Auto Manual Resource: 2009

60-87 GM PU Bolt-In IFS Instructions

INSTALLING THE LOWER A-ARM TO CROSSMEMBER
1. Working on a table is the easiest way to install the lower A-arms to the crossmember. See page 3 for fastener size and location.
2. Find these parts to assemble the lower A-arm. The balljoint comes pressed-in. Refer to the HARDWARD PAGE 3 for fastener sizes. The lower A-arms need to be installed on crossmember first
3. Steering stops go toward the rear
4. Grease all (4) bushings inside and out, along with the cross shaft and the holes in A-arms and in the crossmember on each side. Install the 4 urethane bushings.

INSTALL LOWER A-ARM - Con’t
5. Use only a plastic mallet or rubber hammer to tap the shaft through the first 2 bushings. Then, install a 3/4-inch i.d.spacer between the bushing and the crossmember. Continue to tap the pivot shaft through the crossmember.
6. Tap the cross shaft through just enough to add the spacer.
7. As the pivot shaft meets the other side of the crossmember, install another 3/4-inch i.d. spacer. You should have one spacer on each side of the crossmember.
8. Continue tapping the shaft through the last 2 bushings, then stop with about 1/4-inch of shaft sticking out.
9. Use the aluminum capshaft screw (5/16NF X 3/4 countersunk) to tap the shaft through the last 1/4-inch.

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Carb Instructions

INSTALLATION:
1. Switch vehicle ignition to the off position.
2. Loosen the stock rubber grommet hose clamp that connects the stock intake tube to the throttle body. Pry loose the radiator hose retaining clip with a flat head screwdriver next to the fan shroud. Detach the stock intake tube along with the rubber grommet from the throttle body.
3. On the other end, loosen the hose clamp that connects the stock air duct to the mass flow sensor. Pull and remove the stock air duct from the mass flow sensor and away from the engine compartment.
4. Loosen the stock rubber grommet hose clamp that connects your mass flow sensor to the stock filter box. Pull the sensor away from the filter box and set the sensor aside.
5. Remove the stock filter box by pulling straight up and away from the stock filter box mounting tray.
6. Remove the mounting tray from the chassis by loosening all 6 mm bolts with a 10 mm socket or wrench.
7. Install the Volant adapter and gaskets to the stock mass flow sensor by placing the adapter and Volant gasket in the Volant filter box and the 2nd gasket and stock mass flow sensor threw the 3 ¾” hole on the outside of the Volant filter box.
8. Fasten the sensor to the adapter using the three (3) 10/32 x 3/4” bolts with the 5/16” hex key.
9. Install the Volant filter box in the pre-existing space of the stock filter box mounting tray. Use four (4) 6 MM bolts along, four (4) 1/4” lock washers and four (4) fender washers provided to fasten the Volant filter box to the chassis.
10. Note: If you have a Make: GMC/Chevrolet Model: Tahoe/Suburban/Yukon/Escalade/SS Silverado/Avalanche/Denali the part number should be 15153 and the grommet should be provided from Volant. Apply the rubber grommet to the Volant duct on the end were it connect to the throttle body.
11. Note: If you have a Make: GMC/Chevrolet Model: Silverado/Sierra remove the stock rubber grommet from the stock air duct. Re apply the rubber grommet to the Volant air duct on the end were it connects to the throttle body. Install the Volant air duct by connecting it to the throttle body. Do not tighten the hose clamp yet.
12. Slip on the 3 ¾” X 3 ½” sleeve on the other end of the Volant air duct. Connect the attached 3 ¾” X 3 ½” sleeve to the mass flow sensor. Open the #056 & #060 clamps and wrap both around the 3 ¾” X 3 ½” sleeve. Adjust and tighten the #056 clamp, #060 clamp and the rubber grommet hose clamp located on the throttle body. Do not over tighten.
13. Insert the Volant ram filter in the Volant air box. Connect the ram filter to the Volant air box adapter. Secure the ram filter with the filter clamp provided.
14. Cover the Volant air box with the Volant lid. Align the lid and fasten all five (5) ¼”-20 truss head screws along with the ¼” rubber washers. Tighten all five (5) ¼”-20 truss head screws with a phillips screwdriver.
15. Reconnect the plug to the mass flow sensor.
16. Make sure everything is tightened and properly connected.

