Installation Instructions
Contents
1. Lo Sr K w Jar at jd s Part 021672 jiSUSPENSION jee UL Ka KE Fa A HARDCORE LIMITED LI 5 5 Suspension System Chevy Colorado GMC Canyon 4WD 2015 16 Rev 110615 491 W Garfield Ave Coldwater MI 49036 Phone 517 279 2135 Web live chat www bds suspension com E mail tech bds sporttruckusainc com Read And Understand All Instructions And Warnings Prior To Installation Of 902 System And Operation Of Vehicle THANK YOU BEFORE YOU START BDS Suspension Co recommends this system be installed by a professional technician In addition to these instructions professional knowledge of disassembly reassembly procedures and post installation checks must be known FOR YOUR SAFETY 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 vehicle rollover Failure to drive your modified vehicle safely may result in serious injury or death BDS Suspension 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 conditio2. 9 Disconnect the brake caliper from the steering knuckle retain mounting bolts Hang the caliper out of the way do NOT allow the caliper to hang from the brake line Fig 2 10 Remove the torx head bolt T30 that attaches the rotor to the hub Keep bolt for reinstallation Fig 3 FIG 3 11 Disconnect the ABS wire from the backside of the steering knuckle remove the clip and retain the bolt Fig 4 FIG4 12 Remove the ABS sensor from the side of knuckle T30 retain mounting bolt Fig 5 13 Remove the CV nut CV s have a tight fit to the hubs it may be necessary to use an air hammer to separate them Reinstall the nut a few turns to keep from damaging the CV shaft if this method is used Fig 6 FIG6 14 Remove the factory sway bar links they will not be reused 15 Break the jam nuts loose on the tie rod ends at this time The factory tie rod ends will be replaced later in the installation 16 Remove the ball joint nuts and tie rod end nuts Use an appropriate tool to unseat the tapers from the factory knuckle It is NOT recommended to use a hammer to separate the joints if the knuckles are ever planned to be reused Fig 7 8 17 Remove the knuckle and hub assembly from the vehicle 18 Remove the lower control arms Retain the cam bolts washers Fig 9 10 FIG9 19 Remove the factory struts Remove the lower bolt that attaches to the control arm and the 3 nuts that attach the strut to
3. Qty Description 7 3 8 24 Hex Nut Gr 8 02815 2 4 Rear Block 7 3 8 NAS Washer 962961138QB 4 9 16 x 2 9 16 x 11 3 8 U Bolt Black 02821 1 Colorado Front Drive Shaft Spacer B1131 1 Bag Kit 828 1 Bolt Pack Drive Shaft Spacer 099000 5 Zip Ties 6 10mm 1 50 x 75mm Allen Bolt Class 12 9 W96S B 8 9 16 SAE Washer black loc tite 1 Loctite N96FH B 8 9 16 High Nut black 4 021672 02809 DRV DIFF DROP SHOWN 02810 PASS DIFF DROP 2 02812 STRUT SPACER Sa 02800 KNUCKLE SHOWN 02801 PASS KNUCKLE 02807 FRONT CROSS MEMBER 02816 BACKING PLATE 02811 DIFF SKID 02808 REAR CROSS MEMBER 02813 DRV BUMP STOP SHOWN 02814 PASS BUMP STOP BDS 021674 BOX KIT PART NUMBER DESCRIPTION BDS 021672 02809 DRV 2 02812 STRUT SPACER 02810 PASS DIFF DROP BRKT 805021673 2 95105 159 1 2 RIVET NUT 805 021673 246 INDEX RING BDS 021673 02811 805 021672 805 021672 DIFF SKID PLATE 02808 02807 REAR X MEMBER FRONT X MEMBER BDS 021673 BDS 021672 8 4805G 02816 BACKING PLATE BUSHINGS BDS 021673 2 911122 SWAY BAR LINK BDS 021673 02821 BDS 021673 DRIVE SHAFT SPACER 02813 DRV 02814 PASS BUMP STOP BRACKETS STRUT SPACER HARDWARE HARDWARE _ 2 02812 6 3 8 NYLOCK NUTS 4 5 8 X 4 1 2 a STRUT SPACER 6 3 8 WASHERS 4 5 8 TORQUE NUT a e BOLT PACK 943 8 5 8 WAS
