3651 N. Hwy. 89 • Chino Valley, AZ 86323
(928) 636-7080
2011-2014
2500HD/3500HD
DURAMAX DIESEL PICKUP
(New Body Style) 3” BODY LIFT
INSTALLATION INSTRUCTIONS
KIT #10253
WARNING
Installation of a Performance Automotive Group body lift kit will change the vehicle’s center of gravity and handling characteristics both on and off-road. You must drive the vehicle safely! Extreme care must be taken to prevent vehicle rollover or loss of control, which could result in serious injury or death. Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fastened.
WARNING
Before you install this kit, read and understand all instructions, warnings, cautions, and notes in this instruction sheet and in the vehicle owner’s manual.
CAUTION
Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components. We recommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation. Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components install this kit.
WARNING
DO NOT combine suspension, body, or other lift devices. Use of vehicle with combined lifts may result in unsafe and/or unexpected handling characteristics.
1
WARNING
This kit should only be installed on a vehicle that is in good working condition. Before you install the kit, thoroughly inspect the vehicle for corrosion or deformation of the sheet metal around the factory body mounts. If the vehicle is suspected to have been in a collision or misused, do not install this kit. Off-road use of your vehicle with this kit installed may increase the stress applied to the factory body mounts. We do not recommend that any vehicle with a body lift kit installed be involved in any extreme off-road maneuvers such as jumping. Failure to observe this warning may result in serious personal injury and/or severe damage to your vehicle.
WARNING
Many states and municipalities have laws restricting bumper heights and vehicle lifts. Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law.
WARNING
The installation of larger tires may reduce the effectiveness of the Braking System.
WARNING
Always wear eye protection when operating power tools.
WARNING
Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.
WARNING
Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental deployment during installation of the kit, the Supplemental Restraint System (SRS, or airbag) must remain deactivated. Do not allow anyone near the airbag during installation. Refer to the factory service manual or owner's manual for the recommended procedure to disable the SRS. After you install the kit, reactivate the
SRS before driving the vehicle.
NOTE
Performance Automotive Group recommends using the Loctite® supplied in the kit on the threads of all kit nuts and bolts unless specified otherwise in these instructions.
2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
Before Starting Installation
NOTE
Kit parts are prefaced by the word kit and appear in
bold print.
1. Carefully read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by checking the parts list at the end of this document.
2. Airbag fuse a. Remove cover and airbag fuse “SIR” from fuse panel. Fuse locations may vary. Check fuse chart on back of cover.
Core Support
Push Pins
Airbag
Fuses
NOTE
If parts are missing from kit, please be prepared to provide the following information:
1. Name of purchase location
2. Bar Code on side of box
3. Date above bar code
4. Date inside box cover
5. Inspector # from inside box cover
3.
Only install this kit on the vehicle for which it is
specified. If anytime during the installation you encounter something different from what is outlined in the instructions, call technical support at (928)
636-7080.
4. Special tools needed: a. Die grinder or similar tool capable of cutting metal.
5. Park the vehicle on a clean, dry, flat, level surface and block the tires so the vehicle cannot roll in either direction.
A. Engine compartment
1. Battery cables a. Disconnect battery cables from both batteries.
Disconnect two negative cables first, then two positive cables.
Passenger
Side Shown
Negative
Cable
Positive
Cable
B. Measurements
1. Measure distance between the front bumper and front fenders. Record measurement.
Driver Side _____ Passenger Side _____
2. Measure distance between rear bumper and bed.
Driver Side _____ Passenger Side _____
3. Measure and record distance between cab and bed both sides.
Driver Side _____ Passenger Side _____
Prepare to install kit.
A. Front of vehicle
1. Grille a. Remove cover from core support with seven push pins.
Cover
2 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
b.
Remove four bolts, six clips , and grille from core support. Some GMC models may have extra clips.
Bolt
Clips
d. Remove four nuts, two double-bolt fasteners and two frame brackets from two frame horns.
Frame Brackets Nuts & Double-Bolt Fasteners
2. Front bumper a. If equipped, remove two connectors from two fog lamps.
b. Remove six bolts and two front outer bumper braces from front bumper and frame.
Bolts Frame e. Remove four bolts, two nuts and two tow hooks from frame horns.
Bolts & Nuts Tow Hook
Bumper
Fog Lamp Connector Bumper Brace
c. Remove two bolts from each fender side and remove bumper face from core support and fenders .
Bolts
Bumper Face
Frame Rail
3. Plastic cover and air flap a. Remove five bolts, and plastic cover from frame and core support.
Bolts Skid Plate
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b. Remove plastic cover from push clip, lower radiator hose and vehicle.
Lower
Radiator
Hose
Push Clip
Plastic
Cover c. If equipped, remove clip and harness from air flap.
e. Remove front bumper from frame horns.