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1928-59 GM Disc Brake Conversion Kits CP702, CP706, CP711 Installation Instructions

Instructions:
1. Remove early Chevy drums, brakes and backing plates from spindles. Make sure you retain the bearing nut and keyed washer.
2. Thoroughly clean grease and dirt from spindle. Check for cracks or damage.
3. Using one of the original bolts in the forward hole re-install the steering arm in its stock location on the spindle. Using the hardware supplied in the kit install the caliper mounting bracket on the rear of the spindles as shown in the figure. Insert the 1/4’’ thick round spacers between the braket and the spindle. Check for adequate clearance between the bracket and spindle. Trim bracket if necessary.
4. Examine the inner wheel bearing seating area on the spindle for nicks, etc. VERY IMPORTANT: Emery cloth area as required for a smooth surface.
5. Slide bearing adapter on new smooth surface spindle and drive into place using a hammer and a piece of tubing or pipe of suitable dimensions (1 1/2” pipe works great).
DO NOT DAMAGE THE ADAPTER WHILE INSTALLING (use a rag for padding between tool and adapter). Drive adapter on until it seats firmly against spindle inner bearing shoulder.
6. Remove bearings and inner seal from GM rotor. Remove GM inner bearing race and replace both the race and inner bearing assembly with that from a ‘71-’80 Pinto or ‘70-’78 Mustang. This is a widely used Ford inner wheel bearing that is readily available. It is also known as as A-13 inner bearing and consists of a L68149 cone and a L68110 race. Install a standard GM inner seal (National #8871).
7. Install rotor on spindle making sure that inner bearing seats all the way onto bearing adapter.
NOTE: bearings and adapter are machined to a ±.0005” tolerance. If bearing does not slide onto adapter easily it may be due to tolerance “stack-up”. This can be rectified by a small amount of fine emery “paper-work” on the bearing seating surface of the adapter.
8. Install GM outer wheel bearing followed by the 3/4” I.D. x 1/4” spacer (supplied in kit) and then the stock Chevy keyed bearing retaining washer and retaining nut. Adjust bearings a required and install cotter key and bearing dust cover.
9. Clean and inspect caliper for damage, leaks, etc. install caliper on mounting bracket WITH BLEEDER FITTING UP using stock GM mounting bolts. Make sure the bolts aren’t bent or damaged before installing.
10. Fill the brake system with the correct fluid, bleed and inspect for leaks.
11. Check for any brake caliper /rotor/ wheel interference.
12. A proportioning valve may be required.*

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Light Bar Mounting Instructions

LIGHT BAR CUTTING INSTRUCTIONS
1. Two people will be needed to complete this task.
2. Place ONLY THE MOUNTING END CASTING into the rain-gutters of your vehicle.
3. Level each Mounting End Casting so that the top flat area is parallel to the horizon.
4. Take a tape measure and measure the distance between each open end of each Mounting End Casting .
5. Add 2 inches to that dimension.
6. Subtract that total from the total length of the bar, which is 56″.
7. Take the difference and divide it by two.
8. The amount divided by two is the amount you will cut off each end of your bar.

Installation:
1. Please read the light bar cutting instructions on back carefully.
2. Measure and mark a line on both ends of the steel bar using the dimensions provided.
3. Clamp the end of a bar into a vise. (Be careful not to scar the light bar).
4. Using a hacksaw, cut carefully along the marked lines. (If a vise is not available, put the bar on a table, secure tightly and cut).
5. Place the black plastic booties on the feet of each casting.
6. With the holes in the bar, in the up position, take the casting and by squeezing the end of the bar, place the casting on the bar, until the inside top wall of the casting is flat against the bar.
7. Take a 5/16″ Allen head screw and put it through the hole in the casting, and the slot in the bar, with the head of the screw in the up position.
8. Take the larger washer and put it inside the bar, with the 5/16″ Allen head screw, going through the washer. (IMPORTANT): Be sure that the large washer is completely underneath the casting.
9. With the larger washer in position, take a nylon lock nut and Allen wrench provided, and lightly tighten the bar to casting.
10. Follow the same procedure in steps 5 - 9 to attach other casting to the bar.
11. With both of the castings lightly tightened to the bar, take the entire bar and place the bar, with the castings, into the rain gutter of your vehicle. (Note: If your vehicle does not have rain gutters, please refer to the SPECIAL NOTE on the other side of this page).
12. Loosen, DO NOT REMOVE hardware on bar and casting.
13. Slide castings in or out on bar, so that each casting sets completely in rain gutters. (IMPORTANT): Make sure that the bar is centered and that the bar is evenly divided into each casting and that each casting is directly across from each other.
14. Once again, take the Allen wrench and tighten securely the bar to each casting.
15. Position the foot of the “L” shaped steel brackets underneath the rain gutter and line up the vertical slot of the bracket with tapped hole in the casting. Insert (2) ―” Tamper proof Allen head bolts with lock washers through the “L” bracket securing the bracket to support casting. (DO NOT TIGHTEN).
16. Place a screwdriver through the desired horizontal slot in the steel bracket, at the same time put the screwdriver into one of three slots provided in the casting. (Proper selection of the slots in the bracket and the slots in the casting will result in a tighter fit on the vehicle.).
17. Push the screwdriver against the casting and pry up against each bracket, one at a time, until both the casting and brackets are tightly secured in place. Tighten the two Allen head bolts. (CAUTION): Prying up excessively could result in bending of the bracket or stripping the slots in the castings.
18. Follow the same procedure in steps 15, 16, and 17 to secure other casting to rain gutter.
19. The bar and casting should now be tightly secured to the vehicle.
20. Your light bar hardware may settle in. After 2 or 3 weeks of use, go back and re-tighten all hardware. A periodic check on all hardware is recommended.
21. Do not lose your Allen wrench.
22. To maintain the luster of your light bar, apply a polish on a regular basis.

