CAUTION WARNING WARNING WARNING
Contents
1. 8 1 4 20 Tennerman Nut 14100 eese 4 1 4 20 Hex Locknut 114021 4 1 4 20 x 1 Carriage Head Bolt 14100CCGE 4 3 4 O D x 1 1 4 Lg Sleeve 53 4 3 8 16 x 2 1 2 Lg hex Head Bolt 838212CHHC 4 3 32 x 1 1 4 Lg Cotter Key 332114 2 1 8 x 1 1 4 Lg Cotter Key 180114 3 FRONT INSTALLATION INSTRUCTIONS 1 Block and secure vehicle Disconnect battery Remove battery and box on late models to access vacuum shift actuator On early models actuator is located rearward of battery not requiring removal of battery Remove spring clip and remove cable from actuator on both models 2 Raise vehicle with hydraulic jack or equivalent and place jack stands under frame away from lower control arm anchors Remove wheels skid plates and front sway bar 3 Measure length of exposed thread on torsion bar adjustment bolts Record figures here DVR 55 for use when reassembling Using J22517C or J36202 torsion bar tool or equivalent unload torsion bars 4 Tag torsion bars DVR front and PASS front respectively Remove rear torsion bar crossmember and torsion bars Note On some models loosening or removal of exhaust system may be required to remove torsion bar crossmember 5 Using hydraulic jack or equivalent support lower control arm Dislodge and unplug ABS wire at frame when so eq2. Fig 21 21 Install inner tie rod ends into replacement relay rod S Torque to OE specification Install relay rod assembly Torque idler and pitman arm nuts to OE specifications Install cotter pins provided Fig 22 m ats lr oua LE e mc at na 7 ean 22 Make steering sweep checking clearance between relay rod and differential ear on DVR side Fig 23 Warning Minimum acceptable clearance 7 16 23 If relay rod to differential clearance is adequate proceed to step 25 If not you must lower assembly to gain clearance between relay rod and differential Warning Do not sacrifice steering clearance for pinion angle Ensure engagement heights of R on CR and CL are equal 24 Torque 7 16 and 12mm fasteners in assembly R to specification 25 Torque 1 2 x 1 1 2 bolts retaining 940201 to PASS chassis mount Torque OE fasteners retaining differential to 940201 Note crowding differential while tightening fasteners may increase clearance between receiver CL and differential Refer to step 20 26 Torque to specification 1 2 x 3 bolt retaining DVR side front differential mount Torque OE fasteners mounting differential to drop brackets 27 Make steering sweep Again check clearance between relay rod and differential ear Refer to Fig 23 Warning Minimum acceptable clearance 7 16 In the event that clearance dimensio
3. 8 0 ce S CC EN 1 1 1 1 1 1 1 C 2 5 E 0 0 07020 00 vn co cos EMBED NL ee ee Fig 30 30 Install bracket LR in DVR side upper rear OE control arm receiver Use 1 2 x 4 bolt washers nuts tabs LP and 1 11 16 sleeve provided Note LP fits one way into OE D bolt adjustment tab Reaming center of OE D slots will ease installation of cross bolt Do not tighten fasteners at this time Fig 31 Repeat on PASS side using bracket RR 31 Align holes in bottom of LR with holes in CL Insert two 7 16 x 1 1 4 bolts and washers through LR Install washers and nuts provided on inside of CL Note it may be necessary to ream top 7 16 hole to install bolt Torque 7 16 bolts first then 1 2 cross bolt Fig 32 Repeat step on PASS side engaging bracket RR and 32 On early models with closed top upper rear receivers using hole in top of brackets LR and RR respectively to index drill 1 2 hole in top of OE bracket Install 1 2 x 1 1 2 bolt washer and nut provided Shim gap between LR and OE receiver with one LP tab Tighten fasteners to specification Fig 33 33 Install bracket LF in DVR side upper front control arm receiver Utilize 1 2 x 4 bolt washers locator tabs 1 11 16 sleeve