4. holes and using 3 16 cable clamps with 1 4 self threading bolts BP 683 Fig 33 FIG 33 a j 56 Zip tie the ABS wires to the brakeline to allow adequate slack through wheel travel and turning motions INDEX RING INSTALLATION 57 Note The front driveshaft should be completely removed at this point if it is not remove and retain hardware remove driveshaft from the vehicle 58 Disconnect the U joint hardware remove straps and disconnect rear drive shaft from the rear axle remove rear driveshaft Fig 35 21 60 Disconnect the transfer case shift mechanism wiring harness disconnect wiring harness clips from transfer case Fig 37a 6374 61 Disconnect the breather from on of the transfer case above the front driveshaft output 37b 22 FIG 37 62 Support the transmission with a transmission jack use extra not damage any surfaces the transmission Remove the factory transmission crossmember remove the transmission mount retain all hardware Fig 38a 38b FIG 38A FIG 38B 63 Support the transfer case Remove the 7 nuts that hold the transfercase to the transmission and remove the transfer case from the vehicle 64 Remove the 7 studs from the transfer case Double nut the factory nuts in order to remove them Fig 40 FIG 39 65 66 Install new index ring assembly with loctite on the new 10mm Flat Head Allen Bolts 827
5. x member BDS 4 7 16 14 Nylock Nut yellow zinc 02816 1 BDS Backing Plate Aluminum 683 1 Bolt Pack Skid Plate Bump Stop Misc 02809 1 Colorado DRV Diff Drop BDS 8 1 2 13 x 1 1 4 Bolt Grade 8 02810 Colorado Pass Diff Drop BDS 2 1 2 13 x 2 Bolt Grade 8 B1128 Bag Kit Bolt Packs 12 1 2 SAE Thru Hardened Washer 2 2 13 Prevailing T N 680 1 Bolt Pack Colorado Cross Member 2 7 16 0 281 Hole Vinyl Cushion Wire Clip 4 5 8 11 x 4 1 2 bolt grade 8 4 3 16 Cable Clamp 8 5 8 SAE Thru Hardened Washer 4 1 4 20 x 3 4 Self Threading Bolt 4 5 8 11 Prevailing Torque Nut 2 10 24 x 3 4 Button Head Bolt Stainless 681 1 Bolt Pack Diff Drop Hardware 2 10 SAE Washer 3 9 16 12 x 3 1 2 Bolt Grade 8 2 10 24 Nylock Nut 6 9 16 SAE Thru Hardened Washer 95105 159 3 1 2 Rivet Nut 3 9 16 12 Prevailing Torque Nut s aden a 799 1 Bolt Pack Rivet Nut Installation 2 9 16 SAE Washer clear zinc l 2 1 A OEEO S 1 1 2 SAE Washer 1 1 2 Star Washer 021674 Strut Spacer Box Kit 1 9 16 18 High Hex Nut Part Qty Description 099000 4 ZipTie 02812 2 Colorado 5 5 Strut Spacer BDS A246 1 Index Ring Assembly w Studs 943 1 Bolt Pack Strut Spacers 02820 1 Colorado Index Ring 6 3 8 16 Nylock Nut ARP15AJ1 7 3 8 24 Press in stud 81130 1 Bag Kit Index Ring 827 1 Bolt Pack Index Ring Kit 011406 4 Rear Box Kit 7 10mm 1 50 x 30mm FHSCS Class 10 9 Part
6. 1 FIG 41B FINAL FRONT STEPS 24 70 Recheck differential hardware for proper torque Install skid plate 02811 with 2 x 1 1 4 bolts with washers 683 Tighten to 65 ft lbs 71 Attach the backing plate to the backside of the front cross member with 10 stainless hardware BP 683 72 Recheck all front hardware for proper torque cycle steering to check for adequate clearances 73 Reinstall front wheels Tighten to factory specifications 74 Lower vehicle to the ground Adjust Cams as shown Fig 42a front 426 rear Tighten Cam hardware to 170 ft lbs Tighten lower strut hardware to 95 ft lbs 9 This is not the final alignment but a good start driving to an alignment shop Adjust the toe in to approximately 1 8 in and straighten the steering wheel Do NOT drive the vehicle with the steering wheel off center FIG 42A FRONT aaa REAR INSTALLATION 75 Block the front wheels for safety Raise the rear of the vehicle and support frame rails with jackstands 76 Remove the stock wheels and tires 77 Disconnect the ABS wire from the clip on the side of the frame rail this will allow extra slack in the ABS line Fig 43 78 Remove the e brake cable guide bracket from the side of the frame rail on the driver s side It will not be reinstalled 79 Form the stock brake line upper bracket down to gain adequate slack Use an adjustable wrench to form the stock brake line bracket do
