Trail Master Suspension TM104N CHEVEROLET/GMC 1/2 TON 4WD SUSPENSION LIFT KIT - Manual (Page 10)

10
TM104N
Revised
1.27.14
assemblies and rotate the steering assembly back and forth several times to check for
clearance. Additional washers are supplied to facilitate the correction of any
misalignment issues you may encounter. It is very important to ensure no binding
occurs throughout the entire range of motion of the steering assembly. Once correct
clearances are established. Torque all fasteners to specifications.
15. At this point, if you have purchased the optional dual shocks, install the kit per
the enclosed instructions before proceeding to the next step. Leave all hardware
loose, and leave the front mount through bolt out until the next step is complete.
16. Drill out the sway bar mounting threads to clear 3/8” bolts (13/32”). At the front of the
OEM A-arm stop, it will be necessary to grind the existing droop stop tab back enough
to clear the new PN 82-1466 hardware. See Illustration 8. Install the front, upper A-
arm drops to the existing upper pockets using the supplied 9/16” X 1 1/2” bolts (if
installing with the above mentioned shock kit, install using the 9/16” through bolt
supplied with the shock kit) and the 7/16” X 1 1/4” bolts, washers, and nuts from the
bottom of the adapter through the existing holes in the OEM frame. The back holes in
the adapter must be drilled as indicated on Illustration 9. Leave slightly loose until the
sway bar is installed to assure easy insertion of the sway bar mounting hardware.
17. The factory sway bar is remounted upside down using the OEM bushings and mounts.
The mounts are to the original location with spacer (PN 90-1496), supplied 3/8” X 2 1/4”
socket head cap screws, washers, and lock nuts. See Illustration 9. Tighten the
bushing bolts enough to keep the sway bar from swinging but loose enough to facilitate
the installation of the end links.
18. At this point, check all mounting hardware and adapters for correct fit and check all
fasteners to make sure they are in place and correctly tightened.
19. Install the A-arm assemblies on each side of the vehicle by reversing the disassembly
order. Attach the lower A-arm using the supplied 5/8” X 5 1/2” to the rear, 5/8” X 4 1/2”
bolts to the front, washers and nuts. The upper A-arms are installed using the supplied
new alignment cam (PN 42-778T) assemblies. They are installed with the threads away
from the center of the A-arm. Be careful not to damage the ABS sensor wire. DO NOT
tighten the pivot bolts at this time. For correct positioning of the rubber bushings, the
vehicle should be fully on the ground before these bolts are torqued to specifications.
Note: If there is excessive space between the upper a arm and the new cross
member, shim the space out with the contents of an 90-6275.
20. Install the factory half shafts to the differential with the OEM bolts. Torque to
specifications.
21. Install the sway bar link to the sway bar and lower A-arm with the OEM links. Tighten
until the bushings just start to bulge out. Do not over tighten!
22. Install the front Trailmaster shock absorber (PN TM75551W) to the original position
using PN 90-1079 for the upper mount and the OEM bolts and nuts for the bottom
mount.
23. Install the front drive shaft to the differential.
24. Install the tie rod ends to the steering knuckle and torque to factory specifications.