4. 2265 Crosswind Drive Prescott AZ 86301 928 636 3175 www p a g net 10 5 SSV 1983 1994 5 10 5 4WD Pickup and Blazer 4 Suspension Lift INSTALLATION INSTRUCTIONS N WARNING 1 Read and understand all instructions warnings and cautions in these instructions your owner s manual and related service manuals before 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 4 Many sta
5. 41 Insert upper control arm into TM brackets Check for interference at rear engagement If necessary remove upper control arms and relieve inside edge and dress rear bottom of upper A arms on both PASS and DVH side arms to eliminate interference Fig 42 42 Reinstall upper A arms into TM brackets using OE D bolts Engage ball joint do not tighten at this time Check clearance between A arm and shock with D bolts adjusted inward as far as possible Minimum clearance to shock 1 8 Using template supplied relieve and dress control arm to gain clearance All corners should be radiused and smooth Do not use torch Fig 43 oe m RR unl wy Put a m mh Fig 43 _ 43 Reinstall control arm with OE D bolts facing inside out shock removal will be necessary Refer to step 5 location direction of D bolts Centrally locate D bolt in adjustment slot with major portion down Run up D bolts do not tighten Engage ball joint to knuckle and torque to specification Reinstall shock 44 Reinstall brake hose ABS lead to control arm using OE fasteners Turn knuckle assembly lock to lock and note movement and position of brake hose and ABS lead Ensure ABS lead hose routing is clean and secure Torque to specification See also step 40 Repeat steps 38 45 on opposite side 45 Install tie rod sleeves TRX Thread engagement of inner and outer t
6. CR and CL Install and tighten 7 16 x 1 1 4 bolts washers and nuts provided Insert 12mm x 90mm bolt and washer supplied through CL into differential ear and crossmember retain with OE nut Run up 7 16 and 12mm bolts Do not tighten at this time Fig 19A Note slots in CR and CL at engagement points Raise differential assembly assembly R for late models Lower assembly R for early models Maintain identical engagement heights on CR and CL with assembly Fig 19A Note If you perform step 9 drill two 17 64 holes 5 in from ends of crossmember Fig 198 Install R with 17 64 holes up After final adjustment of assembly step 28 form brake lines over pinion reattach brake line using drilled holes and OE bolts gee 19 Check clearance between differential DVR side lower control arm receiver Minimum clearance 3 16 clearance 15 less than 3 16 relieve and dress receiver and or differential fins to gain clearance Fig 20 20 Using an inclinometer check pinion to transfer case angles Maximum variance 1 1 2 degrees Adjust angle by raising or lowering crossmember R and differential assembly Fig 21 Maintain identical engagement heights on CR and CL with assembly Lh UE Pea a daz ogre aA Hee 5 2
7. CT10LF 1 Upper Control Arm Brkt Front Pass CT10RF 1 Upper Control Arm Brkt Rear Dvr CT10OLR 1 Upper Control Arm Brkt Rear Pass CT10RR 1 Front Diff Brkt Pass 950113 1 Front Diff Brkt Dvr Upper Straight 910904 1 Front Diff Brkt Pass Upper Offset 910905 1 Front Anti Sway Bar Brkt 84 94 CT10SBD 2 Torsion Bar Crossmember Brkt Dvr CT10FD 1 Torsion Bar Crossmember Brkt Pass CT10FP 1 Rear Crossmember Brkt CT10R 1 Steering Center Link 1051 1 Tie rod Adjusting Sleeve CT10TRX 2 9 16 18 x 2 5 8 x 7 3 8 sq U Bolt 0918258Q 4 Shock Absorbers Front 52620 W 7 62620 W SS 72620 W SSV 2 Rear 55430 W N7 65430 W SS 75430 W SSV 2 Hardware 7 8 O D x 2 Lg Sleeve 34 4 7 8 O D x 1 11 16 Lg Sleeve 66 4 7 8 O D x 1 1 4 Lg Sleeve 67 1 7 8 O D x 3 8 Lg Sleeve 60 1 1 2 Sq Washer CT10OLP 10 1 2 Channel Brkt 071057 aa 2 3 Relocation Brkt 2301 6 4 2