7. HER BOLT 680 2 95105A159 1 2 RIVET NUT 7 3 8 FINE NUT 7 3 8 NAS WASH BOLT PACK 827 A246 INDEX RING W STUDS 7 10 X 30mm FLAT HEAD ALLEN BOLT PACK 827 gt DIFFERENTIAL HARDWARE 4 3 9 16 X 3 1 2 BACKING PLATE HARDWARE BUMPSTOP HARDWARE 3 9 16 TORQUE NUTS 2 10 WASHER 2 1 2 TORQUE NUT BOLT 68 2 10 NYLOCK NUT 4 1 2 WASHERS BOLT PACK 683 BOLT PACK 683 2 ye DIFFERENTIAL HARDWARE 2 14 X 35mm BOLT 2 14mm WASHER BOLT PACK 681 6 FACTORY 2 iF HARDWARE 02809 DIFF DROP DRV 02810 DIFF DROP PASS is 2 911122 SWAY BAR LINK 8 4805G BUSHING 6 10 75MM BOLT BOLT 828 4 7 16 NYLOCK NUT 8 7 16 WASHER 02821 SPACER 02813 BUMP STOP BUMPSTOP HARDWARE ret 02814 BUMP STOP PASS 2 1 2 X 2 BOLT Hae WASHERS BOLT PACK 683 BOLT PACK 683 INSTALLATION INSTRUCTIONS 1 TROUBLESHOOTING INFORMATION FOR YOUR VEHICLE RS If using a plasma cutter for frame bracket modification disconnecting the battery is highly TECH 1 recommended Stock 17 amp 18 wheels can not be reinstalled with the lift kit Aftermarket 20 wheels with maximum 5 of 5 25 Backspacing are recommended certain wheel and tire combinations will require weld steering stops these are included in the kit See end of
8. If both are installed correctly there will be an extra rivet nut at the end of the installation 38 Attach the new bump stop extension 02813 DRV 02814 PASS the rivet nut with 12 x 2 hardware use socket and extension to attach the cross member with x 1 1 4 bolt washers and nut BP 683 Fig 26 FIG 26 39 Install lower control arms with factory cam bolts and nuts It is recommended to run the front bolts from Rear to Front and the rear bolts from Front to Rear so that the nuts are easily accessible They must be torqued to 170 ft lbs later in the installation Snug but do not tighten at this time 40 Go back and tighten 5 8 Differential Crossmember hardware to 120 ft lbs 9 16 differential hardware to 90 ft lbs Tighten 7 bump stop hardware to 65 ft lbs 41 Install the factory bump stops into the replacement bump stop brackets Lube the bump stop with a small amount of grease use a jack on the lower control arm to press the bump stops into the cup Fig 27 OK D STRUT MODIFICATION OR OPTIONAL COILOVER INSTALLATION 42 Locate the upper strut spacers 02812 Attach the strut spacers to the stock struts with factory hardware Tighten to 40 ft lbs Fig 28a 28b Note Use a 3 8 chrome 18mm socket with a 3 8 swivel to tighten the nut inside the strut spacer FIG 28 __FIG28B 43 Install the strut and spacer into the vehicle Attach the strut to the upper mo
9. d making a line that goes from front to back Remove this section of material from the vehicle Use a grinder to make the faces flush and remove any sharp edges so that the cross member can be installed easily Coat with paint Fig 17 17b 17 amp 17d Q Tip Due to the factory forming of the front pocket it can be difficult to install the front crossmember Use a hammer or adjustable wrench to unflair the factory pocket if necessary 1178 PASSENGER S REAR POCKET MODIFICATION 26 Draw a line that connects the top of the outside slot and bottom of the inside slot and remove the material from vehicle Use a grinder to remove sharp edges coat with paint when completed Fig 18a 18b FIG 18B DRIVER S REAR POCKET MODIFICATION 27 Draw a horizontal line from the top of the outside slot 28 Draw a vertical line from the center of the outside slot 29 Draw a line that would go through the center of the stock alignment pin that is perpendicular about 45 degrees from horizontal to the inside face 30 Remove this section of material from the vehicle remove any sharp edge with a grinder and coat with paint Fig 19a 19b 19c amp 19d FIG 19B CROSSMEMBER DIFFERENTIAL INSTALLATION 31 Install the new front crossmember with new 5 8 4 1 2 hardware BP 680 Run the bolts from front to rear Do put the nuts on the bolts at this time Crossmember are a tight fit if not enough material was removed duri
10. ench and tighten the 3 8 bolt with 9 16 wrench to set the rivet nut Be sure to hold the rivet nut flush to the surface and square to the hole as it is tightened Fig 2 Q Tip If available an impact gun is recommended for tightening the bolt to ensure the rivet nut remains square to the hole and to ease holding the nut from spinning 7 Fora 1 2 rivet nut hold the nut closest to the rivet nut still with an 7 8 wrench and tighten the 1 2 bolt with a 3 4 wrench to set the rivet 30 0 nut Be sure to hold the rivet nut flush to the surface and square to the hole as it is tightened Fig 2 FIGURE 2 1 2 RIVET NUT SHOWN O 677 Zi 4 TORQUE SPECIFICATIONS 8 3 8 rivet nuts will