3651 N Highway 89 • Chino Valley, AZ 86323
(928) 636-7080 • www.p-a-g.net
CHEVY/GMC 2500HD ONLY
BODY LIFT KIT
INSTALLATION INSTRUCTIONS
2003-2005 2” KIT # 10092
2003-2005 3” KIT # 10093
WARNING
This body lift kit should only be installed on vehicles in good working condition. Before installation, the vehicle should be thoroughly inspected for evidence of corrosion or deformation of the sheet metal around the factory body mounts. This body lift kit should not be installed on any vehicle that is suspected to have been in a collision or misused. Off road use of your vehicle with this body lift installed may increase the stress applied to the factory body mounts. We do not recommend that any vehicle with a body lift 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 now have laws restricting bumper heights and vehicle lifts. Local laws should be consulted to determine if the changes you intend to make to your vehicle comply with state laws.
MANUAL TRANS. REQUIRES
KIT SE4701
WARNING
The installation of larger wheel and tire combinations may reduce the effectiveness of the braking system.
WARNING
Installation of a Performance Automotive Group body lift will change the center of gravity and the handling characteristics of the vehicle. Because of the higher center of gravity and larger tires, the vehicle will handle and react differently both on and off road. You must drive it 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
We will not warranty any damage to the A/C system.
WARNING
Always wear eye protection when operating power tools.
WARNING
Ensure that your vehicle tires are properly blocked and secured before you begin installation of this lift kit.
WARNING
Read and understand all instructions, warnings, cautions, and notes in this sheet and in your owners manual before you begin the installation of this body lift kit.
CAUTION
Proper installation of a Performance Automotive
Group body lift kit requires knowledge of the factory recommended procedures for disassembly and assembly of original equipment components. We recommend that the factory shop manual and any special tools necessary to your vehicle be on hand during the installation. Installation of this body lift kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of your vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components install this body lift kit.
WARNING
To ensure the Supplemental Restraint System (SRS, or air bag) is not accidentally deployed during lift kit installation, always ground yourself and the vehicle.
Do not use power or pneumatic tools. Exercise extreme caution while working near SRS sensors and wiring. Do not allow anyone near air bags during lift kit installation. Accidental deployment can result in serious personal injury or death.
NOTE
Performance Automotive Group recommends using the Loctite® supplied on the threads of all fasteners unless noted in the instructions.
1
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.
‘03-’05 Chevy 2500HD - Kits 10092, 10093
A. Before you start.
NOTE
As you read through this procedure, note that each part referenced has the same callout number throughout. Also, the part number in the text matches the corresponding part number in the pictures. Kit parts are prefaced by the word kit in italics.
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.
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. Welder (or access to a professional welding shop) (manual-shift 4WD only).
b. 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.
6. Disconnect both battery cables. Disconnect the negative cable (1) first, then the positive cable (2) from the battery (3).
7. Remove cover (4) and the airbag fuse (5) from the fuse panel (6). Fuse locations may vary. Check fuse chart on back of cover (4).
2 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
B. Get ready to install the kit.
1. Remove the grille.
a. Remove seven panel clips (7) and cover (8) from core support (9).
b. Remove bolt with captive washer (10), loosen four phillips head/dzeus fasteners (11), remove two clips (12) and grille (13) from core support
(9) and front fenders (14).
3 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
2. Remove the front bumper.
a. Measure distance between the front bumper
(15) and front fenders (14). Record measurement.
b. If so equipped, remove two connectors (16) from fog lamps (17).
c. Remove six bolts (18) and two front side bumper brackets (19) from front bumper (15) and frame
(20).
d. Remove four bolts (21 and 22) and front bumper
(15) from frame (20).
e. Remove six bolts with captive washers (23) and tow hooks (24) from the frame (20).
4 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
f.
Remove five bolts with captive washers (25) and plastic cover (26) from core support (9) and frame (20).
g. Remove three pop-ups (27) and air flap (28) from core support (9).
h. If so equipped, remove two bolts (29), two panel clips (30), and transmission cooler (31) from core support (9) A-frame. Remove two lines (32 and 33) from clip (34). Remove clip from core support.
i.