8. VN 1680 CT10SBD FRONT OF VEHICLE 2620 SSV CT10TRX 06 26 02 0918258Q 75430 SSV INSTRUCTION BOOKLET 14 CT10 CT15 UPPER CONTROL ARM SHOCK CLEARANCE TEMPLATE Area to be removed Locating Holes Inner edge of Control Arm Cut template along line and remove the shaded area Cut out 2 holes to use as locators on the arm Line up the template along inner edge of control arm Lay the template flush along the arm conforming to the curves in arm Line up 2 holes in template with the holes in control arm Mark area to be removed where shaded area was Invert for use on the other side 15 2265 Crosswind Drive Prescott AZ 86301 928 636 3175 www p a g net Performance Automotive Group Rev 7 97 10 99 7 02 5 03 2 06 07 06 Printed in U S A Form No ICT10 16
9. obtained prior to installation of the system 8 Thoroughly clean underside of vehicle prior to component installation Concentrate on areas receiving bracketry 9 If installation is to be performed without assistance of vehicle hoist Trail Master recommends performing rear alterations first GLOSSARY OF TERMS TM Trail Master DRV Driver s side of the vehicle PASS Passengers side of the vehicle OE Original equipment SRS Supplemental Restraint System TORQUE SPECIFICATIONS VAFASTENERS 10 6 5 16 FASTENERS 2 irai n uad ara d iw uaa e vac 17 LBS 3 8 FASTENERS 30 LBS 7 16 14 FASTENERS 50 LBS 7 16 20 FASTENERS 55 85 1 2 13 FASTENERS 75 LBS 1 2 U BOLTS pA 65 80 LBS 9 16 110 LBS 9 16 GRADE 8 FASTENERS 170 LBS 75 90 LBS 5 8 FASTENERS 150 LBS 5 8 U BOLTS 2 85 110 LBS 0 ee 175 LBS PARTS LIST Bracketry Upper Spring U Bolt Plate CT10P 2 Spring Perch Axle Brkt 607105 2 Lower Control Arm Brkt Rear Dvr CT10CL 1 Lower Control Arm Brkt Rear Pass CT10CR 1 Lower Control Arm Brkt Front Universal CT10D 2 Upper Control Arm Brkt Front Dvr
10. Shaped Brake Line Brkt T86FBB 1 9 16 18 Hex high Nut N96FH 8 9 16 12 x 3 1 2 Hex Head bolt 96312 4 9 16 SAE Flat Washer 965 8 9 16 12 Hex Lock Nut N96SCL 4 1 2 13 x 4 Hex Head Bolt 12400CHHC 4 1 2 13 x Hex Head Bolt 12300CHH0O 1 1 2 13 x 1 1 2 Hex Head Bolt 12112CHH0O 10 1 2 13 x 1 1 4 Hex Head Bolt 121140110 4 1 2 13 Hex Locknut N120L 19 12mm 1 75 x 90mm Hex Head Bolt 12M090H1765 1 7 16 14 x 1 1 4 Hex Head Bolt 76114CHHO 9 1 2 x 12mm Flat Washer 12 42 7 16 14 Hex ieiuna poto pra Sato td ae nece tendere osea eheu 9 3 8 16 x 1 1 4 Hex Head Bolt 5 3 8 16 x 1 1 4 Self Tapping Hex Head Bolt 38114HWHT 2 5 16 Flat Washer W56F 22 3 8 16 Hex Locknut N38CL nneeeeeeneennnnennnnnennnnnnnnnnnnnnn 9 9 16 Flat Washer W96F 8 3 8 Flat Washer 38 20 5 16 18 x 1 Hex Head Bolt 56100CHHO 2 5 16 18 Hex Locknut N56CL esses 2 1 4 amp 5 16 Flat Washer W14F
11. and nut provided Install 1 2 x 1 1 4 bolt washers and nut through hole in top of OE bracket and bracket LF Do not tighten fasteners at this time Fig 34 Note Reaming of OE holes may be necessary to obtain a good fit between OE receiver and TM brackets Using bracket RF repeat step on PASS side 34 Insert upper control arm into brackets LF and LR Run up 1 2 x 1 1 4 bolt in top of bracket LF and receiver Using hole in bracket LF as template drill 1 2 hole through frame Insert 1 2 x 1 1 4 bolt and washer through LF Place bracket BP over bolt inside frame Install nut into channel side of and tighten to specification Tighten cross and top bolt to specification Fig 35 Remove control arm Note it may be necessary to tune OE front bracket to facilitate installation of control arm Repeat procedure on PASS side using corresponding control arm TA Fig 35 35 Install brackets D into front OE control arm receivers Utilize 9 16 x 3 1 2 bolts washers 1 15 16 sleeves and nuts Brackets should fit flush with bottom of frame Note lt may be necessary to dress frame to obtain flush fit Fig 36A Using bracket D as template drill two 1 2 holes in flat of frame for each bracket as indicated Fig 36B Install 1 2 x 1 1 2 bolts washers and nuts Torque 1 2 fasteners first followed by 9 16 cross bolts to specification 36 Install OE co