Remove Front Bumper
Harness
Clip
Air Flap d. Remove two clips, three push pins, and air flap from core support.
Clip
Core Support
Air Flap
4. Transmission cooler
Push Pins
Clip
Air Flap
NOTE
Tie transmission cooler to core support so that it hangs free, and not binding hoses.
a. Remove two bolts and transmission cooler from core support.
b. Remove two gromits from transmission cooler.
Bolts
Trans
Cooler
Clips
Gromit
4 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
B. Engine Compartment
1. Air intake a. Loosen clamp from air baffle assembly. Remove wire harness clip from sensor.
Clamp
Air Baffle c. Remove A/C hose from clip on upper fan shroud.
A/C
Hose
Clip
Fan
Shroud
Wire
Harness
Clip
2. Fan shroud a. Remove single push clip and computer from upper fan shroud.
b. Rotate air intake assembly away from engine and towards fender while pulling the air box up and out of rubber grommets on fender.
Computer
Upper Fan
Shroud
Air Intake
Assembly
Fender
Push
Clip
CAUTION
Do not disconnect wiring harnesses from computer module.
b. Lift up and back to remove computer module from fan shroud. Rest assembly on power steering belt/pump.
Grommets
Computer
Module
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c. Remove four pop-ups and upper fan shroud from vehicle.
Pop-ups a. Remove wire clip from upper intercooler pipe at engine intake manifold. Twist hose clamp ring at upper end of intercooler hose to disconnect hose from throtle body.
Hose Clamp
Ring
Upper Fan
Shroud Wire Clip d. Remove computer wiring harness from harness push clip and lower fan shroud.
Upper
Intercooler
Piping Computer
Harness
Harness
Push Clip
Lower Fan
Shroud
Twist Hose
Clamp
Ring e. Lift lower fan shroud from radiator clips on side of radiator body.
NOTE
The following step, requires two people to position lower fan shroud under radiator.
f. Remove two bolts, intercooler, and radiator from core support. Lift intercooler and radiator. Do not remove from vehicle. Carefully push lower fan shroud down under radiator and core support.
b. Remove Lower intercooler pipe and hose from vehicle by twisting ring clip.
Lower
Intercooler
Piping
Bolt
Core
Support
Radiator
Bolt g. Lower intercooler and radiator and install on core support with two bolts.
3. Intercooler piping passenger side
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c. Remove clip and harness from engine mounted bracket.
b. 0Remove bolt and nut from upper and lower steering shaft.
Upper Steering Shaft
Bolt
Nut
Coolant
Bottle
Harness
Clip
Bracket
Lower Steering Shaft
4. Intercooler piping drivers side a. Loosen clamp, silicone hose, and intercooler piping from intercooler. Do not remove.
Hose Clamp
Air Pipe c. Slide upper steering shaft up to separate from lower steering shaft.
6. Wiring harnesses and ground strap a. Remove nut and ground strap from stud on fire wall.
Firewall
Ground
Strap Nut
Intercooler
NOTE
Ensure steering shaft does not turn independently of the steering gearbox. This could cause the air bag system to malfunction, resulting in serous personal injury or damage to the equipment.
5. Steering shaft a. Straighten steering wheel and strap the wheel so it will not turn.
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b. Remove harness from clip and bracket.
NOTE
Driver side inner fender well was removed for clarity and ease of access.
b. Remove clip and harness from frame and shock tower driver side.
Harness
Bracket
Clip c. Remove two clips and harness from cover and inner fender.
Frame And
Shock
Tower
Clip Harness
Cover
Harness
Harness
Clips Inner Fender
7. Wiring harnesses and power steering drivers side a. Remove bolt and two ground wires from frame.
Ground Wires Bolt Frame c. Carefully bend power steering pressure line at power steering pump by pulling toward fire wall as shown. Do not allow line to kink.
Power
Steering
Pump
Pressure
Line
Before
Bending
Direction of Firewall
Before Bending
Direction of Firewall
After Bending
Power
Steering
Pump
Pressure
Line
After
Bending
8 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
d. Carefully bend power assist pressure line up toward hood, to clear accumulator on brake hydro boost.
Brake
Hydro boost
Power Assist
Pressure Line
Accumulator g. Remove bolt, clamp, and power assist pressure line from frame.
Power Assist
Pressure
LIne
Engine Drivers Side
Lower Steering Shaft
Bolt and Clamp Frame
Upper Steering Shaft h. Remove two brake lines from two sets of clips driver side frame.
e. Loosen power assist pressure line fitting at brake droopiest housing and position power assist pressure line along side of accumulator as shown.
f. Tighten power assist pressure line fitting at brake droopiest housing.
