marked off square section of the frame with a saw or cut off wheel Paint exposed metal to prevent rust Install the bumpe
8. ger s side firewall and retain with the OE nut Attach the ground strap to the bracket stud with a nut and SAE washer Fig 30 66 Remove the four nut clips from the lower radiator fan shroud Fig 31 67 Install the upper fan shroud in the vehicle and attach it to the core support with three OE bolts Fig 11 68 Attach the lower fan shroud to the upper fan shroud with four spacers four 3 8 x 3 1 2 bolts nuts and sixteen 3 8 USS washers The washers mount on both sides of the shroud flange to sandwich the plastic Fig 32 69 Reattach the air box cover to the air box Reattach the intake hose to the throttle body 70 Locate the lower fan shroud bracket in the shroud and against the lower surface of the core support Using the bracket as a template mark the mounting hole on the core support Drill a 1 8 hole at the mark Fig 33 Mount the shroud bracket to the core support with a 12 x 72 sheet metal screw Page 10 71 72 73 T4 75 Install the oil filter relocation brackets to the original mounting holes in the core support with the provided 3 8 x 4 bolts x 2 970 sleeves nuts and 3 8 USS washers The front bracket is flat and the rear bracket should bend forward with the notch to the passenger s side of the vehicle fitting over the new radiator shroud bracket Fig 34 The lower holes will be offset to the driver s side Leave bolts loose Note The
9. needed can be purchased from a local parts supplier 3 Perform head light check and adjustment 4 Re torque all fasteners after 100 miles Always inspect fasteners and components during routine servicing 102 S Michigan Avenue Coldwater MI 49036 517 279 2135 s www bds suspension com rev 11 6 2008 Page 1 PARTS LIST Part 3296 2296 234 01642 01602 01633 01749 01752 01719 400410 400406 01720 01723 01722 01731 01746 099000 241 244 342701 Qty Description 12 2 x 3 Body Lift Block 4 2 x 2 Body Lift Block 1 Bolt Pack 1 Ground Strap Relocation Bracket 1 Ground Strap Relocation Bracket 4 Fan Shroud Spacer Tube 1 Rear Bumper Bracket drv 1 Rear Bumper Bracket pass 1 Lower Fan Shroud Support 1 Fuel Filler Hose 2 x 6 1 Vent Hose 3 4 x 6 2 Outside Bumper Bracket 1 Front Oil Filter Bracket 1 Rear Oil Filter Bracket 2 Tow Hook Spacer 2 0 500 x 0 058 x 2 970 Sleeve 6 Zip Tie 2 12 Hose Clamp 2 36 Hose Clamp 1 Loctite BOLT PACK 234 Qty 12 M M K K K GQM M A OO 2 BR NN ND CO A Page 2 Description 12mm 1 75 x 140mm bolt class 10 9 clear zinc 7 16 USS flat washer clear zinc 1 3 4 OD x 1 2 ID s 3 16 thk washer clear zinc 1 4 20 x 3 4 bolt grade 5 clear zinc 1 4 20 prevailing torque nut clear zinc 1 4 USS flat washer clear zinc 10mm 1 50 x 80mm bolt class 8 8 clear zinc 10mm 1 50 x 70mm bolt class 10 9 clear zinc 12mm 1 75 prevailing torque nut clea
10. quipped remove the two wire harness connectors from the running lights and remove the grill from the vehicle Fig 1 6 Remove the two bolts mounting each of the outside bumper brackets to the frame and remove the brackets from the vehicle Fig 4 wt n PY b 1 T h UN XN L if 5 Remove the front bumper by removing the four bolts mounting the bumper to the frame horns Fig 2 and two bolts one on each side mounting the bumper to the out side bumper brackets Fig 3 Remove the bumper from 7 If equipped remove the two bolts mounting each of the the vehicle tow hooks in the frame rails and remove the tow hooks from the vehicle Fig 5 Page 4 8 Remove the plastic air scoop Fig 6 from the core support 11 If equipped remove the AC line from the plastic hose by carefully releasing the four plastic push in fasteners clip on the upper fan shroud Fig 9 9 Remove the six bolts and the front skid plate from the vehicle Fig 7 d ger de LK ir C gid we R m i L nand 3 K s n DL T dR E cee NAE BA 12 Remove the seven bolts mounting the upper fan shroud Lo aa on he etn ENNE to the core support and lower fan shroud Fig 10 11 i 3 D ull Remove the upper fan shroud from the vehicle 10 Disconnect the oil filter mounting bracket from the core support by removing the two shoulder bolts Fig 8 13 Pull the lower fan shroud free from the lower retaining clips and let it