12. areas to cut on OE bracket prior to actual cutting Cut DVR lower rear control arm receiver front and rear surfaces vertically 3 8 toward inside of vehicle from control arm hole Join front and rear cuts with horizontal cut Fig 14 You should now have removed rear OE differential mount Dress to accommodate bracket CL 14 Install DVR side front differential mount using straight bracket 910904 as the outer extension Use offset bracket 910905 as the inner mount extension Insert 1 2 x 3 bolt 1 1 4 sleeve washers and nut provided into upper frame pocket Fig 15 Do not tighten fasteners at this time 15 Install bracket 950113 to PASS side differential chassis mount Utilize two 1 2 x 1 1 2 bolts washers and nuts provided Loosely remount differential to drop brackets using OE fasteners Fig 16 Do not tighten fasteners at this time 16 Install bracket CR into PASS side lower rear control arm receiver Use 1 15 16 spacer 9 16 x 3 1 2 bolt washers and nut provided Fig 17 Note CR must move freely Do not tighten fasteners at this time 17 Install bracket CL into DVR side lower rear control arm receiver Use 1 15 16 spacer 9 16 x 3 1 2 bolt washers and nut provided Bracket CL will also engage rear differential mount Fig 18 Note CL must move freely Do not tighten fasteners at this time 18 Join crossmember R open side rearward to brackets
13. brake lines to 1 4 stud and secure with washers and nut Fig 3R 4 Clamp spring pack Remove center pin invert pin torque to specification 5 Install brackets SP onto axle short end forward Install springs over axle attach spring ends using OE bolts Run up do not tighten anchor bolts at this time Install u bolts placing TM bracket P atop spring and OE u bolt plate on bottom of axle Fig 5R Use 9 16 high nuts and OE washers to retain Run up Crowd OE u bolt plates rearward to ensure clearance for installation of larger bodied shocks provided Torque u bolts to specification lt CT10SP Axle Tube Spring Plate 7 gt FRONT OF TRUCK Fig 5R 6 Install shocks Torque OE mount fasteners to specification Check clearance between shock body and axle tube Minimum clearance 1 4 Slot holes in OE u bolt plate if clearance 15 insufficient Install wheels and tires Torque to specification 7 Lower vehicle to ground Torque spring hanger and shackle fasteners to specification Recheck all fasteners for their correct torque Extended Cab Only Carrier bearing crossmember relocation 1 Support rear drive shaft assembly Remove bolts mounting bearing to crossmember 2 Remove fasteners mounting crossmember to chassis 3 Relocate crossmember under frame using 1 1 4 spacers between frame and crossmember Retain crossmember to frame using 3 8 x 2 1 2 long bol
14. etorque all fasteners Check brake lines for damage Check steering clearances Check to ensure there is adequate clearance between all rotating mobile and fixed members 56 Align front end Set torsion bars to OE Z height Align to OE specifications SAFETY NOTE after setting toe ensure DVR side inner tie rod sleeve clamp bolt assembly is on bottom This procedure will ensure steering clearance at differential REAR INSTALLATION INSTRUCTIONS 1 Block and secure vehicle Remove shocks Using hydraulic jack or equivalent raise rear of vehicle Place jack stands under frame on each side in front of spring hangers Remove wheels and tires 2 Remove retainer nut holding brake line to frame bracket Slit OE bracket with saw DO NOT cause abrasion to brake line Bend bracket open remove line Close bend Install bracket BB using 3 8 x 1 1 4 bolt washers and nut provided Reinstall line into BB and tighten OE line retainer nut Fig 2R On 1994 vehicles remove bolts retaining emergency brake cable to frame at the front spring eye Fig 2R 3 Support rear axle Remove spring u bolts Remove springs Lower axle On 1994 models remove bolts retaining emergency brake cables to frame above front spring hanger Insert 1 4 x 1 carriage bolts into square hole of 1 x 3 flat brackets WS supplied Tighten tennerman nut to hold bolt in place Mount WS brackets with 1 4 bolt down to frame using OE bolts Mount