Line Fitting
Power Assist
Pressure Line
Brake
Hydro boost
Accumulator
Frame
Brake Lines
Clips
C. Frame
1. Parking brake cable a. Remove bolt and ground wires from driver side frame mounting pad.
9
Frame
Mounting Pad
Bolt and Ground Wires
2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
b. Pull some slack in parking brake cable. Clamp two cables at cable housing where indicated by arrows.
a. Remove clip containing three metal lines from bracket.
Bracket
Clip
Lines c. Separate front parking brake cable from rear parking brake cable at cable connector.
b. Remove two nuts and bracket from transfer case. Bracket is not reused. Install two nuts and tighten.
Bracket
Transfer
Case Linkage
Front Brake Cable Rear Brake Cable
Cable Connector d. Remove front bake cable and brake cable housing from front frame mounting pad.
Nut behind bracket Nut Transfer Case c. Remove two clips and transfer case linkage from transfer case and pivot.
3.
Single cab only: Safety cables a. If applicable, remove two bolts and safety cables from two rear frame mounting pads.
Frame Mounting Pad Cable Housing
2.
Manual transfer case: shift linkage
Safety Cable
Frame Mounting
Pad
Bolt
WARNING
10 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
Use extreme caution when working near fuel lines and fuel tank. Clean up spilled fuel immediately. Any spark could cause an explosion or fire resulting in serious personal injury and property damage.
D. Rear of vehicle
1. Fuel filler a. Remove fuel cap, three bolts, and fuel filler from bed.
Bolts
Fuel Filler b. Remove four nuts, two double-bolt fasteners, four bolts and bumper from frame rails.
Frame Rail Bolts & Bumper
Bed
Fuel Cap c.
d. Remove two bolts and bumper from hitch and vehicle.
2. Rear bumper
NOTE
Removal of spare tire might be helpful, but not mandatory (refer to the Owner’s Manual).
a. Unplug rear bumper light wiring harness from frame connector.
Light Harness and Plug
Frame
Connector
Bumper
Hitch
Bolt
Install the kit
A. Cab
1. Prepare to lift cab from frame
WARNING
Failure to replace the OEM body mounting hardware
(except mounting bolts in the kit) in the stock locations could result in serious personal injury or damage to the vehicle.
NOTE
Ensure stock spacers and body bushings stay on vehicle unless otherwise specified in these instructions. Kit lift blocks are installed in addition to the stock spacers and body bushings.
11 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
a. Loosen but do not remove, core support bolt and three cab bolts from drivers side cab.
Core Support
Bolt with Nut
Cab Bolts b. Install a kit lift block under core support and on top of upper body bushing, frame, and lower body bushing with a kit
180mm), kit
Do not tighten.
bolt (12mm-1.75 x
washer (1/2” thick), and stock nut.
Core Support
Shown b. Remove core support bolt, nut, and three cab bolts from passenger side cab.
Core Support
Bolt And Nut
Cab Bolts
Bolt and
1/2” Washer
Core Support
Lift Block
Upper Body
Bushing
Frame
Lower Body
Bushing
Stock
Nut
2. Passengers side
CAUTION
Continually check hoses, wires, lines, etc. to be sure that everything is flexing properly and not binding, or damage to the vehicle could result. Be especially careful of the a/c hoses at the fire wall, the belt pulley, and at the core support. Ensure brake lines extend while lifting. Bending the lines to gain ample slack may be necessary. Be extremely careful not to kink the lines.
WARNING
Use extreme caution when lifting body from frame.
Ensure lifting device is securely placed. Keep hands out from between frame and body, or serious personal injury could result.
a. Using a hydraulic jack and a wooden block, slowly lift cab high enough to position a kit lift
block between core support and body bushing.
Position three kit lift blocks between cab and remaining body bushings.
c. Install three kit lift blocks (with 5/8” hole) under body and on top of top body bushings, frame, and lower bushings, with three kit bolts (14mm-
2.0 x 180mm) and kit washers (14 mm). Do not tighten.
Body
Kit Lift Block
(5/8” Hole)
Upper
Body
Bushing
Frame
Bolt and
Washer
Lower Body
Bushing d. Lower cab onto kit lift blocks.
3. Drivers side
12 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
a. Repeat above steps for the cab driver side.
b. Adjust cab to bed clearance as needed using measurements taken earlier.
4. Finish cab lift block installation a. Remove eight bolts one at a time, place a few drops of kit Loctite® on threads, install and tighten to 55ft.lbs.
B. Bed
1. Prepare to lift bed from frame.
a. Loosen but do not remove four bed bolts driver side (short bed three bolts).
Bed
Bolt b. Position four kit lift blocks (3” Diameter) between bed and frame as shown.
c. Install kit lift blocks on frame and bed with four kit bolts (12mm-1.75 x 100mm) and four kit
washers (7/16” USS). Do not tighten.