approach 40 ft lbs for maximum grip strength Do not exceed 45 ft lbs when setting the rivet nut 9 1 2 rivet nuts will approach 90 ft Ibs for maximum grip strength Do not exceed 100 ft lbs when setting the rivet nut Q Tip Note If using the recommended impact gun use caution to not exceed the recommended torque specifications RIVET NUT TOOL REMOVAL 10 Once the center bolt is tightened remain holding the nut from spinning with the wrench and loosen the center bolt to remove the installation tool Caution It is very important to hold the nut as the bolt is loosened because the grip of the star washer will try to spin the rivet nut and ruin the installation 11 Verify proper installation by checki
11. he correct size rivet nut for the application based on the thickness of material where the rivet nut is to be installed using the following chart Thread Body Material Thickness Drill Size Length in in Size in Om T ax 150 312 200 350 29 HOLE PREPARATION 2 Drill hole to appropriate size for rivet nut installation 1 2 Rivnuts require an 11 16 hole and 3 8 Rivnuts require a 17 32 drill It is critical that this hole is drilled to the correct size Remove any burrs that could keep the rivet nut from seating flat against either side of the hole surface 9 If the correct drill size is not available it is possible to drill the hole an available smaller size and slowly grind it out to until the rivet nut fits tight RIVET NUT INSTALLATION TOOL ASSEMBLY 3 3 8 rivet nut place the provided 3 8 SAE flat washer on the 3 8 x 1 1 2 bolt followed by 7 16 hex nut and then a 3 8 serrated washer Fig 1 Thread this tool assembly into the rivet nut 4 Fora1 2 rivet nut place the provided 1 2 SAE washer on a 1 2 x 2 bolt followed by a 9 16 high nut and 1 2 serrated edge lock washer Thread this tool assembly into the rivet nut as shown Fig 1 RIVET NUT INSTALLATION 5 Place the installation tool with the rivet nut threaded on the end into the appropriately sized hole 6 Fora 3 8 rivet nut hold the nut closest to the rivet nut still with an 5 8 wr
12. inst sheet for details on installation 6 cylinder models require slight exhaust modification 4 cylinder Diesel models could possibly require exhaust modification Rack and Pinion steering is sensitive to tire choice Tires with large lugs little backspacing or extreme amounts of weight may induce a steering wheel bobble h Park vehicle on clean flat and level surface Block the rear wheels 36mm Socket Air Hammer Chisel highly recommended for safety chock both the front and backside of the tires Put the Plasma Cutter or other cutting device sawzall or cutoff wheel transmission in Neutral required for index ring installation Disconnect the battery Raise the front of the vehicle and support the frame rails with jackstands If a plasma cutter is to be used for frame bracket modification later in installation it is recommended to disconnect the battery at this time Remove the front wheels DISASSEMBLY INSTRUCTIONS 6 Remove any differential skid plates if equipped and the front splash shield from the vehicle None of the factory skid plates will be reinstalled Remove the clip from the brake line to allow the brake line to detach from the bolt on brake line bracket Remove the brake bracket from the side of the upper strut mount discard flanged bolt Fig 1 Remove the bracket from the vehicle by cutting a slot in the bracket for clearance to the brake line Discard bracket it will not be reused