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07-09 GMC Sierra 2500\Chevy Silverado 2500 Bull Bar Installation Instructions

PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
2. NOTE: It may be necessary to remove/relocate front license plate and license plate bracket. It is not required, but strongly recommended. If local/state law requires a license plate, license plate relocation kit is available.
3. From underside of vehicle, remove the two bolts holding the driver factory tow hook, then remove tow hook from vehicle. NOTE: This Bull Bar is not compatible with factory tow hooks, so you will not be reinstalling factory tow hooks back onto vehicle.
4. Determine driver and passenger Frame Brackets. NOTE: Refer to Figure above for bracket configuration. Position driver side Frame Bracket to the outside of the frame rail and secure using the included (2) 12mm x 35mm Hex Head Bolts, (2) 12mm lock Washers, (2) 12mm Hex Nuts, and (4) 12mm Flat Washers (Figure 1). Do not tighten at this time.
5. Repeat steps 3&4 for passenger side Frame Bracket.
6. Loosely attach Bull Bar Brackets to Bull Bar using the included (4) 8mm x 25mm Hex Head Bolts, (4) 8mm Lock Washers, and (4) 8mm Flat Washers (Figure 2). Do not tighten at this time.
7. With help position Bull Bar assembly on the inner side of Frame Brackets. Attach Bull Bar Brackets to Frame Brackets using the included (4) 10mm x 30mm Hex Head Bolts, (4) 10mm Lock Nuts, (4) 10mm Hex Nuts, and (8) 10mm Flat Washers (Figure 3 & 4). Do not tighten at this time.
8. Level and adjust Bull Bar, then tighten all hardware at this time. NOTE: If you can’t reach the Bull Bar Bolts (8mm hardware) from behind of bumper and through tow hook cavity, some cutting might be necessary to the tow hook cavity in order to tighten the Bull Bar Bolts.
9. Do periodic inspections to the installation to make sure that all hardware is secure and tight.
To protect your investment, wax this product after installing. Regular waxing is recommended to add a protective layer over the finish. Do not use any type of polish or wax that may contain abrasives that could damage the finish.
For stainless steel: Aluminum polish may be used to polish small scratches and scuffs on the finish. Mild soap may be used also to clean the Bull Bar.
For gloss black finishes: Mild soap may be used to clean the Bull Bar.

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Kodiak Kits Installation Instructions

Step Installation: Complete Part One, then find the section for specific instructions for your model vehicle.
Part One: Rear bracket attachment
Step 1) Attach the rear brackets to the step as shown in Figure 1, using a washer, E, and nut, I, on each stud. Tighten each nut.
Step 2) Place the cross member in position as shown in Figure 2, and secure using washers D and F, and one nut, H on each stud. Leave fasteners loose, as the bracket slots will be used to determine exact fit of rear upright bracket.

Part Two: Mounting the Step
Step 1) Measure from rear edge of door toward the front of the vehicle as shown in Figure 3. The first bolt hole location on the flange under the door will be Dimension ‘X’ (see Table 1) forward, and ― “ up from the underside edge (as shown in Figure 4). The second bolt hole will be 5 ž” forward from the first hole, and ―” up from the lower edge of the rocker panel. Mark both hole locations with a scribe or marker.
Step 2) Center punch each of the marks and drill both holes using a 1/8” drill bit for a pilot, followed by a 5/16” drill bit.
Step 3) Place the step in position, resting the front of the main bracket on the kick-panel. Install the two (2) 5/16-18 x ū button head cap screws. Temporarily tighten the step into position.
Step 4) Loosely assemble the short angle brackets to the step, as shown in Figure 4. NOTE: The step may also be mounted to the body floor rib as shown in Alternate Figure 4 . Place the flange of each bracket against the vehicle frame, and hand tighten all fasteners to hold step tread level or angled upwards slightly. Mark the rear mounting holes in the frame with a scribe or marker. Remove the short angle brackets, and the step if necessary, to provide room for drilling the rear mounting holes.
Step 5) Center punch the rear mounting hole marks on the vehicle frame. Drill the mounting holes using first a 1/8” drill bit for a pilot, followed by a 5/16” drill bit.

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Chevy/GMC Silverado/Sierra P/U 1500 4 Door Pro Step Installation Instructions

Before Starting Installation
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.
3. Only install this kit on the vehicle for which it is specified.
4. Special tools needed:
a. 17/64” & 5/16” drill bits
b. Tool to trim sheet metal
5. Park vehicle on a clean, dry, flat, level surface and block tires so vehicle cannot roll in either direction.