Remove two nut clips (35) from transmission cooler (31) and install in holes on core support
(9) A-frame.
5 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
3. Under the hood.
a. Remove hose (36) from two clamps (37 and 38).
b. Remove hose (39) from clamp (40).
c. Loosen two clamps (41 and 42) and remove air duct (43) from air filter housing (44) and throttle body (45).
d. Remove two bolts (46) securing upper half of fan shroud (48) to upper core support. Remove four pop-ups (47) securing upper half of fan shroud
(48) to bottom half. Remove upper half of fan shroud (49) from engine compartment.
e. Remove two lines (51 and 52) from clip (53).
Remove clip from lower half of fan shroud.
f.
Move lines (51 and 52) out of way and drop the lower half of fan shroud (49) below the core support (9).
g. Rotate lower half of fan shroud (49) around fan blades and remove it from the engine compartment.
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.
6 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
h. Straighten steering wheel and strap the wheel so it will not turn.
i.
Remove bolt (54) and clip (55) and slide upper steering shaft (56) up to separate from lower shaft (57). Upper shaft may not separate from lower shaft until lift blocks are installed.
j.
Remove nut (58) and ground strap (59) from stud (60).
k. Remove clip (61) from bracket (62).
4. Along the frame rails.
a. Remove clip (63) and harness (64) from frame
(20) driver side.
7 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
b. Remove four clips (65, 66, 67 and 68) from frame (21) driver side and wheel well (69).
c. Remove two brake lines (70) from pop-up clip
(71).
d. Remove bolt (72) and two ground wires (73 and
74) from driver side frame mounting pad (75).
e. Remove (you may have to cut) clip (76) and remove harness (77) from driver side frame mounting pad (75).
f.
Remove two clips (78 and 79) and harness (77) from frame (20) driver side.
8 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
g. Measure length of threads on parking brake cable (80) adjuster and remove nut (81) from adjuster and clevis (82).
h. Pull parking brake cable (80) through two driver side frame mounting pads (75).
i.
Bend up two clips (83 and 84) on frame (20) passenger side.
5. Remove the 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. Remove gas cap (85).
b. Remove three bolts (86) from bed (87) and fuel filler (88).
9 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
6. Remove the rear bumper.
a. Measure distance between rear bumper (109) and tailgate (110).
b. Remove lock (111) from spare tire winch tube
(112).
c. Disconnect two license plate lights (113) from rear bumper (109). d. Remove three clips (114) and harness (115) from rear bumper (109).
10 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
e. Remove two bolts with captive washers (116), four nuts with captive washers (117), and two double stud fasteners (118) from two rear bumper brackets (119), two rear side bumper brackets (120), and frame (20).
f.
If equipped with a trailer hitch (121), remove four bolts (122 and 123) from hitch and frame (20).
g. Remove two rear bumper brackets (120) and rear bumper (109) from frame (20).
h. Remove four nuts with captive washers (123), four bolts with captive washers (124), and two rear bumper brackets (120) from rear bumper
(109).
11 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
C. Install the kit.
1. Prepare to lift cab from frame.
WARNING
Failure to replace the OEM cab mounting hardware
(except mounting bolts in the kit) in the stock locations could result in serious personal injury or damage to the vehicle.
NOTE
Depending on model year, some washers used with cab bolts may be captive washers and some may be standard washers. Standard washers are to be used during reassembly.
a. Measure distance between the cab and the bed.
Record measurement for later cab to bed alignment reference in these instructions.
b. Loosen (do not remove) four cab mounting bolts
(89 and 92) (one bolt at core support mount and three bolts at cab mounts (99).
WARNING
Use extreme caution when lifting cab from frame.
Ensure lifting device is securely placed. Keep hands out from between frame and cab, or serious personal injury could result.
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 firewall, the belt pulley, and at the core support. Ensure brake lines stretch while lifting. Bending the lines to gain ample slack may be necessary. Be extremely careful not to kink the lines.
c. While lifting, ensure two power steering lines (93 and 94) are not becoming too taut. If lines are too taut, carefully bend lines to gain some slack.
