Read and understand all instructions and warnings

T2502 Installation Instructions
2007-2017 Toyota Tundra 4wd
5" Suspension System
Read and understand all instructions and warnings prior to installation of product
and operation of vehicle.
Zone Offroad Products 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. Minimum tool requirements
include the following: Assorted metric and standard wrenches, hammer, hydraulic floor jack and a set of jack stands. See the "Special
Tools Required" section for additional tools needed to complete this installation properly and safely.
»»P
roduct
Safety Warning
Certain Zone 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. Zone Offroad Products 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 conditions.
Always wear your seat belt.
Difficulty Level
»»T
echnical
Support
www.zoneoffroad.com may have additional information about this product including the latest instructions, videos, photos, etc.
Send an e-mail to tech-zone@sporttruckusainc.com detailing your issue for a quick response.
888.998.ZONE Call to speak directly with Zone tech support.
»»P
re-Installation
Notes
easy 1
2
3 4 5 difficult
Estimated installation: 8 hours
Special Tools Required
-Reciprocating Saw or Equivalent
-Welder
Tire/Wheel Fitment
Tire:
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.
35 x 12.50
2.Adhere to recommendations when replacement fasteners, retainers and keepers are called
out in the OE manual.
18x9 w/ 5.5" BS
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.
Wheel:
20x9 w/5.5-6.25" BS
4.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.
5.Secure and properly block vehicle prior to installation of Zone Offroad Products. Always wear safety glasses when using power tools.
6.If installation is to be performed without a hoist, Zone Offroad Products recommends rear alterations first.
7.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.
rev032117
»»Zone Offroad Products • 491 W. Garfield Ave., Coldwater, MI 49036 • 888.998.ZONE • www.zoneoffroad.
com
Kit Contents
*Important* Verify you have all of the kit components before beginning installation.
QtyPart
1
1
2
2
1
1
4
4
1
1
1
1
1
1
2
Steering Knuckle (drv)
Steering Knuckle (pass)
Tie Rod End
Steering Stop
Front Crossmember
Rear Crossmember
Cam Washer - Front Crossmember
Cam Washer - Rear Crossmember
Bolt Pack - Crossmembers
Weld-in Plate (pass)
Weld-in Plate (drv)
1/4" Breather Hose - 8" Long
1/8" Vacuum Line - 10" Long
Bolt Pack - Differential Mounts
Sway Bar Drop Bracket
T2502 Installation - pg. 2
1
2
1
1
2
2
1
2
4
1
2
4
1
1
1
Bolt Pack - Sway Bar Drop
Bump Stop
Bump Stop Mount (drv)
Bump Stop Mount (pass)
Front Brake Line Relocation Brkt
Front ABS Line Wire Clamp
Bolt Pack - Bump Stops/Misc.
Strut Extension Assembly
Crush Sleeve - 0.625 x 0.109 x 0.560
Bolt Pack - Strut Extension
3" Lift Block
9/16" x 2-1/2" x 10" U-bolt
Bolt Pack - Rear Kit
ABS Line Bracket
Brake Line Bracket
INSTALLATION INSTRUCTIONS
»»P
re-Installation
Notes
1.
Steering Disassembly/Assembly: According to the Toyota factory service
manual, the factory steering rack should not be turned to full extension (full
lock) while the tie rod ends are disconnected from the steering knuckles. Fully
extending the steering rack may damage the internal oil seals and cause leakage
and/or failure of the steering rack. We highly recommend locking the steering
wheel in the center position before beginning the installation.
2.
Park the vehicle on a flat, clean surface and block the rear wheels for safety.
3.
Disconnect the positive and negative battery cables - minor welding is required
during the installation.
»»F
ront Installation
1.
Raise the front of the vehicle and support with jack stands under the frame rails.
2.
Remove the wheels.
3.
Remove the factory plastic mud flaps from the front and rear portions of the
front wheel well. These will not be reused.
4.
Locate and remove the front factory skid plate. Figure 1
Figure 1
5.
Loosen the tie rod end jam nuts Figure 2. The tie rod ends will be removed later
in the installation.
T2502 Installation - pg. 3
Figure 2
6.