15. hassis Carefully remove differential assembly from chassis 11 Important installation Note Trail Master recommends all modifications to OE bracketry be performed with plasma cutting devices Sawz All or cut off wheel The use of a cutting torch is not recommended Check position of fuel brake and other lines in area prior to cutting Insulate or move to alleviate damage For safety never work alone Have fire extinguisher readily available 12 CAUTION Fuel lines are located inside frame on driver side exercise caution in this area Scribe areas to be cut on OE bracket prior to actual cutting To remove bottom section of OE rear upper control arm bracket Cut the extension stop gusset off flush with frame Il Cut front surface of bracket 1 2 below the bottom of frame horizontally out 2 Cut vertically down bracket to intersect horizontal cut Fig 12A II Cut rear side of bracket flush with frame 3 4 up Cut bracket horizontally out 2 from this point Cut bracket vertically to intersect horizontal cut and outside edge of receiver Fig 12B You should now have removed the OE extended stop IV Trim front leg of lower receiver flush with outside of frame Tune leg rearward Fig 12C Dress and final fit STEP 31 to accommodate installation of brackets LR and RR respectively Repeat step 12 on opposite side V Cut OE steering stabilizer chassis mount flush withframe Fig 12D 13 Scribe
16. ie rod ends to TRX must be identical Initial TRX adjustment 24 7 16 center center from inner to outer tie rod ends Engage outer tie rod ends to knuckles torque to specification Install cotter keys Safety Note inner DVR side TRX clamp bolt must be rotated to bottom Fig 46 This procedure will ensure clearance between clamp and differential 48 Install OE torsion bar crossmember onto FD and FP using OE fasteners Torque TM and OE fasteners to specification 49 Install torsion bars Reload bars using the J36202 torsion bar tool Set adjustment bolts to initial setting Le pce e M obtained from step 3 Note Minor torsion bar adjustment Fig 46 B may be required to level vehicle side to side Set trim height within OE specifications 46 Install sway bar extension brackets SBD to frame utilizing 3 8 x 1 1 4 bolts washers and nuts Do not 50 Vacuum actuator relocation on early models move tighten Install sway bar anchors to A arms Install bar to actuator from side of fender to inner fender Using OE SBD Fig 47 Tighten all fasteners to specification bracket as a template drill two 5 16 holes into inner fender Install 5 16 x 1 bolts washers and nuts supplied NOTE Lifting A arms will ease installation of sway bar Tighten to specification Fig 51A Relocate cable over heater hoses Reinstall cable and clip Ensure relocation of kcu 0 48 actuator provides adeq
17. ired OE service manual for model year of vehicle Necessary tools OTC J25517C or J 36202 torsion bar tool ball joint and tie rod separators refer to GM manual plasma cutting machine or cutoff wheel disc grinder die grinder with carbide burr or equivalent and inclinometer Additional tools unique to installation are mentioned in the following instructions 3 System will not work on vehicles with ZR2 or highrider package 4 Removal of portions of OE bracketry are necessary to accommodate this suspension system Refer to FRONT INSTALLATION steps 11 14 for details 5 Modification of exhaust crossover necessary to accommodate lowering of differential Trail Master offers two kits to perform this modification Part CX48 for the 4 3 liter models up to 1992 Part CX28 for the 2 8 liter models Each kit comes complete with instructions and hardware An experienced exhaust shop can perform this modification 6 Ride Height Due to payload options and initial ride height variances of the S vehicle the designation of 4 lift is a ground figure With OE torsion bar settings your vehicle will retain it s stock attitude Final ride height dimensions may vary in accordance to the original vehicle attitude 7 Adhere to recommendations when replacement fasteners retainers and keepers are called out in OE manual This system may not include all replacement fasteners recommended by the OE manual Additional replacement fasteners should be