NOTE
Install the kit lift blocks on top of the original cab bushings. The kit lift blocks must be installed in addition to the original cab bushings.
12 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
d. Remove nut with captive washer (90), bottom bushing (95), and bolt with captive washer (89) from the passenger side core support mount
(96).
e. Remove three bolts with captive washers (92), bottom bushings (95 and 97), and two rear bushing washers (98) from the passenger side cab mounts (96).
2. Lift the cab.
a. Using a hydraulic jack and a wooden block, slowly lift the passenger side of the cab a little more than 2” (10092) or 3” (10093).
3. Install kit lift blocks on passenger side of cab.
a. Set the appropriate kit lift block (101) on top of the metal cup (102) at the core support mount
(89) and three cab mounts (92).
• Block, lift, 2” height x 3” diameter (10092)
• Block, lift, 3” height x 3” diameter (10093) b. At the core support mount, install the appropriate
kit
bolt (103) through a kit 7/16” USS washer
(104), frame (96), top bushing (105), metal cup
(102), kit lift block (101), core support (91), kit
1/2” thick washer (106), and stock nut (90).
LEAVE THE BOTTOM BUSHINGS (95) OFF
FOR NOW. Do not tighten.
• Bolt, 12mm-1.75 x 160mm (10092)
• Bolt, 12mm-1.75 x 180mm (10093) c. At three cab mounts, install the appropriate kit bolt (103) through a kit 7/16” USS washer (104), frame (96), top bushing (105), metal cup (102),
kit
lift block (101), and into the cab (99). LEAVE
THE BOTTOM BUSHINGS (95 and 97) OFF
FOR NOW. Do not tighten.
• Bolt, 12mm-1.75 x 160mm (10092)
• Bolt, 12mm-1.75 x 180mm (10093) d. Lower the cab on the kit lift blocks.
4. Install kit lift blocks on driver side of cab.
a. Repeat the previous steps to install kit lift blocks on driver side of cab.
5. Finish the cab kit lift block installation.
a. Remove eight kit bolts (103) one at a time, coat threads with Loctite®, INSTALL THROUGH THE
BOTTOM BUSHINGS (95 and 97) AND TWO
REAR BUSHING WASHERS (98) NOW, and reinstall. Tighten to 55 lb-ft.
13 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
6. Install kit lift blocks on passenger side of bed.
a. Loosen (do not remove) four bed mounting bolts
(107) on driver side of bed.
b. Remove four bed mounting bolts (107) from passenger side of bed (87).
14 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
c. Using a hydraulic jack and a wooden block, slowly lift the passenger side of the bed a little more than 2” (10092) or 3” (10093).
d. At the rearmost bed mount, set the appropriate
kit
lift block on the frame (96).
• Block, lift, 2” height x 2” diameter, with 1/2”
bolt hole (10092)
• Block, lift, 3” height x 2” diameter, with 1/2”
bolt hole (10093)
NOTE
Kit
lift blocks (2” diameter with 5/8” bolt hole) are for the rear bumper and hitch.
e. At the other bed mounts, set the appropriate kit lift block on the frame (96).
• Block, lift, 2” height x 3” diameter (10092)
• Block, lift, 3” height x 3” diameter (10093) f.
At each bed mount, install the appropriate kit bolt (108) through a kit 7/16” USS washer (104), frame (96), kit lift block (101 and 107), and into the bed (87). Do not tighten.
• Bolt, 12mm-1.25 x 80mm (10092)
• Bolt, 12mm-1.25 x 100mm (10093) g. Lower the bed onto the kit lift blocks.
7. Install kit lift blocks on driver side of bed.
a. Repeat the previous steps to install kit lift blocks on driver side of bed.
8. Finish the bed kit lift block installation.
a. Adjust the cab to bed clearance using the measurements recorded earlier.
b. Remove eight bed mounting bolts (108) one at a time, coat threads with Loctite
£, and reinstall.
Tighten to 55 lb-ft.