Engine Compartment
1. Disconnect both battery cables. Disconnect negative cable first, then positive cable.
2. Remove Factory Side Bars if equipped
NOTE: Kit parts are prefaced by the word kit and appear in bold print.
NOTE: If parts are missing from kit, please be prepared to pro-
vide 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
Positive Cable
Negative Cable
Prepare to Install Kit
Drivers Side of Vehicle
1. Mounting locations.
2. Enlarge holes using grinder or body saw in three mounting locations to accept kit bracket (slotted) and install one kit bolt & hanger in each.

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Guardian II Commercial Lift Interlock GRD602-C Installation Instructions

GUARDIAN MODULE - Remove the lower dash panel below the steering column. The Guardian Module should be positioned in a secure area below the steering column. It can be secured using self tapping screws, adhesive foam tape, or wire ties. Do not secure the module until all harnesses are installed and proper lift operation has been verified.

LED DISPLAY PANEL – This harness can be identified by the blue tape near the 6-pin connector. Locate a suitable position on the dashboard, within view of the driver for the mounting of the LED Display Panel. The length of the display harness is 40”. This is the maximum distance the display can be from the Guardian module. Drill a พ” hole in the dashboard where you wish the center of the display to be. Snap the blue taped end of the LED display harness into the Guardian Module in the connector labeled in blue “Display”. Run the other end of the harness under the dash and out through the พ” hole. Snap the end of the display harness into the LED Display Panel. Ensure panel is level, and secure using the supplied screws.

LIFT HARNESS - This harness can be identified by the green tape near the 6-pin connector. Attach the red wire with the inline fuse to the vehicle battery positive post (run wire through bulkhead see FIG. 2). There is a large eyelet taped to the fuse holder that can be used for this purpose. Attach the black wire with the eyelet to a good ground point. Run the gray cable back towards the lift (Foot-well and drivers kick panel trim may be removed for harness routing). The black wire in the gray cable will attach to the lift door switch. This switch must provide a ground only when the lift door is open. Attach the red wire in the gray cable to the interlock input to the lift. This wire will provide 12V to the lift when all interlock conditions are met. Maximum current for this circuit is 8A.
Application compatible for:
Chevy/GMC Full Size Van (GMT 610)
2008 - All Engines
2009 – All Engines Except 6.6L

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1999-2005 GM-All Mini Vans, Astro & Venture Secure Idle Installation

“SECURE IDLE” is an ignition switch bypass device designed to provide all the electrical functions that the OEM ignition switch normally provides. For proper operation and long term performance, do not deviate from the wire connection instruction. For each wire connection, remove approximately one half inch of insulation from the OEM wire, but DO NOT cut the wire into. Cutting the wires causes high resistance and a possible failure point. Strip app. one half inch of insulation from the end of the “SECURE IDLE” wires to be attached to the OEM wires. Wrap the “SECURE IDLE” wire around the bare area of the OEM wire and solder the connection. Tape the connection thoroughly after it cools.

DO NOT use “Scotch Lock” type pinch thru connectors. These connectors cannot handle the higher amperages of the ignition circuits, and will void the “SECURE IDLE” warranty.
Use the attached wiring diagram to locate the correct wire and pin location.

INSTALLATION
1. Remove the lower dash panel under the steering column to access the OEM ignition switch which is mounted on the steering column. Mount the “SECURE IDLE” unit near the ignition switch.
2. Locate a good metal ground and connect the BLACK “SECUER IDLE” wire using the ring connector provided.
3. Locate the OEM ignition switch and wiring.
Remove the insulation from the ORANGE wire, Pin C6, Circuit 300, and attach the RED 14 Ga. “SECURE IDLE” wire according to the above instructions. This OEM wire will be hot in RUN only.
4. Locate the BROWN wire, Pin D6, Circuit 4.
Attach the Violet 14 Ga. “SECURE IDLE” wire according to the instructions. This OEM wire will be hot in RUN and ACC.
5. Locate the PINK wire, Pin C5, Circuit 3.
Attach the WHITE 14 Ga. “SECURE IDLE” wire according to the instructions. This OEM wire will be hot in RUN and START.
6. Locate the WHITE wire, Pin C1, Circuit 1390.
Attach the YELLOW 14 Ga. “SECURE IDLE” wire according to the instructions. This OEM wire will be hot in START and RUN only.
7. Locate the RED wire, Pin D2, Circuit 342.
Attach the GRAY “FUSIBLE LINK” wire according to the instructions. Connect the RED 10 Ga. wire to the “FUSIBLE LINK” by way of the quick disconnect connector. This OEM wire will be HOT CONTINUOUSLY.
8. Locate the YELLOW wire, D1, Circuit 5.
Cut this wire into, being sure to leave enough room to strip back the ends and install Butt connectors.
Strip back the ends of the OEM wires app. one quarter of an inch. Crimp on the BLUE 14/16 Ga. Butt connectors.
Connect the GREEN “SECURE IDLE” wire to the YELLOW wire end which leads back to the wire harness.
Connect the BLUE “SECURE IDLE” wire to the YELLOW wire end which leads to the ignition switch.
This OEM wire will be HOT in START only.

