Trail Master 6.0 Inch Knuckle Suspension Lift Kit with Rear NGS Shocks (TM103N) - Manual (Page 11)

11
TM103N
Revised
1.28.14
banjo bolt after modification.
63. Route the ABS wire through the factory clips on
the upper A-arm. Secure the ABS line to reloca-
tion bracket (90-7876) mounting holes. The
ABS line plastic push pin will install to one hole
and the locating tab will install into the remain-
ing hole. See ILLUSTRATION 13.
NOTE: On some vehicles the driver’s side
OE wire harness that connects to the ABS wire
may be shorter, from the factory, than others.
If the line needs to be extended GM #19149296
(ACD#PT2232) can be installed into the chas-
sis wire harness.
64. Reattach the ABS wiring and secure it to the top
hole on the knuckle using the supplied Adel
clamp and supplied OE bolt and washer. See
ILLUSTRATION 13.
NOTE: The Adel clamp has a flat side and
a rounded side, make sure the flat side is facing
out toward the tire.
65. On both sides of the vehicle loosen the jam nut
and remove the outer tie rod ends and jam nuts.
66. The inner and outer tie rod ends may need to be
shortened. Measure in 9/16” from the end of the
inner tie rod end and scribe a line. Measure in
7/16” from the end of the outer tie rod end and
scribe a line. Using a suitable cutting tool,
(abrasive cutoff wheel, Sawz-all, etc.) cut the
ends along the previously marked line. Be sure
the cut is made straight and square or else the
jam nut will not hold it’s torque properly.
67. Install the supplied 16mm jam nuts onto the in-
ner tie rods. Thread the jam nut and outer tie
rod ends on as far as they will go on the inner tie
rods with the stud facing down.
68. Reinstall the outer tie rod ends onto the inner tie
rod ends. Thread them on as far as they will go
with the stud facing down.
69. Insert from the top and secure the tie rod end to
the knuckle and torque to factory specifications.
Be sure to clean the threads and use thread lock-
ing compound on the tie rod end nut.
70. Install the sway bar drop brackets (82-3632
drvr and 82-3635 pass) to the original sway bar
mounting holes in the frame, angled toward the
rear of the vehicle, using the supplied 10mm-1.5
X 30mm bolts and hardware. See ILLUSTRA-
TION 14.
71. Using the previously made sway bar orientation
markings as a guide, flip the sway bar 180 de-
grees and reinstall it to the sway bar drop brack-
ets using the supplied 7/16” X 2 1/2” bolts and
hardware for 2007-2009 models or the previ-
ously removed OE bolts and 10mm flat washers
and 10mm nuts for 2010-2012 models. Leave
hardware loose at this time. See ILLUSTRA-
TION 14.
72. Install the previously removed OE sway bar end
links into their original location on the lower A-
arms. See ILLUSTRATION 14.
73. Reconnect the sway bar end links to the sway
bar.
74. Torque the sway bar hardware according to the
Mounting
Studs
ABS
Relocation
Bracket
90-7876
ABS Line
Mounting Holes
1/4”
Hardware
Front Brake Line Drop
Bracket 90-7734 drvr and
90-7735 pass
Illustration 13
Brake Line Relocation
Bracket Install and Routing
5/16” X 1” Bolt
OE Brake
Line