15 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
9. Install the rear bumper.
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.
a. Trim spare tire carrier (125) as shown.
b. Coat threads of bolts (122, 124, 128, 133 and
140) and nuts (123, 130, 132, 135 and 137) with
Loctite®
.
c. Install two kit rear bumper main brackets (126) on rear bumper (109) with four bolts (124) and nuts (123). Do not tighten. d. Position two kit rear bumper main brackets
(126), rear side bumper brackets (119), and kit rear bumper small studded brackets (127) in frame (20) rails. Ensure spare tire winch tube
(112) fits in original hole in rear bumper. Install two kit 7/16” x 1 1/2” bolts (128), four kit 7/16”
USS washers (129), two kit 7/16” nylock nuts
(130), six kit 1/2” USS washers (131), six kit 1/2” nylock nuts (132), two kit 3/8” x 1 1/2” bolts
(133), four kit 3/8” USS washers (134), and two
kit
3/8” nylock nuts (135). Do not tighten.
16 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
e. If equipped with a trailer hitch (121), install hitch on frame (20) with four bolts (122), two kit 1 1/2” x 1 1/2” rectangular washers (136), and two kit
14mm nylock nuts (137). Do not tighten.
f.
Install two of the appropriate kit lift blocks (138) on rear bumper (109) and hitch (121) with two kit
14mm washers (139) and two of the appropriate
kit
bolts (140).
• Block, lift, 2” height x 2” diameter, with 5/8” bolt hole (10092)
• Bracket, rear bumper middle (10093)
• Bolt, 14mm-2.00 x 90mm (10092)
• Bolt, 14mm-2.00 x 110mm (10093)
Kit
Bracket
(Rear Bumper
Middle)
Kit
Bolts
(14mm x 110mm) g. Adjust bumper to body clearance and tighten bolts (122, 124, 128, 133 and 140) and nuts
(123, 130, 132, 135 and 137) to 55 lb-ft.
h. Install three clips (114) and harness (115) on rear bumper (109).
i.
Connect two license plate lights (113) in rear bumper (109).
j.
Install lock (111) in spare tire winch tube (112).
17 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
10. 2003 Models: Install 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. Remove clamp (141) and filler hose (142) from gas tank (143). Leave ground wire (144) and vent hose (145) attached.
b. Carefully cut filler hose (142) in half where shown. ENSURE YOU DO NOT CUT
THROUGH PLASTIC TUBE (146) INSIDE
FILLER HOSE.
c. Install kit fuel filler extension (147) on filler hose
(142) with two kit #36 clamps (148).
d. Install filler hose (142) on gas tank (143) with clamp (141).
e. Install fuel filler (88) on the bed (87) with three bolts (86).
18 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
f.
Install gas cap (85).
11. 2004 Models: Install 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.
Bolt & Ground
Wire a. Remove bolt and fuel filler ground wire from frame.
Frame b. Loosen fuel filler hose and vent hose clamps.
Clamps c. Remove clips from vent hose and fuel filler hose.
Clips d. Remove fuel filler from vehicle.
e. Mark and cut fuel filler neck as shown.
Alignment Mark
Cut Here
19 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
f.
Deburr edges of cut ends.
g. Install kit extension (fuel filler) with two kit clamps (#20 hose). DO NOT TIGHTEN.
Kit
Clamps
(#20 Hose)
Kit
Extension
(Fuel Filler) h. Install fuel filler onto body with three bolts.
Bolts i.
Install fuel filler onto fuel filler hose. Adjust kit extension (fuel filler, rubber) and fuel filler hose.
TIGHTEN kit clamps (#20 hose) and fuel filler hose clamp. Install fuel filler vent hose onto fuel filler and TIGHTEN vent hose clamp.
Fuel Filler
Fuel Filler Hose j.
Install clips onto fuel filler and vent hose.
Clips
20 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
k. Install ground wire onto frame with bolt.
l.
Install fuel cap.
Bolt & Ground
Wire
Frame
12. Along the frame rails.
a. If possible, install two clips (78 and 79) and harness (77) on frame (20) driver side.
b. Drill 1/2” hole 2” up and 1/2” to left of original parking brake cable hole.
Drill 1/2” Hole Here
Original Parking Brake
Cable Hole
1/2”
2”
c. Bend tab on frame mounting pad up.