13. leave the factory gasket on the transfer case Tighten to 35 ft lbs Fig 40a Q Tip The indexing ring has a specific orientation it will only go on one way rotate until all of the holes align Reinstall transfer case with new indexing ring with new 3 8 washers and nuts with loctite on the threads BP 827 Tighten to 45 ft lbs Fig 40b FIG4OA _____ FIG 40B 67 68 69 Reinstall transmission mount and crossmember with factory hardware reattach wiring harness and transfer case breather Reinstall the rear driveshaft with factory straps and hardware Tighten all hardware to factory specifications The front crossover exhaust pipe will be close to the front driveshaft when installed Loosely fit the front driveshaft and mark the area just below the driveshaft on the crossover pipe Squish in the top part of the exhaust tube approximately 1 4 to create clearance when the driveshaft is installed Use a clamp with support on the bottom side or use a torch to heat the area and dent in with a hammer Fig 41a 2 Tip When the front driveshaft is installed there will be approximately a 1 4 gap this is not enough clearance when in 4wd and the crossover pipe must be modified Reinstall the front driveshaft Use factory hardware with loc tite at the transfer case output Attach driveshaft to the front differential with new 10mm bolts BP 828 with loc tite and driveshaft spacer 02821 Torque to 45 ft lbs 416 FIG 4
14. lower bolts are torqued to 170 ft lbs after alignment OPTIONAL WELD ON STEERING STOPS 93 Included are optional weld on steering stops These can be welded to the lower control arm to reduce rubbing or eliminate any interference issues that my be present at full steering lock Disconnect the batter prep lower control arm for welding weld steering stop onto the lower control arm as shown Coat with paint when completed Fig 48a 48b 27 FIG 48A m OPTIONAL FRONT FENDERWELL MODIFICATION FOR TIRE CLEARANCE 94 Remove the 4 lower T 15 Torx head bolts that hold the fenderwell to the plastic support piece Fig 49a 49b FIG 49B 95 Trim back to the first full support rib Remove this section from the support piece Fig 50a 506 Q Tip A sawzall works well for trimming the factory plastic A box cutter style knife with the blade heated by a MAP gas propane torch cuts the factory plastic bumper cover nicely and leaves a good smooth finish 28 FIG 504 __ 16508 96 Remove the nut clips from the trimmed piece Hold the inner fenderwell up to the front support piece and drill new holes for the mounting hardware at a convenient location Attach the inner fender to the plastic support piece with factory torx bit hardware Trim a slight amount on the plastic bumper cover for additional clearance if required Fig 51a 51b FIG 51 FIGS1B RIVET NUT INSTALLATION INSTRUCTIONS RIVET NUT SIZING 1 Verify t
15. ng for consistent rivet nut deformation to see the threads are square and centered to the rivet nut Fig 3 FIGURE 3 WE WANT TO SEE YOUR RIDE Grab photos of your BDS equipped truck in action and send them in for a chance to be featured Send it in to our Bad Ass Rides customer gallery at bds suspension com bar and post them on the BDS Fan Page on Facebook at facebook com BDSSuspensions Don t forget about your BDS swag BDS offers t shirts hoodies decals and more available on the BDS website or through your local BDS distributor Thank you for choosing BDS Suspension For questions technical support and warranty issues relating to this BDS Suspension product please contact your distributor installer before contacting BDS Suspension directly 72 31
16. ng the frame pocket modification Fig 20 32 Install the new differential drop brackets 02809 DRV 02810 PASS with new 14mm x 30mm bolts and washers 681 to the frame Brackets will attach to the front cross member hardware attach with 5 8 nuts and washers Push the differential brackets all the way towards the front of the vehicle and tighten 14mm hardware to 95 ft lbs Leave 5 8 hardware loose Fig 21 33 Install differential to the new drop brackets with 9 16 x 3 1 2 hardware BP 681 Fig 22a 22b FIG 22 34 Raise the rear differential mount Install rear cross member with new 5 8 x 4 1 2 hardware 680 Attach differential to rear crossmember with new 9 16 x 3 1 2 hardware 681 Fig 23 FIG 23 35 Reconnect the differential breather line and the central axle disconnect wiring harness BUMP STOP INSTALLATION 36 Remove the factory bump stops use a hammer and a punch to get the bump stops to pop out of the factory cup Fig 24 FIG 24 37 Clearance the hole inside the bump stop cup to 11 16 a step drill is highly recommended if one is not available a rotary die grinder can be used Insert and seat 1 2 rivet nut Follow rivet nut installation at the end of the instruction sheet Fig 25 Q Tip See the end of the instruction sheet for how to install 1 2 rivet nuts There is one extra rivet nut provided in the kit incase one is installed incorrectly