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2001-2004 GM Duramax 6.6L LB7 Power Edge LB7 EZ Installation Instructions

Thank you for purchasing the Power Edge LB7 EZ Module for the Chevy/GMC
Duramax® Diesel LB7. The EZ module has been developed and produced from the highest quality materials available to ensure the best performance for years to come. If you have any questions, please contact Edge Products. The EZ Module is an add-on Engine Control Module (ECM) for the Duramax® Engine that offers additional features not available with the factory setup. Since it is an add-on ECM, it uses all the factory data, and then enhances the factory settings to optimize your truck’s performance.

These features include:
• Engine temperature monitoring and power increase from the EZ module as engine reaches operating temperature
• Three selectable power level settings that can be changed on the fly
• Smart power control during torque converter lockup to allow a smooth, easy torque converter clutch lock-up

The EZ module offers a large power increase over stock throughout the rpm range, but the power is most noticeable in the midrange rpm’s. This greatly improves drivability and towing performance. Transmission downshifting is greatly reduced, especially while passing or towing.

The EZ also regulates power delivery based on engine temperature. This means that while the engine temperature is below 140° F no additional fueling is delivered. At 140° F the module begins delivering fuel at 25% of the calculated additional fuel, and the percentage increases as the engine temperature increases, until at full engine temperature (174° F) the EZ delivers 100% of the calculated additional fuel.

Warning: Do not stack the Edge LB7 EZ with the Edge LB7 Juice. It can cause severe damage to the engine.

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Chevrolet/GMC 1500 Short & Long Bed 2500 Light Duty Short Bed Installation

Installation Instructions
1. Figure 2 shows a cable bracket which holds a brake line to the inside of the frame rail. Loosen this bracket from the top of the frame and move the brake line down about 1/2” so that it is not interfering with hitch cross members.
2. From underneath the passenger’s side of vehicle remove or cut out the section of the heat shield that is located between the frame rails and the bed of the vehicle.
3. From the driver’s side wheel well, notch or bend the sheet metal flange as shown in Figure 3. (Optional: The vehicle bed can be lifted to insert the hitch cross members by loosening the bolts that attach the bed to the frame).
4. Slide the hitch cross members half way through the notches or bends in the sheet metal flange and place 5/8 carriage bolts from the 9461/9463 fastener kit into the long slots from underneath the vehicle. Slide the hitch cross members above both vehicle frame rails and align hitch cross members as shown in Figure 4.
5. Place 1/4 X 1.00 X 3.00 blocks and 1/2-13 X 2.75 hex bolts through slots in the driver’s side and passenger’s side of vehicle frame pointing outwards.
6. Install the hitch frame brackets by aligning the rearward holes in the brackets with the fasteners installed in installation step 5. Loosely install the 5/8-11 X 1.50 hex bolts, lock washers, and flat washers through the slot in the hitch frame brackets and into the threaded blocks on the ends of the hitch cross members (see Figure 5).
7. Install the frame bracket clamp by placing the clamp to the inside of the frame rail, insert the 1/2-13 X 4.50 GR5 carriage bolts through the square holes in the clamp and through the frame bracket with the threaded end pointing outwards. Install the lock washers and hex nuts.
8. When installing the 9461/9463 Hide-A-Goose hitch, a 4” hole must be drilled in the bed of the truck. Mark and drill a 1/4” hole 44-3/4 inches (short box) / 49-1/2 inches (long box) from the rear of the bed and centered between the wheel wells. Refer to the 9461/9463 Hide-A-Goose hitch instruction sheet. Drill the 4 inch hole in the bed of the truck with a 4” hole saw using the 1/4” hole as a pilot.
9. Place the trim ring from the 9461/9463 Hide-A-Goose kit into the 4” opening.
10. Loosely install the 9461/9463 Hide-A-Goose hitch. Refer to the 9461/9463 instruction sheet.
11. After fully installing the 9461/9463 Hide-A-Goose hitch and 4431mounting kit, carefully align the hitch ball sleeve with the 4” opening and the trim ring in the truck bed. Torque all 5/8-11 GR5 fasteners on the brackets to 150 ft.-lb. (203 N-m) and 1/2-13 GR5 fasteners to 75 ft.-lb. (102 N-m). Use the following sequence: a) torque frame brackets to the frame of the vehicle, b) torque cross members to the frame brackets c) torque Hide-A-Goose hitch to cross members.
12. If sheet metal flange is notched or bent in installation step 4, use paint to prevent corrosion on the sheet metal flange. If vehicle bed was lifted to insert cross member, tighten bolts that attach the bed to the frame.