Step 6 Note
See pre-installation note #1..
Remove the tie rod end cotter pin. Remove the nut from the tie rod end and
thread back on a couple of turns. Strike the steering knuckle near the tie rod end
to dislodge the taper Figure 3. Remove the nut and the tie rod end from the
knuckle. Save the nut and discard the cotter pin.
Figure 3
7.
Disconnect the sway bar links from the lower control arms. Figure 4. Save the
lower mount bolts.
Figure 4
T2502 Installation - pg. 4
8.
Note how the sway bar is oriented on the vehicle. Disconnect the sway bar
mounts from the frame rails and remove the sway bar from the vehicle. Figure 5A
Take care not to lose the plastic frame bushing spacers. Figure 5B Save mounting
hardware.
Figure 5A
Figure 5B
9.
Disconnect the brake line brackets Figures 6A, B from the steering knuckles (2
per knuckle). Save hardware.
Figure 6A
T2502 Installation - pg. 5
Figure 6B
10.
Disconnect the brake line bracket from the frame Figure 7. Save bolt. Remove
the ABS line from the retaining bracket on the upper control arm. Discard the
retaining bracket it will not be reused.
Figure 7
11.
T2502 Installation - pg. 6
Remove the ABS sensor bolt Figure 8A from the knuckle (requires a 5mm hex
socket). Carefully remove the sensor from the knuckle Figure 8B. It is held in
place by an o-ring. Take extra care not to damage the sensor. Save mounting
bolt.
Figure 8A
Figure 8B
12.
Remove the bolts mounting the brake caliper to the steering knuckle Figure 9.
Hang the caliper and the brake/ABS lines out of the way. Save caliper hardware.
Figure 9
13.
Remove the brake rotor from the hub.
T2502 Installation - pg. 7
14.
Remove the hub dust cap from the hub by carefully working around the lip with
a small chisel and hammer Figure 10. Take care not to overly deform the mounting lip so it can be reinstalled later.
Figure 10
15.
Remove the cotter pin and castellated nut cap from the end of the axle shaft. Remove the axle nut from the axle. Save the axle nut and cap Figure 11. Discard
the cotter pin (new one provided).
Figure 11
16.
T2502 Installation - pg. 8
Unseat the axle shaft from the knuckle. Use an air hammer with blunt nose
punch (recommended) or a hammer and punch, unseat the axle from the hub
Figure 12. A large rubber mallet can be used also, but make sure to thread the
axle nut on flush with the end of the axle to protect the threads.
Figure 12
17.
Disconnect the hub bolts from the steering knuckle. Figure 13A The bolts are
captive in the hub assembly. Remove the hub, brake dust shield and hub o-ring
from the steering knuckle and set aside Figure 13B.
Figure 13A
Figure 13B
T2502 Installation - pg. 9
18.
Remove the upper ball joint cotter pin and save. Remove the upper ball joint nut
and thread back on a couple of turns by hand. Strike the knuckle near the upper
ball joint to dislodge the ball joint taper Figure 14. Take care not to strike the
ball joint. Pull down on the upper control arm and remove the upper ball joint
nut. Save nut.
Figure 14
19.
Disconnect the steering knuckle from the lower ball joint mount. Remove the
two bolts Figure 15 and remove the knuckle from the vehicle. Save bolts and
knuckle.
Figure 15
20.
T2502 Installation - pg. 10
Loosen but do not remove the lower control arm cam bolts. On the front, loosen
the bolt from the front. On the rear, loosen the nut from the front Figure 16.
Figure 16
21.
Disconnect the lower strut mounting bolt and remove from the lower control
arm Figure 16. Allow the lower control arm to swing down. Save the strut
mount hardware.
Figure 17
22.
Remove the lower control arm cam bolts and remove the control arms from the
vehicle. Save arms and hardware.
23.
Locate the front differential actuator wire connector on the front passenger's side
of the differential. Push in on the retaining clip and pull the connector free from
the actuator Figure 18.
T2502 Installation - pg. 11
Figure 18
24.
Locate the differential vacuum and breather lines on the upper driver's side of
the differential Figure 19. Disconnect the lines from the hard lines at the frame.