Bed
Block
Frame b. Remove four bed bolts from frame passenger side.
Bed
Bolt
Frame
Bolt and
Washer d. Lower bed onto kit lift blocks.
3. Install driver side bed kit lift blocks.
a. Repeat above steps for driver side.
4. Finish the bed kit lift block installation.
Frame
2. Bed passenger side a. Using a hydraulic jack and a wooden block, slowly lift the bed high enough to position the kit lift blocks between bed and frame mounting pads.
NOTE
Place a few drops of Loctite® on threads of all bolts.
a. Adjust bed to cab clearance as needed using measurements taken earlier.
b. Remove eight kit bolts one at a time, place a few drops of kit Loctite® on threads, install and
Tighten to 55ft.lbs.
13 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
C. Rear of vehicle
WARNING
The following procedure is intended only to enhance the appearance of the vehicle. The rear bumper will no longer be rated for towing of any kind. Towing with the rear bumper after it has been lifted can result in death, serious personal injury, or damage to the vehicle. Towing after the bumper has been lifted should be accomplished using a rated Class III receiver type hitch.
1. Install rear bumper a. Mark, cut, and bend crossmember for spare tire crank tube as shown.
Cut
b. Remove two bolts from bottom of bumper.
Bumper Bolt
c. Remove six nuts, two carriage bolts and bumper
support from bumper.
Nuts Bumper
Crossmember
Spare Tire
Crank Tube
2. Rear bumper
a. Remove two clips from fascia and bumper.
Bumper Fascia
Bumper Support Nut & Carriage Bolt
d. Cut two brackets and remove from bumper sup-
port as shown.
Bracket Cut Welds
Clip
AFTER CUT
14 2011
Chevy / GM 2500 & 3500 Diesel-Kits 10253
e. Position two kit brackets (bumper, rear) onto bumper support against stop.
Kit Bracket (Bumper, Rear, Left)
Kit Bracket (Bumper, Rear, Right)
g. Install bumper onto frame rails with all O.E.
double-bolt fasteners. Snug, but DO NOT
TIGHTEN.
Frame Rail Kit Bracket (Bumper, Rear)
O.E. Double-Bolt
Fasteners
h. Mark eight holes through two kit brackets
(bumper, rear) onto bumper support.
Mark Holes Kit Bracket (Bumper, Rear)
Bumper Support Stop
NOTE
Please note that Frame is boxed in and there is no access to inside of frame rails.
f. Install bumper support and two kit brackets
(bumper, rear) onto bumper with two O.E.
carriage bolts and six nuts. Snug, but DO NOT
TIGHTEN
Nuts Kit Bracket (Bumper, Rear)
Bumper Support
i. Remove two O.E. double-bolt fasteners, two nuts and bumper from frame rails.
j. Remove six nuts, two carriage bolts and bumper support from bumper.
Bumper Support Nut & Carriage Bolt
15 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
k. Drill eight 1/2” holes through bumper support at marked locations.
Drill Here Bumper Support
o. Install fascia onto bumper with two clips.
p. Install bumper onto frame rails with all O.E.
double-bolt fasteners and nuts. DO NOT
TIGHTEN...
Frame Rail Kit Bracket (Bumper, Rear)
l. Install bumper support onto two kit brackets
(bumper, rear) with four kit bolts (1/2”-13 x 3”), eight kit washers (1/2” SAE) and four kit nuts
(1/2”-13 Stover). DO NOT TIGHTEN.
Bumper Support Kit Bracket (Bumper, Rear)
Nuts & Double-Bolt
Fasteners q. Install kit bracket, hitch spacer, on rear bumper and hitch with two kit bolts (14mm x 110mm) and two kit washers (14mm). Do not tighten.
Bumper
Hitch Spacer
Bracket
Hitch
Kit Bolts (1/2”-13 x 3”),
Kit Washers (1/2” SAE),
Kit Nuts (1/2”-13 Stover)
m. Install bumper support and two kit brackets
(bumper, rear) onto bumper with two O.E. carriage bolts and six nuts. DO NOT TIGHTEN.
Nuts Nut & Carriage Bolt
Bolts and
Washers r. Adjust bumper to bed clearance using measurements taken earlier and tighten hitch bolts first then remaining bolts and nuts to 55 lbft.
n. Install bottom of bumper onto bumper support with two bolts.
16 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
s. Plug license plate light harness in at crossmember connector.
Light
Harness and Plug
Frame
Connector b. Install two safety cables on kit brackets, safety cable extension with two kit bolts (3/8” x 1 1/2”), four kit washers (3/8” USS), and two nuts (3/8” nylock).