18. is 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 in fasteners becoming loose over time 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 A N 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 Not recommended for 1983 vehicles if installed on 1983 vehicles purchase of an additional 8025 sway bar kit and 8024 D bolt kit required 2 Special literature or tools requ
19. mpression stops on bottom of brackets LR and RR Torque to specification Fig 37 37 Using hydraulic jack or equivalent raise lower control arm assembly into TM brackets Install and run up OE control arm bolts Engage inner to differential mating flange Install OE fasteners torque to specification Install brake caliper and caliper bolts torque to specification 38 Insert the 1 4 x 1 carriage bolts into square hole of 1 x 3 flat brackets WS Tighten tennerman nut to hold bolt in place Attach upper end of bracket to frame at original brake line mount point using OE fastener Remove bolts and clamps retaining brake lines to frame at shock towers Carefully acquire slack in brake lines Carefully extend brake line outward and down and mount to 1 4 bolt in extension bracket DO NOT KINK LINE Remount lines to frame using OE clamps and bolts Fig 39 Fig 39 39 Vehicles with ABS brakes will require loosening clamps retaining ABS wires to frame Acquire sufficient slack in frame lead to reconnect knuckle sensor lead Remove excess slack in ABS leads using OE clamps and tie wraps provided Ensure relocation is clean and secure See also step 45 40 Install shocks supplied Use OE bolts washers and nut Shim shock forward if necessary remove upper control arms and using 1 2 washers provided to gain clearance between shock body and C V Fig 41 Torque OE fasteners to specification Fig 41
20. n 15 less than 7 16 you must revert to steps 23 27 If clearance measurement is sufficient torque 9 16 cross bolts in brackets CR and CL Continue to step 29 28 Check clearance between differential output flange and OE lower rear control arm receiver PASS and DVR side Minimum clearance 3 8 Dress receiver ear or tune to gain clearance Fig 29A Make diagonal measurement on rear of system as shown Fig 29B In the event that system fails to meet dimensional specification locate interference and alleviate Failure to meet this specification may result in the inability of the completed system to meet vehicle alignment specification Check clearance between front differential and engine oil pan It may be necessary to concave pan at PASS side axle tube flange to gain adequate clearance A minimum clearance of 1 2 inch between differential flange and engine oil pan is required _ 22 1 2 Approx Fig 298 29 Note position of ears on upper portion of bracket CL Measure and locate center of ears transfer coordinates to external surface of OE receiver Drill 1 2 hole through OE receiver and bracket CL in front and rear legs Install 7 16 sleeve in gap between bracket CL and front leg of OE receiver Install 1 2 x 1 1 2 bolt assemblies running front bolt through 7 16 sleeve Torque fasteners to specification Fig 30 Se ee ee ee ee eee nut E