11. r on the vehicle by aligning the origi nal mounting holes with the corresponding holes in the new brackets Use a 1 2 x 1 1 4 bolt nut and 1 2 SAE washers in the rear most mounting hole Use the OE hardware in the remaining holes Fig 28 Do not tighten at this time Adjust the bumper to body distance using the measure ments made at the beginning of the installation and tighten all the bumper mounting hardware securely Install the plastic bumper cover on the top of the bumper by aligning the clip holes and pushing them into place Install the license plate lights Install the license plate with the original hardware Remove the bolt retaining the fuel filler ground wire to the frame Loosen the hose clamps retaining the fuel filler and vent hoses to the fuel tank Remove the filler neck from the vehicle Outside of the vehicle the steel filler tube must be cut so it can be extended Cut the main filler tube and vent tube half way between the body end and the first bend Remove all metal shavings from the tubes Reconnect the two metal filler tube halves with the provided rubber filler and vent tube extensions and hose clamps Leave clamps loose Install the filler neck assembly in the vehicle and at tach the filler and vent hose to the fuel tank with the provided hose clamps Adjust the rubber extensions and tighten the hose clamp securely Attach the filler neck to the body shroud with the OE screws Attach the ground
12. r zinc 3 8 16 x 4 bolt grade 5 clear zinc 3 8 16 x 1 bolt grade 5 clear zinc 3 8 USS flat washer clear zinc 3 8 16 x 3 1 2 bolt grade 5 clear zinc 3 8 16 prevailing torque nut clear zinc 12 x 3 4 sheet metal screw clear zinc 1 2 13 x 1 1 4 bolt grade 5 clear zinc 1 2 13 prevailing torque nut clear zinc 1 2 SAE flat washer clear zinc TORQUE SPECIFICATIONS Fastener Max Torque ft lbs 1 4 10 5 16 17 3 8 30 7116 14 50 7 16 20 55 1 2 13 15 1 2 U Bolt 65 80 9 16 110 9 16 Grade 8 170 9 16 U Bolt 75 90 5 8 150 5 8 U Bolt 85 110 3 4 270 10mm 30 12mm 55 9 01602 SS 01633 Ne A 01642 01749 N Ne 01746 12mm x 140mm o 4 Nut 3n 4 txd L Nut 3n Nut 12mm Nut l 21 O D x x Washer i6 USS Page 3 INSTALLATION INSTRUCTIONS 1 Park the vehicle on a clean flat surface and block the wheels for safety Place automatic transmissions in park and manual transmissions in neutral 2 Remove the negative battery cable first then the positive battery cable If equipped the Supplemental Restraint System will be deactivated when the battery is disconnected 3 Measure and record the space between the bumpers and the body for reference during installation of the kit FRONT UNDER HOOD 4 Remove the grill by pulling the ten retaining clips free from the core support Remove the turn signal lamps from the signal housings If e
13. steners retainers and keepers are called out in the OE manual 3 Larger rim and tire combinations may increase leverage on suspension steering and related components When selecting combinations larger than OE consider the additional stress you could be inducing on the OE and related components 4 Secure and properly block vehicle prior to instal lation of BDS Suspension components Always wear safety glasses when using power tools 5 BDS Suspension Co body lifts are designed to be used on vehicles in good operating condition It is not recommended that body lifts be used on vehicles in poor physical shape This includes rusted body mounts damaged or worn frame to body mounting brackets and poor mechani cal condition Perform a visual inspection of the vehicle before beginning installation POST INSTALLATION WARNINGS 1 Check all fasteners for proper torque Check to ensure for adequate clearance between all rotat ing mobile fixed and heated members Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring harness Check steering gear for clearance Test and inspect brake system 2 Perform steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating mobile or heated members Inspect rear brake hoses at full extension for adequate slack Failure to perform hose check replacement may result in component failure Longer replace ment hoses if
14. the 3 8 hardware in the upper holes Leave hardware loose Adjust the bumper using the measurements made at the beginning of the installation and tighten all the mounting hardware starting with the four main mounts in front Install the grill by first reattaching the turn signal and running lights Align the retain clips in the core support holes and carefully push the grill into place If equipped install the tow hook spacer block in the frame rail and line up the holes with the original tow hook mounting holes Apply Loctite to the threads of four 10mm x 70mm class 10 9 bolts Insert the tow hook in the frame rail and line 83 84 85 86 up the holes with the spacer and frame Install the 10mm x 70mm bolts with 3 8 SAE washers through the frame spacer and into the threaded tow hook mounting holes Tighten the bolts securely fi Nii iy Tie Install the front skid plate in the original location with the six OE mounting bolts Note In some cases the skid plate may need to be trimmed slightly for oil line clear ance as a result of lowering the oil filter location Fig 37 Check all fasteners for proper torque Adjust headlights Check hardware after 500 miles ZR 2 Models Only On some ZR 2 models the steering col umn angle may be too steep after the body is lifted resulting in steering bind After the lift is completed take the vehicle for a slow test drive and turn the steering wheel through its full
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