Tab
21 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
d. Install front parking brake cable housing.
Parking Brake Cable
Housing e. Install two ground wires onto frame mounting pad with bolt. Connect front and rear parking brake cables. Remove clamps from rear parking brake cable.
Ground Wires & Bolt f.
If possible, install two brake lines (70) in pop-up clip (71).
22 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
g. If possible, install four clips (65, 66, 67, and 68) in frame (21) driver side and wheel well (69).
h. If possible, install harness (64) and clip (63) in frame (20) driver side.
i.
If possible, install clip (61) in bracket (62).
j.
Singe cab: Install two kit cab safety cable extension brackets on frame rear mounting pads with two bolts.
k. Install two safety cables on kit brackets with two
kit
3/8” x 1 1/2” bolts, four kit 3/8” USS washers, and two kit 3/8” nylock nuts.
Kit
Cab Safety
Cable Extension
Bracket
(1
1/2
” x 4
3/4
”)
23
Frame Rear
Mounting Pad
‘03-’05 Chevy 2500HD - Kits 10092, 10093
13. Under the cab.
NOTE
This step is for vehicles with automatic transmission only. Other models skip this step.
a. Ensure automatic transmission cable (153) has enough slack and is not pulling on boot (154) or binding. If cable is pulling or binding, remove cable from clip (155).
14. Lengthen and install manual transmission shift lever.
NOTE
Extension of the manual transmission shift lever requires kit extension (SE4701, sold separately).
a. Remove four screws (156) and four pop-ups
(157) from floorboard (159). (It may be necessary to cut pop-ups.) Slide shift boot (158) up onto shift lever.
b. Loosen jam nut on input lever. Remove shift lever from input lever.
24
Shift Lever Input Lever Jam Nut
‘03-’05 Chevy 2500HD - Kits 10092, 10093
c. Install kit extension (SE4701, sold separately) on input lever. Rotate kit extension until it is in the best position for shifting (about 45º from centerline of transmission), then tighten jam nut.
d. Install shift lever on kit extension.
Kit
Extension (SE4701, sold separately)
Shift Lever e. Check transmission shift lever operation. Ensure there is complete engagement in all gears.
f.
Install shift boot (158) on floorboard (159) with four screws (156). Check transmission shift lever operation again.
25 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
15. Lengthen and install transfer case shift linkage rod.
NOTE
This step is for vehicles with manual-shift transfer case. Vehicles with automatic-shift transfer case skip this step.
a. Remove three lines (167) from bracket (168).
Remove two nuts (169) and bracket (168) from transfer case (170).
b. Remove two clips (171) and transfer case linkage rod (172) from transfer case (169) and pivot
(173).
c. Scribe a line along the axis of the linkage rod
(172) as shown. Cut the linkage rod into two pieces through the line and deburr as necessary.
WARNING
A certified welder should perform all welding.
d. Position kit transfer case shift linkage extension
(174) between the two pieces of linkage rod
(172). Ensure scribed lines on kit extension and linkage rod are aligned, then weld the kit extension in place.
e. Install linkage rod (172) on transfer case (167) and pivot (173) with two clips (171).
f.
Check transfer case shift lever operation.
Ensure there is complete engagement in all ranges. If necessary, adjust the linkage.
16. Under the hood.
a. Install kit ground strap bracket (175) on stud (60) with nut (58). Install ground strap (59) on kit ground strap bracket (175) with kit 1/4” x 1” bolt
(176), two kit 1/4” SAE washers (177), and kit 1/
4” nylock nut (178).
17. Install kit steering extension.
WARNING
Ensure kit steering extension is installed properly and bolts are torqued according to Performance Accessories specifications.
a. Coat threads of retaining bolts (54 and 180) with
Loctite®
.
b. Install kit steering extension (179) on upper steering shaft (56) with kit 3/8” x 1 3/4” retaining bolt (180), two kit 3/8” SAE washers (134), and
kit
3/8” nylock nut (135). Do not tighten.
26 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
c. Install lower steering shaft (57) on kit steering extension (179) with the stock retaining bolt (54) and clip (55).
d. Tighten bolts (54 and 180) to 33 lb-ft.