21. ntrol Property damage or personal injury may result Large tire and wheel combinations may also alter soeedometer 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 Retain this and all information regarding your altered vehicle for future reference Thank you for choosing Trail Master For questions contact our Technical Assistance Department at 928 636 3175 PRODUCT SAFETY LABEL Supplied in kit is a safety warning label Install label inside cab Locate label in a highly visible location to all operators of this vehicle If label becomes lost or damaged contact Trail Master at 928 636 3175 for a replacement Rev 03 Copyright 07 06 Performance Automotive Group www p a g net 13 TRAIL MASTER CT10SSV SUSPENSION SYSTEM COMPONENT LAYOUT 0 WEIGHT 118 Ibs 2 boxes 72620 SSV CT10TRX CT10D CTIOLF n as
22. tes 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 N 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 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 recommends that th
23. ts washers and lock nuts 4 Remount bearing to crossmember using OE bolts Torque all fasteners to specification 12 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 Visually 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 wear on steering components leading to increased maintenance and greater risk of component failure including loss of steering co
24. uate slack in cable On late models with vacuum actuator located under battery relocate assembly over 1 OE hole toward inside of vehicle and reattach using OE fastener Using bracket as a template drill a 5 16 hole in inner fender and install second OE fastener Torque both to specification Plug OE 5 mount hole with 5 16 bolt washer and nut Reinstall m actuator cable and clip Ensure relocation of actuator provides adequate slack cable Reinstall battery and box Fig 51B Fig 47 47 NOTE Fuel lines run inside frame on DVR side Use caution when performing this step Dress welds on bottom of frame Ream OE torsion mount frame holes to 7 16 Install bracket FD on DVR side of vehicle using 7 16 x 1 1 4 bolts washers and nuts provided Fig 48 Use 1 2 washers to shim space between frame and FD if so required Using front hole in FD as guide drill 5 16 in frame Install 3 8 x 1 self tapping bolt provided Repeat using FP on PASS side 10 Fig 518 51 Perform exhaust modification See Pre Installation notes 52 Reinstall drive shaft Check clearance at OE crossmember Remove crossmember and press front edge or peen to gain clearance Minimum clearance 1 2 Fig 53 Fig 53 53 Install wheels and tires Torque nuts to specifications 54 Lower vehicle to ground Torque lower control arm anchor bolts Torque upper control arm D bolts to specification 55 R
25. uipped Remove fasteners attaching brake line and ABS wire to frame and upper control arm Remove brake caliper from knuckle and safely support Do not allow caliper to hang by hose 6 Remove fasteners retaining DVR inner C V joint to differential flange Disengage flange from differential Remove shock Disengage outer tie rod from knuckle Disengage upper ball joint from knuckle Remove D bolts from upper control arm Remove upper arm from chassis 7 Remove bolts attaching lower control arm to frame Remove arm knuckle assembly from chassis Repeat steps 5 through 7 on opposite side 8 Disengage inner tie rods from OE relay rod Remove tie rod sleeves from tie rod ends Note tie rod ends are right and left hand threaded Tag for location i e inner outer DVR or PASS Disengage OE relay rod from pitman and idler arm Remove front compression stops located below rear upper control arm receivers Note position for installation on TM brackets 9 Early model S vehicles have a crossmember located directly rear of engine Fig 9 This crossmember must be removed Remove brake line fasteners attached to crossmember Remove crossmember fasteners and crossmember Remove front drive shaft Do not allow slider yoke to disengage from shaft Fig 9 10 Using hydraulic jacks or equivalent support differential Disconnect the lock indicator wire plug from differential Remove fasteners mounting differential and actuator cable to c
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