Figure 19
T2502 Installation - pg. 12
25.
Disconnect the front driveshaft from the front differential by removing the four
mounting nuts. Save nuts. Pull the driveshaft free from the differential input
flange.
26.
With the help of an assistant, support the front differential with a proper jack.
Remove the outer bolt and inner nut mounting the rear differential bracket to the
frame. Remove the bolt mounting the rear differential bracket to the differential
and remove the bracket from the vehicle Figure 20A. Save bracket and hardware.
Remove the two bolts mounting the front differential brackets to the frame
Figure 20B and remove the differential from the vehicle.
Figure 20A
Figure 20B
27.
In order to clear the differential in its new lower position the factory rear frame
crossmember must be removed. On the driver's side make cut marks up the
front and back faces of the crossmember that extend from the bottom inside edge
of the control arm pocket Figure 21A. This line will be approximately 3-13/16"
from the front outer control arm pocket edge Figure 21B and 3-3/8" from the
inside of the frame on the back face Figure 21C. Connect the top of the two
vertical cut lines along the top surface of the crossmember.
T2502 Installation - pg. 13
Figure 21A
Figure 21B
Figure 21C
28.
T2502 Installation - pg. 14
On the passenger's side, measure in and mark 3" from the inside edge of the control arm pocket Figure 22. Extend the line along the bottom of the crossmember
(parallel to the inside edge of the control arm pocket) and up the front and back
faces of the crossmember.
Figure 22
29.
Using a reciprocating saw (highly recommended), hack saw or cut-off wheel, cut
the rear crossmember out of the vehicle along the driver's and passenger's side
cut lines Figure 23.
Figure 23
30.
With the rear crossmember removed, clean any burrs, grease/oil and paint from
the cut area. Prep the area properly for welding in the new provided metal
plates.
31.
Position the provided driver's and passenger's side weld-in plates up to the cut
surfaces by matching up the profiles Figure 24-pass, Figure 25-drv. On the driver's side make sure the bottom edge of the new plate is even with the bottommost edge of the cut. Tack weld the plates in place.
T2502 Installation - pg. 15
Figure 24-passenger's side
Figure 25-driver's side
Step 33 Note
32.
Double check the weld-in plate positions and completely weld into place. Once
the weld area has cooled, paint any bare metal to prevent rust.
33.
Locate the (2) provided front crossmember crush sleeves (0.875 OD x 2.250
Long). Place the sleeve in the top differential mounting holes in the crossmember. Take care not to drop them into the crossmember tube. Figure 26
Front crossmember hardware is
located in hardware pack #650.
Figure 26
T2502 Installation - pg. 16
34.
Install the new front crossmember into the front lower control arm pockets
Figure 27 with the provided 7/8" x 5-1/2" bolts and (2) provided rectangle cam
washers (set with large hole). Run the bolts from front to rear and loosely fasten
with remaining (2) rectangle cam washers and 7/8" nylock nuts.
Figure 27
35.
Locate and replace the factory vacuum and breather lines on the top of the differential Figure 28. Transfer the hose clamps from the factory breather hose to
the new provided one. The vacuum line does not have clamps and just slides
onto the hard line.
Figure 28
36.
With the help of an assistant and an appropriate jack, raise the differential up to
the new front crossmember. Align the holes in the factory differential mount
brackets with the corresponding holes in the crossmember. Fasten the differential Figure 29 to the front crossmember (through the holes with the crush sleeves)
with 9/16" x 5-1/2" bolts, nuts and washers along with the large lower factory
washer. Leave hardware loose.
Step 36 Note
All front differential mounting
hardware is located in hardware pack
#652.
T2502 Installation - pg. 17
Figure 29
37.
Locate the factory rear differential mount that was removed earlier. Locate the
bottom outer mount surface and the cast ribs that extend close to the mounting
hole. These ribs need to be ground down flush to the mounting surface back
into the mount body about 1/4" to provided clearance with the new differential
mount Figure 30. This can easily be done with a standard angle grinder.
Figure 30
38.