Kit Bolts (3/8” X 1 1/2”), Kit
Washers (3/8” USS), Nuts
(3/8” Nylock)
3. Fuel filler
WARNING
Use extreme caution when working near fuel lines and fuel tank. Clean up spilled fuel immediately. Any spark could cause an explosion or fire resulting in serious personal injury and property damage.
a. Install fuel filler on the bed with three bolts.
Install fuel cap.
Bolt
Kit Brackets,
Safety Cable
Extension
Frame
2. Parking brake cable.
Bolts
Fuel Filler
NOTE
Some filing of drilled 7/16”” hole may be required to allow parking brake cable housing to fit properly.
a. Using kit parking brake bracket as templet, mark
& drill a 7/16”” hole in the frame over original hole as shown.
Bed
Fuel Cap
Frame
Mark &
Drill
Hole
D. Frame
1. Safety cables, single cab only a. Install two kit brackets, safety cable extension on frame rear mounting pads with two bolts.
Original
Hole
17 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
b. Relocate parking brake cable into kit park
bracket and mount using kit 7/16” hardware. .
Parking Brake
Cable
Kit Parking
Brake Bracket b. Scribe a line along transfer case linkage as shown. Cut transfer case linkage into two pieces through the scribed line and deburr.
Scribed Line Cut Here
Transfer
Case
Linkage
Kit 7/16”
Hardware c. Install two ground wires on frame mounting pad with bolt. Connect front and rear brake cables.
Remove clamps from rear cable. Note: Kit
washer may be used between kit bracket and body mount to keep bracket aligned.
WARNING
A certified welder should perform all welding.
c. Position kit pin 4x4 extension between two pieces of transfer case linkage. Ensure transfer case linkage scribed lines align and weld kit pin extension in place.
Kit Pin
Frame
Mounting
Pad
Ground
Wires
Bolt Transfer Case Linkage
NOTE
The following step is for vehicles with manual transfer case only. Other models skip this step.
3. Lengthen and install transfer case shift lever.
a. Remove two spring clips and transfer case linkage from shift lever, transfer case shift arm.
Transfer Case
Linkage
Spring Clip d. Install transfer case linkage on transfer case shift arm and shift lever with two clips.
e. Check transfer case shift lever operation.
Ensure there is complete engagement in all ranges. If necessary, adjust the linkage.
4.
Manual transmission shift lever.
NOTE
Manual transmissions require shift extension SE4701
purchased separately. Automatic transmission models skip this step.
Transfer
Case
Shift Arm
5. Driver side wheel well and frame rail.
18 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
a. If possible, install four harness clips on frame and wheel well.
Harness
Clips a. Remove factory flex hose from Upper and Lower
Piping.
**VERY CAREFULLY** cut nylon clamps from Upper and Lower piping. **Be sure NOT to
cut factory flex hose during this process**
Removing
Clamp
Removed
Clamp
Factory Flex
Hose
Frame b. If possible, install two brake lines in two sets of clips. If brake lines will not fit back into position, wrap lines with two kit zip ties individually, and then secure the lines together with one kit zip tie as a bundle.
Brake Lines
Frame b. *Measure and Cut* Upper and Lower intercooler pipes. *Measure and Mark* 3/4” from EACH end of the Upper and Lower intercooler pipes. *Carefully cut intercooler pipes without damaging inner metal support ring. Be sure to clean ALL metal & plastic particles from pipes.
Lower Pipe Measure & Cut Upper Pipe
Clips c. If possible, install harness in clip on frame driver side.
Harness
Clip
Frame
E. Engine Compartment
1. Intercooler piping passenger side
19 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
c.
*Measure and Cut* O.E. Flex Hose. *Measure and Mark* 3/4” from EACH end of the Flex
Hose. *Carefully cut Flex Hose. Be sure to clean
ALL particles from Flex Hose.
Measure & Cut Flex Hose e. Install factory upper and lower intercooler pipes onto throtle body and intercooler. Adjust and
Tighten two kit hose clamps on O.E. Flex Hose.
Throtle Body
Ring clamp
Factory
Elbow
Kit Clamps
2. Intercooler piping drive side a. Position silicone elbow on intercooler and air pipe with two clamps.
Hose Clamp
Air Pipe d. Place O.E. Flex Hose onto Upper / Lower intercooler pipe. Install two kit clamps onto intercooler pipe and Flex Hose, do not tigthen kit clamps at this time. .
Factory Flex
Hose
Intercooler
3. Wiring harnesses and ground strap a. If possible, install clip in bracket (top of engine).
Kit Clamps
WARNING
When installing factory hose clamps, make sure the clamp is not rubbing on other hoses once it is tight.
Harness
Bracket
Clip
20 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
b. Install ground strap on stud with nut.
Firewall
Nut
Ground
Strap a. Trim tabs from edges of lower fan shroud at mark, both sides, as shown.