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2001-2004 Chev/GMC Duramax Diesel S6000AL Install Series

Removal of stock system:
First using 15mm socket or wrench, remove four (4) nuts at flange located approximately under the passenger side seat. Remove rear exhaust from rubber hangers and remove the system from under the truck.
NOTE: If you have purchased the optional front pipe, Remove the stock front pipe on the truck by removing the exhaust hanger on the transmission using a 13mm socket, then remove the band clamp at the front of the pipe, then remove stock front pipe from the truck. ( Note: the band clamp will be re-used during the installation of your new MBRP system).

Installation of MBRP Inc. Performance Exhaust:
NOTE: Only for those who have purchased the optional front:
Install front exhaust pipe using stock band clamp.
Install steel hanger back on transmission and hook to steel rod welded on pipe.

Standard installation:
Install the slip joint to the stock front pipe. ( Four Bolt Flange )
Install extension pipe into the front pipe (Installation tip: Temporarily hang the muffler and tail pipe in place using the two OEM rubber hangers and measure to the down pipe to determine the length needed) approximately 9―” needs to be cut off for extended cab short bed and 20″ for the regular cab long bed. Crew Cab Long Bed Trucks Require an 18″ extension.
Install muffler over the extension pipe(s) and then install the tailpipe into the muffler from the rear of the truck.

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2004-2006 Chevy Colorado Brute Force Intake System Installation Instructions

Getting Started
a) Make sure vehicle is parked on a level surface. Set parking brake.
b) Disconnect negative battery terminal from the battery.
c) If engine has run within the past two hours, let it cool down.

Removal of the stock intake system.
a) Before removing any of the O.E. components, label each individual part so that no components become mixed up during the installation process.
b) Unplug the wire harness from the Mass Air Flow (MAF) sensor. Remove the two screws retaining the MAF sensor and carefully remove the MAF sensor
c) Loosen the hose clamp on the stock air box. Remove the air box by removing the two bolts and the nut securing it. Lift air box out of vehicle.
d) Loosen the hose clamp on the throttle body attached to the stock intake resonator. Unplug the small breather hose connected to the front of the resonator.
e) Remove the two bolts securing the resonator to the valve cover. Lift the resonator up and remove the breather hose from the valve cover and remove the resonator.
f) Remove the rubber breather hose adapter plug from the hard plastic breather hose by gently pulling it off while holding the hard plastic line.

Installing the AEM Brute Force Intake
a) When installing the Cold Air Intake System, DO NOT completely tighten the hose clamps or mounting tab hardware until instructed to do so later in these instructions.
a) Install the supplied rubber mount on to the AEM heat shield using one each of the supplied washers and locknuts.
b) Install the AEM heat shield, using two supplied bolts and washers and the original air box mounting nut. Install rubber edge trim to the top of the heat shield.

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1998-99 Chevy/GMC C/K Pickup - 2 Dr, Ext Cab Installation Instructions

Installation Instruction:
1. Verify all the parts from the list above are present and accounted for. Please read instructions completely before starting.
2. Remove existing body mount bolts as shown. DO NOT DISCARD! (Fig. 1)
3. Install front and rear brackets as shown (Fig. 1 & 4). Hand tighten.
4. Remove existing plugs from rear inside body panel as shown (Fig. 2).
5. Attach plastic washer to bolt plate. Insert bolt plate as shown (Fig. 2).
6. Remove existing M8 bolt and flat washer from underside of front body panel as shown. DO NOT DISCARD! (Fig. 4)
7. Install front and rear support braces as shown. Hand tighten. (Fig. 1, 3, 4)
8. Place oval step bars on brackets. Each step bar is marked driver and passenger.
9. Assemble with M10 button head bolts and M10 washers. 2 bolts per bracket, 4 bolts per bar (see Fig 5). Hand tighten.

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GMC Wipers Electric Motor Replacement for OEM Hydraulic Wiper Motor

This is the installed electric motor conversion kit. Notice that the base plate is attached through the same bolt holes which held the hydraulic wiper motor in place. The pivot bolt for the Idler Arm Assembly is in the same position as the shaft of the hydraulic motor and the Linkage Arm (hidden at top) is the same length and configuration as that on the OEM motor, with one exception: the OEM driver and passenger wiper linkages were held to the linkage arm by latches; this design uses washers and cotter pins instead.

The geometry of the Motor Arm, the Idler arm, and the Connecting link with the ball joint on each end makes the Linkage Arm move in exactly the same motion as did the motor arm on the hydraulic motor, with three exceptions: 1. Holes in the Idler Arm allow the wiper arm sweep to be set to one of three fixed arcs to allow for variations in assembly and wear between different coaches. 2. A slotted ball joint hole in the motor arm allows infinitely variable adjustment around the fixed sweeps established by those holes. 3. The length of the link between the ball joints can be changed to adjust the position of the wipers’ sweep arc, minimizing the need to move the wiper arms on their pivots.