T2502 Installation - pg. 18
Loosely install the modified factory rear differential mount to the differential
with the original bolt Figure 31. The mount should be positioned as it was when
removed with the captive stud to the inside and pointing down. Leave the bolt
loose so the bracket can move freely.
Figure 31
39.
Install the new rear crossmember in the rear lower control arm pockets Figure 32.
When installing the crossmember, align the captive stud on the rear differential
bracket with the mounting hole in the crossmember. Fasten the crossmember to
the frame with the provided 18mm x 170mm bolts and (2) rectangle cam washers (set with small hole). Run the bolts from rear to front. Install the remaining
(2) cam washers on the bolt but do not install the nut.
Figure 32
40.
With the rear crossmember installed, fasten the factory rear differential mount to
the outer crossmember mount with a 9/16" x 2-1/2" bolt, nut and washers. Also,
install the factory flanged high nut on the captive stud, which is accessed
through the bottom of the rear crossmember Figure 33. Leave hardware loose.
Step 40 Note
All front differential mounting
hardware is located in hardware
pack #652.
T2502 Installation - pg. 19
Figure 33
41.
After all of the differential hardware is installed, push the differential rearward
as far as possible and torque the two front differential mount bolts to 90 ft-lbs.
Leave the remaining differential hardware loose at this time.
42.
Connect the new differential breather and vacuum lines to the hard lines at the
frame on the driver's side. Reconnect the differential wiring connector to the
differential actuator.
43.
Reconnect the front driveshaft to the differential with the original nuts/washer.
Torque nuts to 50 ft-lbs.
44.
Locate and install the factory lower control arms into the new front and rear
crossmembers Figure 34. Loosely fasten the control arms with the factory cam
bolts. The front cam bolts run from front to rear and the rear cam bolts run from
rear to front. Thread the cam bolts just enough to seat the cams between the
cam stops on the crossmembers but do not tighten.
Figure 34
T2502 Installation - pg. 20
45.
With the lower control arms installed, go back and torque the (3) rear differential
mount bolts to 90 ft-lbs (two at the crossmember, one into the differential).
46.
With all the differential mount bolts tight, torque the main 7/8" front crossmember bolts to 250 ft-lbs.
47.
Locate the provided weld-on steering stop adapters. Position the adapters on
the factory steering stops, located on the ball joint mounts toward the front side
of the control arm Figure 35A. The adapters will roughly match the contour
and shape of the factory steering stop. Clean the paint from the top and bottom
edges of the factory parts and weld the steering stop adapters in place Figure 35B.
After they are cool, paint any bare metal.
Figure 35A
Figure 35B
48.
Locate and remove the rear factory rubber bump stops from the frame Figure 36.
These are threaded into the frame and can be removed with large channel-lock
pliers. Discard bump stops.
T2502 Installation - pg. 21
Figure 36
49.
Step 49,50 Note
Bump stop hardware is located in
hardware pack #649.
Locate the provided driver's and passenger's side bump stop mounts and new
bump stops. The new mounts are side specific. The large tab will mount to the
rear crossmember bolt and the small slotted hole mounts to the frame. Install the
provided bump stops Figure 37A to the new mounts with a 3/8" flanged nut.
Tighten nut securely (do not overtighten, causing the bump stop to deform).
Figure 37A
50.
Step 50 Note
The 18mm nuts and 3/4" washers for the crossmember bolts are
located in hardware pack #650.
T2502 Installation - pg. 22
Install the bump stop mounts to the original bump stop location on the frame
with 10mm x 25mm bolts and 3/8" USS washers. Before installing the bolt
make sure the rectangle cam washer is in place on the crossmember bolt
Figure 37B - installed earlier and the bump stop mount is positioned over the cam
washer. Leave 10mm hardware loose and fasten the mount at the crossmember
with a 3/4" washer and 18mm nut. Torque the 10mm bolt to 20 ft-lbs followed
by the 18mm bolt to 140 ft-lbs.
Figure 37B
Figure 37C
»»L
51.
ower
Strut Mount Assembly
Locate the new lower strut extension assemblies. Install the extension on the
factory strut so the pinch tabs are toward the inside of the vehicle. Slide the
extension over the strut body. Figure 38
Note: 2014 models will require the use of a rubber mallet or dead blow hammer to get
the strut mount over the narrow section of the strut body and will not fit bilstein equipped
vehicles.