Lower Fan
Shroud
4. Install kit steering extension.
a. Place a few drops of kit Loctite® on threads of bolts for both following steps.
b. Install kit steering extension on upper steering shaft with kit bolt (3/8” x 1 3/4”), two kit washers
(3/8” SAE), and kit nut (3/8” nylock). Do not tighten.
c. Install kit steering extension into lower steering shaft with bolt and nut. Tighten bolt to 33 lb-ft.
Upper Steering
Shaft
Kit Bolt (3/8” X 1 3/4”),
Kit Washers (3/8” SAE),
Kit Nut (3/8” Nylock)
Kit Extension
Steering
Bolt And Nut
Lower Steering
Shaft
5. Lower fan shroud.
Tabs
Mark
6. Upper fan shroud.
a. Measure upper fan shroud from top down
1-1/2”. Mark and cut upper fan shroud as shown.
1 1/2”
Mark
Upper Fan
Shroud b. Clamp fan shroud on table top as shown.
c. Position kit bracket, upper fan shroud (center) on fan shroud with two tabs under shroud and edges on top of shroud as shown.
Kit Bracket, Upper
Fan Shroud (Center)
Clamp
21
Tabs
Edges
Upper Fan
Shroud
2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
d. Assemble three kit
brackets, upper fan shroud
(left, center, and right) with two kit
bolts (1/4” x
3/4”), four kit
washers (1/4” SAE), and two kit
nuts (1/4” nylock) as shown. Snug, bolts but do
not tighten.
g. Using three kit
brackets, upper fan shroud
(left, center, and right) as templates, drill 1/4” holes in fan shroud.
h. Install three kit
brackets, upper fan shroud
(left, center, and right) on upper fan shroud with one kit
clips push, fifteen kit bolts (1/4” x 3/4”),
thirty kit
washers (1/4” SAE), and fifteen kit nuts
(1/4” Nylock).
Kit
Bracket, Upper Fan Shroud
(Left, Center, And Right) from table top as shown. Ensure bracket is level.
Kit
Bracket, Upper Fan Shroud
(Left, Center, And Right)
Kit
Bolts (1/4” X 3/4”), Kit
Washers (1/4” SAE), &
Kit
Nuts (1/4” Nylock)
Kit Bolts
(1/4” x 3/4”) e. Measure kit
bracket, upper fan shroud (center)
Measure
Upper Fan
Shroud f. Clamp two scrap pieces of metal (or rulers) to fan shroud as shown. Position upper fan shroud on metal scrap and under kit
bracket, upper fan
shroud (center).
Kit
Clip Push
Kit
Bolts (1/4” X 3/4”),
Kit
Washers (1/4” SAE),
Kit
Nuts (1/4” Ny lock)
Upper Fan
Shroud i. Using kit
bracket, upper fan shroud (center) as
template, drill two 1/4” holes in fan shroud lip.
Install kit
bracket, upper fan shroud (center) on
upper fan shroud lip with two kit
clips push.
Upper Fan
Shroud
Holes
Kit
Clips
Push
7. Lower fan shroud a.
Notches
Upper Fan Shroud
Scrap Pieces
Clamp
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Chevy / GM 2500 & 3500 Diesel-Kits 10253
b. Position bottom fan shroud in vehicle and rest below lower core support.
e. Mark & Drill two holes in upper fan shroud bracket using computer module as a templete.
Install computer module on upper fan shroud with two pop-up clips.
Upper Fan
Shroud
Mark & Drill
Bottom Fan
Shroud
Core
Support c. Install upper fan shroud assembly on core support with two bolts. Do not tighten.
Top Fan
Shroud
Assembly Upper Fan
Shroud
Pop-up Clips
Computer
Module
Bolts d. Install top fan shroud on bottom fan shroud with four pop-ups. Check fan to shroud clearance.
Ensure gap is the same all around shroud.
Top Fan
Shroud
Pop-ups
Bottom Fan
Shroud f. Install three kit lower fan shroud plates with two kit bolts (1/4” x 3/4”), four kit washers (1/4”
SAE), and two kit nuts (1/4” nylock).
Kit lower fan shroud plates
Kit Bolts (1/4” X 3/4”),
Kit Washers (1/4” SAE),
& Kit Nuts (1/4” Ny lock)
23 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
g. Mark & Drill four 1/4” holes into core support using kit lower fan shroud plates (assembly) as template on core support.
h. Install kit lower fan shroud plates (assembly) on core support with four kit bolts (1/4” x 3/4”), eight kit washers (1/4” SAE), and four kit nuts
(1/4” nylock). Using fan shroud plates as template, mark and drill one 1/4” hole into center of fan shroud as shown. Install one kit bolts (1/4” x
3/4”), two kit washers (1/4” SAE), and one kit
nuts (1/4” nylock). .
a. Install air box assembly in rubber grommets on fender and position air inlet hose on intake manifold.