18. Radiator.
a. Trim ears off of the sides of the lower half of the fan shroud (49).
b. Mark and trim upper fan shroud as shown.
Trim Here c. Set lower and upper halves of fan shroud into position in engine compartment. Attach upper and lower halves of fan shroud to each other using the pop-ups.
d. Install kit brackets and kit urethane radiator onto fan shroud using kit 1/4” nylock nuts and kit 1/4”
SAE washers. (For 2” kit, holes will need to be drilled in kit urethane radiator).
Kit
Urethane
Kit
Brackets
Kit
Nuts &
Washers
27 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
e. Install two kit fan shroud upper brackets on core support with original bolts. (On 8.1L, install four
kit
brackets.)
CAUTION
Use care when drilling hole into core support. DO NOT drill into radiator. Severe damage could occur.
Bolts f.
Drill 1/4” hole through kit urethane radiator into upper core support. Install kit push clip into kit urethane radiator and upper core support.
g. Remove four clips holding wire harness to bottom of core support. Remove four clips from wire harness.
Drill & Install
Kit
Push Clip h. 10092: Drill two 9/32” holes in vertical face of core support where kit fan shroud lower brackets
(“L”) will be installed.
10092
Drill Drill i.
10093: Using kit brackets (L-shaped) as templates, mark two holes in lower fan shroud as shown. Using kit brackets (L-shaped) as templates, mark two holes in lower core support as shown.
Kit Bracket
(L-Shaped)
28
Mark & Drill
Here
‘03-’05 Chevy 2500HD - Kits 10092, 10093
j.
Install kit fan shroud lower brackets on core support using kit 1/4” fasteners. Using the hole in each kit lower bracket as a template, mark the fan shroud for drilling.
k. Remove fan shroud. Drill holes in lower half of fan shroud where marked. Set both halves of fan shroud into position in engine compartment and attach them to each other using pop-ups.
l.
Secure upper half of fan shroud to kit upper brackets.
m. Secure lower half of fan shroud to kit lower brackets using kit 1/4” fasteners. Be sure to install two kit wire harness clamps on wire harness.
n. Check fan to fan shroud clearance. Ensure gap is the same all around shroud, then tighten all bolts and nuts.
o. Position air duct (43) on air filter housing (44) and throttle body (45) and tighten two clamps
(41 and 42).
p. Install hose (36) in two clamps (37 and 38).
q. Install hose (39) in clamp (40).
19. Transmission cooler (if so equipped).
a. Install two kit transmission cooler “S” brackets with stud (186) on two clip nuts (35) on core support (9) with bolts (29). Do not tighten.
b. Install transmission cooler (31) on two kit brackets (186) with two kit 1/4” SAE washers (177) and kit 1/4” nylock nuts (178). Do not tighten.
c. Install two kit transmission cooler spacer tubes
(187) with two 1/4” x 3” bolts (188), four 1/4”
SAE washers (177), and two 1/4” nylock nuts
(178).
d. Tighten nuts (178) and bolts (30 and 188).
e. Carefully bend hard line (32) as shown and secure with kit zip tie (189).
Fan Shroud
Kit Bracket
(L-Shaped)
Kit Wire
Harness
Clamps
Core Support
29 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
f.
Trim air flap (28) as shown if a test fit indicates it interferes with hard lines (32 and 33).
g. Install air flap (28) on core support (9) with three panel clips (30).
h. Install plastic cover (26) on frame (20) and core support (9) with five bolts with captive washers
(25).
20. Install the front bumper.
NOTE
Some models may not require any cutting or trimming of the front bumper valence or front bumper brackets.
Test fit bumper before proceeding.
a. Chevy Models: Trim the front bumper valance
(190) in two places as shown.
b. Chevy Models: Trim two front bumper brackets as shown. Check fitment and trim as necessary.
Front Bumper
Bracket
Trim Here
30 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
c. GMC models: Mark and cut driver side front bumper as shown
Cut Here
Cut Here
Cut Here
31 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
d. GMC models: Repeat above step for passenger side front bumper. Check fitment and trim driver and passenger side, if necessary
Passenger
Side, After
Cut
NOTE
To install factory tow hooks, additional front bumper and/or valence modification is required. Tow hooks can not be installed on some models.
e. Apply a small amount of kit Loctite® onto threads of bolts (19, 22, and 128) and nuts
(130).
f.