The Lumina APV motor is shown with the motor housing extending to the driver’s side of the GMC (3 o’clock position). Late production mounting bases have 3 additional holes which allow the motor to be oriented to the 7 o’clock position.

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Flip Tarp Assembly Instructions

The Flip tarp is designed and pre-assembled for a drivers side mount, however it can also be mounted on the passenger side by applying some simple modifications. FOR A DRIVERS SIDE MOUNT SKIP TO STEP II.
Modifications for a drivers side mount
a. Locate the power unit mounting plate in the motor assembly.
b. Unbolt the mounting plate and rotate 180 degrees. Re-place bolts.
c. Unbolt the actuator and rotate it until the valves are one bolt pattern off vertical, pointing down and towards the power pack. Re-place bolts. (task is best accomplished with 2 people, one holds the actuator which weighs approx. 50 lbs, and the other removes and places the bolts.)
d. Unbolt the Sun Hydraulic Counterbalance Valve and rotate it 180 degrees. Re-place bolts.

Front and rear arm assemblies
a. Attach the straight arm and the bent arm to the mounting angle using 5/8”x 6” bolts with washers placed under the bolt head and the nut. Snug the nut against the ear; do NOT deform ears when tightening.
b. When mounting the arms, mount the bents arms to the middle most ears in relation to the trailer body.
c. The end plate is then bolted between the two arms. Adjust the end plate so that it clears the trailer by approximately one (1) inch.

Connecting the arm and the motor assembly to the trailer body
a. Once the front arm is assembled, position the holes in the outside of the mounting plate on the out side of the straight arm in alignment with the holes on the three-inch angle located on the motor assembly. Bolt the mounting plate to the motor assembly.
b. Using a lifting device such as a forklift or a crane, lift the two pieces until the mounting angle for the arms is resting on the side of the truck, and the back plate of motor assembly is flush against the front of the trailer.
c. Clamp the motor assembly and the mounting plate to the trailer. If necessary shim under the mounting plate.
d. Drill holes and bolt mounting plate to the trailer.
e. Make sure that the motor assembly is still properly placed; adjust connection between mounting plate and motor assembly if needed.
f. Drill holes and bolt motor assembly into place.

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01-06 Chevy/GMC 2500 HD 4×4 3″ Suspension lift Installation Instructions

FRONT DISASSEMBLY:
1.With vehicle on flat level ground set the emergency brake and block the rear tires. Place floor jack under the lower control arm’s front cross member and raise vehicle. Place jack stands under frame rails, behind the front wheel wells and lower the frame onto the stands.
2. Remove both front factory skid plates located in front of and under the front differential using 15mm socket.
WARNING: Be extremely careful when loading or unloading the torsion bars; there is a tremendous amount of stored energy (load pressure) in the bars. Keep your hands and body clear of the adjuster arm assembly and puller tool in case anything slips or breaks
NOTE: A special PULLER TOOL is required for SAFE
REMOVAL/INSTALLATION of the Torsion bars. This special puller can be purchased from a GM Dealer (Tool #J36202) or from Kent Moore Tool Group, Roseville, MI (800) 345-2233 or (313) 774-9500 (Part #J-22517-C).
3. Locate the torsion bar adjuster bolt on the bottom of the rear cross member, measure and record the length of the torsion bar adjusting bolt that is exposed below the nut, and remove the torsion bar adjusting bolt. Apply a small amount of lubricating grease to the puller threads and the puller shaft-to-adjuster arm contact point. Position puller and load adjuster arm until the adjuster nut can be removed from the cross member. With the bar unloaded, slide it further forward into the lower control arm. If the bar seems lodged, use a hammer and punch through the hole in back of the cross member. When the bar shifts forward, the adjuster will fall free. (See Photo #2). Repeat this process on passenger side.
4. With torsion bars removed from rear cross member, remove torsion bar cross member using 21mm socket. With cross member removed, remove the torsion bars from the vehicle, be sure to mark driver and passenger for reinstallation.
5. Remove front tires and remove the front shocks using 21mm socket and 15mm wrench. Remove front sway bar links using 13mm wrench. Be sure to save sway bar link bushings. They will be reused in further installation.
6. Remove the tie rod end nut from knuckle using 21mm socket. Remove the tie rod end from the knuckle by striking the knuckle to dislodge the tie rod end. Be careful not to damage the tie rod end.