Air Intake
Assembly
Fender
Kit Bracket, Lower Fan
Shroud Plates (Assembly)
Kit Bolts (1/4” X 3/4”),
Kit Washers (1/4” SAE),
& Kit Nuts (1/4” Ny lock)
Grommets b. Tighten clamp on air intake assembly. Install wire harness clip on sensor.
Clamp Air Baffle i. Install Air Flap with three push pins in holes provided in kit lower fan shroud plates. Install two outer Air Flap clips.
Clip
Core Support
Air Flap
Wire Harness
Clip
Push Pins
Clip
Air Flap c. Install A/C hose from clip on upper fan shroud.
A/C
Hose
Clip
8. Air intake
Fan
Shroud
24 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
F. Front of vehicle
1.
Transmission cooler (If so equipped) a. install two kit 2” studded drop brackets with
O.E. bolts into nut clips from transmission cooler.
Install two kit 1/4” studded brackets in holes on core support A-frame using kit 1/4” nuts &
washers..
Transmission
Cooler
Bolts Drop Bracket b. Install plastic cover on frame and core support with five bolts.
Bolts
Plastic
Cover b. Install two kit Spacers in between lower transmission cooler bracket and core support using kit (3/8 x 2 1/2”) hardware.
Transmission
Cooler
Spacer & Hardware Trans Bracket
3. Install front bumper a. Place a few drops of kit Loctite® on threads of bolts.
NOTE
Kit washers (1/2” x 1-3/8”) are fitted between kit
brackets (bumper, front) and frame horn.
b. Install kit bracket (bumper, front, left) and kit
bracket (bumper, front, right) onto left frame horn with four kit washers (1/2” x 1-3/8”), four kit
bolts (1/2”-13 x 5-1/2”), eight kit washers (1/2”
SAE) and four kit nuts (1/2”-13 Stover). DO NOT
TIGHTEN.
Kit Bracket (Bumper, Front, Left)
Kit Bracket (Bumper, Front, Right)
2. Plastic splash guard a. If removed, install clip and harness on air flap.
25
Frame Horn Kit Washers (1/2” x 1-3/8”)
2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
c. Install frame bracket onto kit brackets (bumper, front) with two kit sleeves (.75” OD x .532” ID x
3.35” L), four kit bolts (1/2”-13 x 5-1/2”), eight kit
washers (1/2” SAE) and four kit nuts (1/2”-13
Stover). DO NOT TIGHTEN.
Frame Bkt.
g. Install two bumper supports onto kit brackets with two kit bolts (7/16”-14 x 1-1/2”), four kit
washers (7/16” SAE), two kit nuts (7/16”-14
Stover) with four O.E. bolts to body mount. DO
NOT TIGHTEN.
O.E. Bolts Large Washer Bumper Support
Kit Bolts (1/2”-13 x 5-1/2”),
Kit Washers (1/2” SAE),
Kit Nuts (1/2”-13 Stover)
Kit Sleeves(.75” OD x .532” ID x 3.35” L)
d. Repeat above substeps for right frame horn.
e. Install bumper onto frame brackets with two O.E.
bolts. DO NOT TIGHTEN.
Bumper Bolt
Kit Bracket
(Bumper, Front,
Support)
Kit Bolts (7/16”-14 x 1-1/2”),
Kit Washers (7/16” SAE),
Kit Nuts (7/16”-14 Stover)
h. Adjust bumper to body clearance using measurements from removal section. Align bumper to previous measurements and TIGHTEN all bumper hardware.
i. If so equipped, install two connectors on two fog lamps.
Fog Lamp
Connector
f. Install two kit brackets (bumper, front, support) onto bumper with two kit large washers between bumper and kit bracket. DO NOT
TIGHTEN
O.E. Bolts Large Washer Bumper Bracket.
4. Install Front Grill a. Remove two bolts from each fender side and remove bumper face from core support and fenders .
Bolts Bumper Face
26 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
b. Position grill on core support and install six clips and four bolts in core support and front fenders.
Bolt
Clips
G. After installation is complete
1. Install airbag fuse in fuse panel. Install cover
Airbag
Fuses c. Install cover on core support with seven push pins.
Cover
Core Support
Push Pins
5. Install crush blocks
2. Connect both battery cables to the battery. Be sure to reconnect the positive cables first, then the negative cables.
Passenger
Side Shown
Negative
Cable
Positive
Cable
NOTE
Short wheel base trucks have two plastic disks and use two kit crush blocks.
a. Remove four plastic disks from frame.
b. Install four kit crush blocks on frame with four kit washers (5/16” USS) and four kit screws (5/
16” x 3/4” self tapping).