Install two kit front bumper main brackets (191) on frame with two stock bolts (21), two kit 7/16” x
1 1/2” bolts (128), four kit 7/16” USS washers
(129), and two kit 7/16” nylock nuts (130). Do not tighten
21
191
128,
129,
130 g. Install kit front bumper inner brackets (192) on kit main brackets with four kit 7/16” x 1 1/2” bolts
(128), eight kit 7/16” USS washers (129), and four kit 7/16” nylock nuts (130). Do not tighten.
h. Install front bumper (15) on two kit main brackets
(191) and two kit inner brackets (192) with two bolts (22), two kit 7/16” x 1 1/2” bolts (128), four
kit
7/16” USS washers (129), and two kit 7/16” nylock nuts (130). Do not tighten.
32
192
128,
129,
130
‘03-’05 Chevy 2500HD - Kits 10092, 10093
i.
10093: Install front outer bracket to kit bracket
(front bumper, outer) with two kit bolts (7/16” x
1-1/2”) four kit washers (7/16” USS) and two kit
nuts (7/16” Nylock). DO NOT TIGHTEN.
j.
10093: Install kit bracket (front bumper, outer) onto passenger side frame with factory bolts.
Apply a few drops of kit Loctite® to threads of factory bolt. DO NOT TIGHTEN.
k. 10093: Apply a few drops of kit Loctite® to threads of factory bolt. Install front outer bracket to front bumper with factory bolt. DO NOT
TIGHTEN.
l.
10093:Repeat above steps for driver side of vehicle.
Kit
Bolts
(7/16” x 1-1/2”),
Kit
Washers
(7/16” USS),
Kit
Nuts
(7/16” Nylock)
Front Outer
Bracket
Factory
Bolt
Kit
Bracket
(Front
Bumper,
Outer)
Factory
Bolts
Front
Bumper m. 10092: Install passenger side front outer bracket to front bumper with factory bolt.
n. 10092: Using passenger side front outer bracket as a template, drill two 1/2” holes through body mounting pad on frame.
o. 10092: Install passenger side outer bracket to frame with two kit bolts (7/16” x 1-1/2”), four kit
washers (7/16” USS) and two kit nuts (7/16”
Nylock). DO NOT TIGHTEN.
p. 10092: Repeat above steps for driver side of vehicle.
q. If so equipped, install two connectors (16) on fog lamps (17).
r.
Tighten nuts (130) and bolts (18, 21, and 128).
Check measurements between front bumper
(15) and front fenders (14). Adjust bumper to cab clearance and tighten bolts and nuts to 55 lb-ft.
33
Drill Here
Passenger
Outer
Bracket
Factory
Bolt
Kit
Bolts
(7/16” x 1-1/
2”),
Kit
Washers
(7/16” USS),
Kit
Nuts
(7/16” Nylock)
Passenger
Outer
Bracket
‘03-’05 Chevy 2500HD - Kits 10092, 10093
21. Install the grille.
a. Position grille (13) on core support (9) and install two clips (12) in front fenders (14).
b. Tighten four phillips head/dzeus fasteners (11) and install bolt with captive washer (10).
c. Install cover (8) on core support (9) with seven panel clips (7).
22. Install crush blocks (metal bed spacers).
a. Remove four rubber bumpers (194) from bed
(87).
b. Install four kit crush blocks (195) on bed (87) with four kit 5/16” USS washers (151) and four
kit
5/16 x 1” self-tapping bolts (196).
34 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
D. After installation is complete.
1. Install airbag fuse (5) in fuse panel (6). Install cover
(4).
2. Connect both battery cables to the battery (3). Be sure to reconnect the positive cable (2) first, then the negative cable (1).