17. ns Always wear your seat belt BEFORE INSTALLATION Special literature required OE Service Manual for model year of vehicle Refer to manual for proper disassembly reassembly procedures of OE and related components Adhere to recommendations when replacement fasteners retainers and keepers are called out in the OE manual 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 Post suspension system vehicles may experience drive line vibrations Angles may require tuning slider on shaft may require replacement shafts may need to be lengthened or trued and U joints may need to be replaced Secure and properly block vehicle prior to installation of BDS Suspension components Always wear safety glasses when using power tools If installation is to be performed without a hoist BDS Suspension Co recommends rear alterations first Due to payload options and initial ride height variances the amount of lift is a base figure Final ride height dimensions may vary in accordance to original vehicle attitude Always measure the attitude prior to beginning installation i X 4 N 7 7 gii UE 305 55 20 5 1 4 Backspace Wheel BEFORE YOU DRIVE Check all fasteners for proper t
18. orque Check to ensure for adequate clearance between all rotating 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 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 replacement hoses if needed can be purchased from a local parts supplier Perform head light check and adjustment Re torque all fasteners after 500 miles Always inspect fasteners and components during routine servicing 021670 021671DRV Knuckle Box Kit Box Kit 021673 Part Qty Description Part Qty Description 02800 1 Steering Knuckle DRV 021670 02811 1 Colorado Diff Skid Plate BDS 02801 1 Steering Knuckle Pass 021671 911122 2 Sway Bar Link Colorado 401 1830 1 Tie Rod End 021670 021671 02813 1 Colorado Bump Stop BDS drv 965 1 9 16 SAE washer 021670 021671 02814 1 Colorado Bump Stop BDS pass B1129 1 Bag Kit Sway Bar Bump Stops Box Kit 021672 4805G8 8 Sway Bar Link Bushing Part Qty Description 682 1 Bolt Pack Sway Bar Links 02807 1 Colorado Front x member BDS 8 7 16 USS Flat Washer Grade 9 yellow zinc 02808 1 Colorado Rear
19. the tie rod end Use stock hardware Tighten lower ball joint to 92 ft lbs upper ball joint to 70 ft lbs tie rod end to 44 ft lbs CV nut to 177 ft lbs 49 Reinstall the brake rotors with the torx bit holding the rotor to the hub assembly 50 Reinstall the brake calipers with factory hardware Tighten to 148 ft lbs 51 Clean any debris from the ABS sensors Install the ABS sensors into the steering knuckle with factory hardware Tighten to 11 ft lbs Fig 31a 52 Attach the ABS sensor wire to the back of the steering knuckle with a new cable clamp BP 683 and factory hardware The grommet on the ABS wire can be slid by spraying it with silicone spray Ensure there is adequate slack through wheel travel and full steering range of motion ensure the ABS wire can not rub on the CV shaft Fig 31b _ 6 FIG31B 53 Install new sway bar links 911122 with 8 washers and 8 bushings 48050 as shown Attach with 4 7 16 nylock nuts 682 Fig 32 Tighten until the bushings begin to swell do NOT over tighten the hardware 20 0 BRAKE LINE ABS WIRE MODIFICATION 54 Carefully form the brake line to allow the mounting end to attach to the side of the bump stop cup Reinstall the factory retaining clip to hold the brake line in place 55 Reform the hard line slightly to create clearance from any sharp edges Attach brake line to the side of the frame rail and the factory bump stop bracket by drilling 7 32