Step 51,52 Note
Strut mount hardware is located in
hardware pack #648.
2007-2013 models only: The
extension may need to be tapped
on to Bilstein struts because of the
slightly larger body diameter. Use
a rubber mallet.
Figure 38
T2502 Installation - pg. 23
52.
Align the mount holes with the factory strut bushing and fasten with a 5/8" x 3"
bolt, nut and washers. Torque bolt to 125 ft-lbs.
53.
Locate the provided 0.625 OD x 0.560 Long crush sleeves (4 total). Position
the sleeves between the pinch tabs on the upper portion of the strut extension
Figure 39 and fasten with 3/8" x 1-3/4" bolts, nuts and washers. Torque bolts to
25 ft-lbs. Double check that the strut extension is tight on the strut body. For
Bilstein strut equipped vehicles (yellow strut) - it may be necessary to place a
3/8" SAE washer on each side of the crush sleeves before installing the pinch
bolts. These are needed to compensate for the slightly larger diameter strut body
compared to the standard (black) strut.f
Figure 39
54.
With the strut installation complete, swing the lower control arms up to the strut
and attach with the original lower strut bolt/nut Figure 40. Leave lower control
arm bolt loose.
55.
Locate the new steering knuckles and the corresponding factory steering
knuckles. The factory hub seal needs to be removed from the original knuckles and placed in the new knuckles. Carefully remove/install the seals without
damaging them using a blunt nose punch and hammer (a small block of wood
works well to install). Be sure the seal is completely seated in the new knuckle
Figure 40A, B. If the seal needs replaced do so now. Toyota part #90312A0002.
Figure 40A
T2502 Installation - pg. 24
Figure 40B
56.
Install the new steering knuckles on the appropriate side of the vehicle. Run the
CV shaft through the knuckle hub bore and fasten the knuckles to the lower ball
joint mount with the original mounting bolts Figure 41. Use Loctite on the bolts
and torque to 175 ft-lbs.
Figure 41
57.
Pull down on the upper control arm and attach the upper ball joint to the new
steering knuckle with the factory upper ball joint nut. Torque the upper ball
joint nut to 80 ft-lbs and install the factory cotter pin. Never loosen the nut to
align the cotter pin holes, only tighten.
58.
Install the factory wheel hubs onto the factory CV shaft and into the new knuckles along with the factory dust shield and outer hub o-ring. Apply Loctite to the
(4) captive hub bolts and torque to 73 ft-lbs. Be sure the dust shield is oriented
correctly.
59.
Install the factory CV axle nut and torque to 250 ft-lbs. Install the factory castellated nut cap and new provided 5/32 x 1-3/4" cotter pin. Reinstall the factory
hub dust cap and tap into place with a rubber mallet.
60.
Install the factory brake rotor on the hub followed by the brake caliper. Attach
the caliper to the knuckle with the original mounting bolts. Torque caliper bolts
to 73 ft-lbs. The brake caliper may contact the dust shield on the bottom side of
the brake caliper, check for clearance before tightening the brake caliper to the
knuckle. Cut the dust shield as shown in Figure 42 if needed.
Step 58 Note
Cotter pin is located in hardware
pack #649
T2502 Installation - pg. 25
Figure 42
61.
Attach the factory brake line bracket to the new steering knuckle with the
original bolt. It might be necessary to carefully reform the brake hard line at the
caliper in order to attach the bracket. Torque bolt to 8 ft-lbs.
62.
Route the ABS sensor wire over the axle shaft to the front of the steering knuckle and install with the original bolt. Be sure to seat the sensor complete into the
knuckle before tightening the bolt Figure 43. Torque bolt to 8 ft-lbs.
Figure 43
63.
T2502 Installation - pg. 26
Attach the ABS wire bracket to the backside of the knuckle in the provided
tapped hole with the original bolt Figure 44A. On the driver's side it will be
necessary to remove the extra tab on the bracket to mount it properly Figure 44B.