3. Install Gap Guards.
4. Stick kit warning sticker on the dash in plain sight of all vehicle occupants.
5. Double check the vehicle.
CAUTION
Retorque all fasteners after 500 miles and after off road use. All body lift components should be visually inspected and fasteners retorqued 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. With the number of hoses on this vehicle, it is vital that this be checked thoroughly.
c. Check vehicle electrical system.
d. Adjust headlights.
Accessories
Available: Front & Rear Gap Guards
35 ‘03-’05 Chevy 2500HD - Kits 10092, 10093
E. Kit Parts List
Qty. Description
Kit 10092
2 Block, 2” height x 2” diameter (1/2” hole)
2 Block, 2” height x 2” diameter (5/8” hole)
14 Block, 2” height x 3” diameter
8 Bolt, 12mm-1.75 x 80mm
8 Bolt, 12mm-1.75 x 160mm
2 Bolt, 14mm-2.00 x 90mm
14 Bolt, 7/16” x 1
1/2
”
2 Bracket, fan shroud lower (“L”)
4 Bracket, fan shroud upper (flat, 2” hole-to-stud)
2 Bracket, front bumper inner (“C”)
1 Bracket, ground strap (flat, 2” hole-to-hole)
4 Crush block (bed spacer, 2” square tube)
14 Nut, 7/16” nylock
2 Nut, 1/2” nylock
1 Pin, transfer case shift linkage extension (1/2” x 2”)
44 Washer, 7/16” USS
2 Washer, 1/2” USS
Kit 10093
2 Block, lift, 3” height x 2” diameter (1/2” hole)
14 Block, lift, 3” height x 3” diameter
8 Bolt, 12mm-1.75 x 100mm
8 Bolt, 12mm-1.75 x 180mm
2 Bolt, 14mm-2.00 x 110mm
14 Bolt, 7/16” x 1
1/2
”
2 Bracket, fan shroud lower (flat, 1” hole-to-stud)
4 Bracket, fan shroud upper (flat, 3” hole-to-stud)
1 Bracket, front bumper inner, driver side (“L”)
1 Bracket, front bumper inner, passenger side (“L”)
2 Bracket, front bumper outer brace
1 Bracket, ground strap (flat, 3” hole-to-hole)
2 Bracket, “L” (if needed for fan shroud)
1 Bracket, rear bumper, middle
4 Crush block (bed spacer, 2” x 3” rectangular tube)
14 Nut, 7/16” nylock
6 Nut, 1/2” nylock
1 Pin, transfer case shift linkage extension (1/2” x 3”)
40 Washer, 7/16” USS
6 Washer, 1/2” USS
Qty. Description
Kit 10092 / 10093
5 Bolt, 1/4” x 1”
2 Bolt, 1/4” x 3”
4 Bolt, 3/8” x 1
1/2
”
1 Bolt, 3/8” x 1
3/4
”
2 Bracket, cab safety strap extension (1
1/2
” x 4
3/4
”)
1 Bracket, front bumper main, driver side
1 Bracket, front bumper main, passenger side
1 Bracket, rear bumper main, driver side
1 Bracket, rear bumper main, passenger side
2 Bracket, rear bumper side strap (studded)
2 Bracket, transmission cooler (“S”, 2” hole-to-stud)
2 Clip, push
1 Extension, fuel filler
1 Extension, steering
2 Hose clamp, #20
2 Hose clamp, #36
1 Label (sticker), logo
1 Label (sticker), warning
1 Loctite, 6ml tube
2 Nut, 14mm nylock
11 Nut, 1/4” nylock
5 Nut, 3/8” nylock
4 Screw, 5/16” self-tapping
2 Spacer tube, transmission cooler (1/2” x 2”)
1 Tie, zip
1 Tube, fuel filler extension
1 Urethane, radiator
2 Washer, 14mm
20 Washer, 1/4” SAE
6 Washer, 5/16” USS
2 Washer, 3/8” SAE
8 Washer, 3/8” USS
2 Washer, 1/2” thick
2 Washer, 1
1/2
” x 2
1/2
” rectangular
2 Wire harness clamp, rubber-clad
36
Rev. 06, Copyright 09/06
Performance Automotive Group www.p-a-g.net
‘03-’05 Chevy 2500HD - Kits 10092, 10093
