Rough Country 5040 - Manual

INSTRUCTION SHEET
Page 1
THE ORIGINAL OFF ROAD PEOPLE
’73 - ’91 CHEVY/GMC FRAME REINFORCEMENT
FOR SOLID AXLE ½ AND ¾ TON TRUCKS
5040
Please read instructions before beginning installation. Check the kit hardware against the parts list. Be sure you have all needed parts and
know where they go.
5040 PARTS LIST
GM Frame Section Bottom
GM Frame Section Side
NOTES:
1. This bracket system is not intended as a frame rail section replacement. It is intended use is a frame section support for use on frames
where minor fatigue and/or cracks have started to develop about the steering gear box area.
2. Before starting verify that the frame rail is straight and in alignment. If you can not determine this yourself check with your local frame
shop.
3. This bracket system requires welding. The welding should be done by a certified welder (welder needs complete understanding of
MIG welding). Welding wire to be used is ER-70-S, using 100% CO2sheilding gas in a controlled environment.
INSTALLATION INSTRUCTIONS
Step 1. Lift front of vehicle and place safety stands under front of axle
housing. Remove drivers side tire.
Step 2. Remove steering gear box. This is done by removing steering
drag link assembly, steering shaft (you will probably need a
pitman arm separation tool)and gear box to frame bolts.
Step 3. Place side section on frame and determine if brake line will have
to be relocated for installation. After installation reinstall brake
line by drilling a whole in frame support.
Step 4. On vehicles equipped with power steering you must remove
hydraulic lines from gear box prior to removing gear box from
frame. Keep lines in upright position and seal ends so
contamination can not enter system.
Step 5. Check frame for cracks. At the end of any cracks drill a small
stop hole (1/8 “ diameter). Grind a small v-grove along the
length of the crack. Be careful to only grind a minimum of
material away. Try not to enlarge the crack.
Step 6. Fully weld the length of all cracks and then grind flush so that the
new support plate lays as flat as possible against the frame rail.
Step 7. Install new side support plate (included in kit) using bolts, nuts
and washers on frame rail through gear box mounting holes.
Tighten the four bolts. (It may be necessary to use a c-clamp to
obtain a flat, flush fit on the support plate.)
Step 8. With plate installed and frame free of any dirt, grease, oil or
scale, you can begin to skip weld unit into place. Do not make a
solid continuous weld. Skip weld only in areas shown in the
diagrams . Plug weld the elongated holes for added coverage.
Step 9. Now the skip weld of the side plate is complete, you must go
back and fully weld the bottom edge of this plate to the frame.
Step 10. Install the bottom cover plate so that the two holes in it line up
with the existing rivets on the bottom of the frame rail.
Step 11. Once again c-clamp the unit for as plat and flush fit as possible
for welding.
Step 12. Do not make a solid continuous weld. Skip weld only in areas shown.
Step 13. Install steering gear box onto frame. Wire brush the threads on the four retaining bolts and clean out the threaded holes in the
gear box. Torque the four bolts in a criss-cross pattern to 70 ft. lbs.
Steering Gear Box
Locate with rivets
Brake Line
Plug Weld
90504000