The ABS line can be slid in the plastic retainer clips that attach to the metal
brackets to adjust the line for proper slack. Lubricate the line with spray lubricant and pull through the plastic clips as necessary. Torque bracket bolt to 8
ft-lbs.
Figure 44A
Figure 44B
64.
Locate the new brake line relocation brackets. Attach the brackets to the original frame mount with the original bolt. The stud on the bracket will point out
and the bracket will angle in toward the strut about 20-30 degrees from vertical
Figure 45. Torque bolt to 10 ft-lbs.
Figure 45 - passenger's side view
T2502 Installation - pg. 27
65.
Carefully reform the brake hard line at the frame and attach the original brake
line mount bracket to the stud on the relocation bracket Figure 46A. Fasten with
the provided 1/4" nut, flat washer and lock washer. Tighten hardware securely.
66.
Attach the ABS line to the upper control arm with the provided wire clamp
Figure 46B.
Step 64 Note
Brake line bracket hardware is
located in hardware pack #649
Figure 46A
Figure 46B
T2502 Installation - pg. 28
67.
Cycle the knuckle back and forth to check for proper slack and clearance of the
ABS and brake lines. Adjust where necessary.
68.
Locate the new sway bar drop brackets and mount to the original sway bar
mount point on the frame rails with the factory hardware. Figure 47 The open
face of the brackets should be toward the inside of the vehicle. Torque bolt to 40
ft-lbs.
Figure 47
69.
70.
Loosely fasten the sway bar to the new drop brackets with the provided 7/16" x
1-1/4" bolts, nuts and washers. Be sure the sway bar is oriented correctly and
the factory plastic bushing spacers are in place. Figure 48
Attach the factory sway bar links to the lower control arms and fasten with the
original bolts. Torque link bolts to 90 ft-lbs. Go back and torque the 7/16" sway
bar mount bolts to 40 ft-lbs.
Step 67 Note
Sway bar drop bracket hardware is
located in hardware pack #407
Figure 48
71.
Remove the factory driver's and passenger's side tie rod ends. Thread the new
provided tie rod ends back on up to the jam nut. Figure 49 Install the rod ends
into the new steering knuckles (top down) and fasten with the factory castellated nut. Torque nut to 51 ft-lbs. Insert a new 5/32 x 1-1/4" cotter pin. Do not
loosen the nut to align the cotter pin hole, only tighten.
T2502 Installation - pg. 29
Figure 49
72.
With the new tie rod ends installed, snug the jam nuts up against the tie rod ends.
73.
Install the wheels and lower the vehicle to the ground. Torque lug nuts to 100
ft-lbs for aluminum wheels or 150 ft-lbs for steel wheels.
74.
Bounce the front of the vehicle to settle the suspension. Torque the lower control arm cam bolts to 200 ft-lbs. Torque the lower strut mount bolts to 140 ft-lbs.
75.
Check all hardware for proper torque.
»»O
ptional
Front Skid Plate Modification
76.
The front skid plate can be cut and mounted in front of the lowered sway bar for
aesthetics as well as to provide a mount for the lower bumper plastic tabs.
77.
Using a square and tape measure, measure 6-1/4" from the center of the factory
front mounting holes and make a cut line across the entire skid plate. Using a
plasma cutter (recommended) or reciprocating saw, cut on the line. Figure 50
Step 77 Cut in line with these edges
6-1/4"
Step 76 Cut Line
Figure 50
T2502 Installation - pg. 30
78.
Next cut down both sides of the skid plate along the factory notch.
Figure 50 Clean up the edges and paint.
79.
Install the skid plate to the frame using the (2) factory bolts. Install the plastic
tabs to the skid plate with the (3) factory bolts. Figure 51
Figure 51
80.
The skid plate can be slightly formed down to be level with the sway bar by
gently pulling on the end. Make sure there is enough clearance to the sway bar
so interference cannot occur. Modify your cut if necessary.
»»R
ear Installation
1.
Block the front wheels for safety. Raise the rear of the vehicle and support with
jack stands under the frame rails.
2.
Remove the wheels.
3.
