BMR Suspension TAS002 - Manual (Page 5)

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(CONTINUED)
23. Center punch the marks on the frame to provide a drill centerline.
24. The recommended (and easiest) way to drill
through the frame rails is with a step type drill
bit. Using a ½” bit (or step bit) drill through the
outer portion of the frame rail as shown in
Image 9. Take extra care to angle the drill
correctly before drilling through the other side
of the frame rail. Continue drilling through the
frame rail until the bit starts to appear through
the inner bolt holes of the BMR cross-member.
In most cases, the holes in the cross-member
will “self-align” the drill bit, forcing the bit to
center itself in the hole.
25. Once both ½” holes are drilled through the sub
frame, it is necessary to enlarge the outer frame
holes to ¾” to allow insertion of the provided
frame reinforcement inserts. Using either a ¾”
drill bit or a step bit (much easier), enlarge
ONLY the outer holes in the frame rail.
26. Assemble the outer reinforcement plate, frame
inserts and ½” x 3” bolts with stainless washers
as shown in Image 10. Slide the assembly
through the subframe until the bolts protrude
through the BMR cross-member on the inside of
the frame rail. Thread a nut and stainless
washer onto the exposed portion of the bolts and
then tighten these bolts to 80 ft/lbs.
27. Duplicate steps 22-26 for the other side of the
vehicle.
28. Position stands under the vehicle to support the
new BMR 9” axle housing.
29. Place the housing on the stands in such a way
that the housing does not rotate. Center the
housing in the wheel wells.
30. Before proceeding with the rest of the torque
arm installation, it is necessary to install the
third member (pumpkin or center section).
31. Begin by applying a thin bead of black or grey
RTV silicone around the gasket face of the
BMR 9” axle housing then position the gasket
over the studs. Apply another bead on the
outside of the gasket then place the third member over the studs. Tighten all nuts to 40
ft/lbs in a criss-cross pattern. NOTE: the rearend shown in the following images does
not have the third member installed for illustrative purposes.