3. Install Gap Guards (you did remember to order your
Gap Guards, didn’t you?).
4. Stick kit warning sticker on the dash in plain sight of all vehicle occupants.
5. Double check the vehicle.
Bed
Kit Crush Blocks
Kit Washer (5/16” USS)&
Kit Screws (5/16” X 3/4”
Self Tapping)
Frame
CAUTION
Retorque all fasteners after 500 miles and after off road use. All body lift components should be visually inspected and fasteners re torqued during routine vehicle servicing.
a. Check all mounting hardware to ensure it is properly tightened.
b. Check all wires, hoses, cables, etc. to ensure they have been properly connected and there is ample slack. Check all belts and pulleys to ensure there is no rubbing or interference. With the number of hoses on this vehicle, it is vital that this be checked thoroughly.
c. Check vehicle electrical system.
27 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
d. Start vehicle and check the steering in both directions to ensure that there is no bind. Check clutch operation. Check the operation of the brake system and the parking brake. Check both shift levers’ operation. Ensure that there is proper engagement in all gears and 4 wheel drive ranges.
CAUTION
Never open a closed cooling system after the vehicle has been started. Only fill the cooling system if the cap has been removed while the vehicle was still cold.
e. Check coolant level. Fill coolant to the proper level (refer to the Owner’s Manual).
f. Test drive vehicle in all gears and 4 wheel drive ranges. Pay close attention to all vehicle systems. Check all hardware again in 500 miles and as part of your regular maintenance schedule.
NOTE
All warranty information, instruction sheets, and other documents regarding the installation of this product must be retained by the vehicle owner. Information contained in the instructions and on the warranty card will be required for any warranty claims. The vehicle owner needs to understand the modifications made to his vehicle and how they affect vehicle handling and performance. Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury.
CAUTION
Performance Accessories does not recommend any particular wheel and tire combinations for use with its body lifts and cannot assume responsibility for the customer’s choice of wheels and tires. Reference your owner's manual for recommended tire sizes and warnings related to the use of oversized tires. Larger wheel and tire combinations increase stress and wear on steering and suspension components, which leads to increased maintenance and higher risk for component failure. Larger wheel and tire combinations also alter speedometer calibration, braking effectiveness, center of gravity, and handling characteristics. Consult with an experienced local off road shop to find what wheel and tire combinations work best with your vehicle.
28 2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
2
3
8
2
6
2
2
1
4
4
1
2
2
2
1
1
1
1
1
1
1
1
1
1
4
2
1
1
PARTS LIST KIT 10253
QTY DESCRIPTION
4 Bolt, 1/2 x 3”
8
30
2
1
12
35
2
Bolt, 1/2”-13x5-1/2”
Bolt, 1/4 x 3/4
Bolt, M10-1.5x40mm
Bolt, 12-1.75 x 100mm
Bolt, 12-1.75 x 180mm
Bolt, 14-2.00 x 180mm
Bolt, 14-2.00 x 110mm
Bolt, 3/8 x 2 1/2”
Bolt, 3/8 x 1 3/4”
Bolt, 7/16 x 1 1/2”
Bracket, z-shaped, 2”
Bracket, ground, 3”
Bracket, front bumper driver side
Bracket, front bumper outer
Bracket, front bumper passenger side
Bracket, rear bumper driver side
Bracket, rear bumper passenger side
Bracket, hitch spacer
Bracket, lower fan shroud center
Bracket, lower fan shroud driver side
Bracket, lower fan shroud passenger side
Bracket, upper fan shroud center
Bracket, upper fan shroud driver side
Bracket, upper fan shroud passenger side
Bracket, parking cable extension
Crush block with hole
Clamp, 3” Clamp
Label, logo
Label, warning
Loctite, 6ml
Nut, 1/2-13 Nylock
Nut, 1/4 Nylock
Nut, M10-1.5 Stover
Nut, 14mm Nylock
Nut, 3/8 Nylock
29
2
4
4
24
8
4
1
10
24
65
10
2
20
1
4
16
Nut, 7/16 Nylock
Pin, 4x4 extension, 1/2” X 1”
Screw, 5/16 x 3/4, self-tapping
LIft block, 3” height x 3” diameter w/ 5/8” Hole
Sleeve, .75” ODx.532” IDx3.35” L
Steering extension
Washer, 1/2”x1-3/8”
Washer, 1/2” USS
Washer, 1/4” SAE
Washer, 14mm
Washer, 3/16” x 1 1/2” x 2 1/2”
Washer, 3/8” SAE
Washer, 3/8” USS
Washer, 5/16” USS
Washer, 7/16” USS
Zip tie
Copyright 1/11
Performance Automotive Group
2011 Chevy / GM 2500 & 3500 Diesel-Kits 10253