Support the rear axle with a floor jack and remove the factory rear shocks. Save
the axle mount hardware, discard the upper hardware and shocks
4.
Disconnect the parking brake cable brackets from the driver's and passenger's
side of the axle Figure 52. Remove the brackets from the cables.
Figure 52
5.
Disconnect the rear brake lines from the (3) mounting points at the center of the
axle Figure 53A. Save hardware and leave the factory clamps on the hard lines.
Disconnect the plastic ABS line clip from the top of the differential Figure 53B.
Remove the plastic clip from the ABS line, it will not be reused.
T2502 Installation - pg. 31
Figure 53A
Figure 53B
6.
Disconnect the ABS line bracket from the driver's side of the axle Figure 54.
Save hardware. Carefully bend the factory ABS line bracket down at the charcoal canister located on the frame Figure 55A,B.
Figure 54
T2502 Installation - pg. 32
Figure 55A—Before
Figure 55B—After
7.
With the axle still well supported, remove the passenger's side u-bolts. Lower
the axle enough to place the provided lift block between the axle and leaf pack.
Align the pins and pin holes in the block, leaf and axle. Raise the axle to seat all
of the components. The block has a slight taper. Make sure the short end of the
block is toward the front of the vehicle.
8.
With the lift block installed, install the new u-bolts, nuts and washers Figure 56.
Snug u-bolts but do not torque at this time. Final torque will be done with the
weight of the vehicle on the suspension.
T2502 Installation - pg. 33
Figure 56
9.
Repeat block installation on the driver's side.
10.
With both sides complete, install the new shocks with the provided bushings,
sleeves and hardware. New upper hardware is supplied and the factory axle
hardware will be reused. Torque the upper shock stud nut to 20 ft-lbs. Torque
axle mount bolt to 65 ft-lbs.
11.
Locate the provided ABS relocation bracket (flat bracket - 3" hole-to-hole) and
attach to the original axle mount with the factory bolt. Position the bracket
vertical and torque bolt to 10 ft-lbs. Attach the factory ABS line bracket to the
relocation bracket Figure 57 with the provided 5/16" x 1" bolt, nut and washers.
Torque 5/16" hardware to 10 ft-lbs.
Step 11-13 Note
All rear brake line hardware is
located in hardware pack #651
Figure 57
12.
T2502 Installation - pg. 34
Locate the provided brake line relocation bracket (flat bracket - 1" hole-to-hole),
provided 1/4" hardware and wire clip. Install the wire clip on the ABS wire
where the factory plastic clip was removed Figure 58A, B. Remove the 1/4" x 1"
bolt w/washer through the clip, into the new relocation bracket and into the front
of the original ABS mount tab on the top of the differential. Fasten with a 1/4"
nut and washer. Position the relocation bracket vertical and torque bolt to 8-10
ft-lbs.
Figure 58A
Figure 58B
13.
Attach the factory brake line bracket to the front of the relocation bracket with
the remaining 5/16" hardware. Torque bolt to 10 ft-lbs.
14.
Flip the two remaining brake hardware line clips and reattach to the original
locations on the back of the axle Figure 59. The lines will now be running above
the mount bolts instead of below. Torque bolts to 10 ft-lbs.
Step 13 Note
The brake hard lines will need to be
reformed slightly.
T2502 Installation - pg. 35
Figure 59
15.
Install the wheels and lower the vehicle to the ground. Torque lug nuts to 100
ft-lbs for aluminum wheels or 150 ft-lbs for steel wheels.
16.
Bounce the rear of the vehicle to settle the suspension. Torque the u-bolts to
100-120 ft-lbs.
17.
Check all hardware for proper torque.
»»P
ost-Installation
Post-Installation
Warnings
1. Check all fasteners for proper
torque. 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.
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.
3. Perform head light check and
adjustment.
4. Re-torque all fasteners after 500
miles. Always inspect fasteners and
components during routine servicing.
T2502 Installation - pg. 36
1.
Check all hardware (front and rear) for proper torque. Check hardware after
500 miles.
2.
Reconnect the battery.
3.
Vehicle will need a complete front end alignment.
4.
Adjust headlights.
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