20. the upper strut mount Do NOT remove the center nut that holds the strut assembly together DIFFERENTIAL REMOVAL 20 Disconnect the differential breather hose from the differential and the central axle disconnect wiring harness Fig 11 12 2 Tip The differential breather line is tough to access wait until the differential is lowered a slight amount to pull the hose off if necessary FIG 11 FIG 12 21 Disconnect the front drive shaft from the differential Discard front mounting hardware it will not be reused Fig 13 Disconnect the front driveshaft from the transfer case SAVE hardware it will be reused Remove the front driveshaft from the vehicle 22 Remove the rear differential mounting bolt Fig 14 Remove the rear factory cross member Fig 15 Discard hardware it will not be reused FIG 14 FIG 15 wee gt a iF 23 Support the differential with a hydraulic jack transmission jack preferred Remove the remaining two front mounting bolts and lower the differential from the vehicle Fig 16 FIG 16 FRAME MODIFICATION 24 The front factory lower control arm pocket will need to be modified to allow the new crossmember to be installed FRONT POCKET MODIFICATION 25 Measure down 1 1 8 from the BOTTOM of the factory slot on both the front and back sides make a horizontal mark Connect these two lines by measuring in towards the center of the vehicle 1 1 8 an
21. unt with new 3 8 nylock nuts and washers 943 Attach lower mount to the lower control arm with factory bolts Tighten the 3 8 hardware to 35 ft lbs do NOT tighten the lower mount at this time It will be done at the end of the installation with the vehicle weight on the ground Fig 29a 29b FIG 29 _ 29 44 Optional Install coilover assembly so that the hose is to the rear of the vehicle and loops below the upper control arm Attach reservoir bracket and upper mount with included hardware Use factory lower hardware to attach the bottom Tighten upper hardware to 40 ft lbs lower hardware to 95 ft lbs Attach reservoir to the bracket with included hose clamps Cycle the upper control arm to ensure there will be clearance between the hose at full droop and clearance to the reservoir under compression KNUCKLE ASSEMBLY 45 Remove the factory hub and dust shield from the stock knuckles Transfer them over to the new steering knuckle Note You MUST install the dust shield failure to do so will cause ABS problems Fig 30 46 Apply loctite to the factory hub bolts and tighten hub hardware to 133 ft lbs 47 Install grease zerk into new tie rod ends Install the new tie rod ends onto the factory inner tie rods 48 Install new steering knuckle assembly to the lower control arm and run the CV shaft through the hub Attach upper ball joint and new tie rod end to knuckle assembly use the included washer under the nut for
22. wn Fig 44a 44b 25 FIG 44 80 Working on one side of the vehicle at a time Support the axle with a hydraulic jack remove the factory u bolts Remove the stock shocks retain hardware 81 Lower the axle and install new lift block Install new u bolts with nuts and washers Snug but do not tighten at this time Fig 45a 45b FIG 45 FIG 45B 82 Repeat block installation on opposite side of vehicle 83 Grease and install new bushings and sleeves into shocks Install the shocks with factory hardware Tighten to 55 ft lbs 84 Lower the axle and check for adequate slack in the brake lines and abs wire adjust as necessary 85 Slide the grommet on the ABS wire the passenger s side by the exhaust up use silicone spray to allow the grommet to slide easily Slide the ABS wire heat shield tubing up and secure with a zip tie Fig 46a 86 Attach the ABS wire to the u bolt with included zip tie Fig 46b repeat on opposite side 26 021672 FIG 468 87 Use two zip ties secure the e brake cables together in front of where the old e brake cable guide bracket contacted the cables Fig 47 FIG 47 88 Install wheels tighten lug nuts to factory specifications 89 Lower the vehicle to the ground and torque u bolts to 110 ft lbs 90 Reconnect the battery 91 Recheck all hardware for proper torque Check again after 500 miles 92 front end alignment is now required Ensure the
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