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96-00 Chevrolet/GMC C/K 7.4L PowerAid Throttle Body Spacer Installation Instructions

Installation Instructions:
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Remove air cleaner assembly.
3. Using 10mm socket remove (3) nuts and studs from front side of throttle body. (Ref. “C”)
4. Remove air cleaner mounting stud and bolt from throttle linkage bracket and save.
5. Install (2) linkage extension plates using (2) 5/16 x 3/4” flat head screws. (Ref. “D”)
6. Install air cleaner mounting stud (Refer to Step 4) using 5/16-18” nut and lock washer.
7. Install power plate using (2) gaskets. (Ref. “A”)
A. Place one gasket between the throttle body and the power plate
B. Place second gasket between the power plate and intake manifold.
8. Replace nuts and studs (Refer to Step 3) with (3) 6mm x 60mm bolts.
10. Inspect & Test the throttle linkage for full Open & Closed travel before driving. Some cruise or kickdown cables may require adjustment. Please refer to your vehicles service manual for proper adjustment.
11. Reinstall air cleaner assembly using Step 2 as an example.
12. Reconnect battery cable. Enjoy!

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2004-2005 Chevy Silverado 2500HD & 3500 Brute Force Intake System Installation

The AEM Brute Force Intake System is the result of extensive development on a wide variety of cars. It is the most advanced short pipe air intake system on the market. Each system is specifically engineered for its particular application. All AEM Brute Force Intake Systems deliver maximum performance gains through the lightweight, all-aluminum, mandrel-bent tubing that is tuned in both length and diameter. The tube length and diameter are matched for each specific engine to give power over a broad RPM range. Every intake is coated with a high-gloss, heat-reducing Zirconia based powder coating.

This special blend of powder coating helps reduce heat penetration, which in turn reduces the temperature of the inlet air charge. The cooler inlet air temperature translates to more power during the combustion process because cool air is denser than warm air. The air mass flow to the engine is increased because of the increased airflow and reduced inlet temperature, which translates to more power.

Getting Started
a) Make sure vehicle is parked on a level surface. Set parking brake.
b) Disconnect negative battery terminal from both batteries.
c) If engine has run within the past two hours, let it cool down.

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GM Duramax 6.6L Edge LLY EZ Module Installation Instructions and Manual

Thank you for purchasing the Power Edge LLY EZ Module for the Chevy/GMC Duramax® Diesel LLY. The EZ module has been developed and produced from the highest quality materials available to ensure the best performance for years to come. If you have any questions, please contact Edge Products.

The EZ Module is an add-on Engine Control Module (ECM) for the Duramax® Engine that offers additional features not available with the factory setup. Since it is an add-on ECM, it uses all the factory data, and then enhances the factory settings to optimize your truck’s performance.

These features include:
• Engine temperature monitoring and power increase from the EZ module as engine reaches operating temperature
• Three selectable power level settings that can be changed on the fly
• Smart power control during torque converter lockup to allow a smooth, easy torque converter clutch lock-up

The EZ also regulates power delivery and timing based on engine temperature. This means that while the engine temperature is below 160° F no additional fueling or timing is delivered. At 160° F the module begins delivering fuel and adding timing at 50% of the calculated additional fuel, and the percentage increases as the engine temperature increases, until at full engine temperature (174° F) the EZ delivers 100% of the calculated additional fuel and added timing.

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Chevrolet/GMC Trucks & Suburbans Performer Multi-Point EFI System TBI-Equipped

Performer Multi-Point EFI Systems are designed for 1987-1992 (#3502) and 1993-1995 (#3501) 5.7L Chevy/GMCs originally equipped with Throttle Body Injection. These complete systems utilize the stock computer and throttle body unit for a simple and effective conversion to multi-point fuel injection. Fuel is injected directly into each port in the head for ideal fuel distribution and efficiency.

In 1987, Chevrolet introduced their Throttle Body Injection (TBI) systems. Produced from 1987 to 1995 on all pick-up trucks and Suburbans, this TBI system was essentially an intermediate step between a carburetor and true port (multi-point) fuel injection. In these TBI systems, two injectors are positioned above the throttle blades of a two-barrel throttle body and fuel is injected into the manifold, much like a carburetted system. This arrangement suffers from distribution problems because the fuel spray from the injectors does not stay in suspension with the incoming air, resulting in uneven distribution. Our Performer Multi-Point Systems include an intake manifold designed to deliver an equal air charge to each cylinder. Each injector delivers exactly the same amount of fuel to each cylinder for an extremely even air/fuel ratio from cylinder-to-cylinder. This permits us to tune the system for ideal fuel and spark delivery for more horsepower, torque and improved mileage.

Performer Multi-Point Systems include all parts needed to make the conversion. The stock TBI unit is retained as an air valve and the factory computer (re-programmed) is also retained to control the injectors in a batch-fire mode. In the Edelbrock systems, all of the factory sensors are retained and fully functional. The compact size was achieved by using extruded aluminum fuel rails with new Magnetti Marelli® pico injectors. These are half the size of conventional style injectors.

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Riser Water Pump Kit Instructions

Use stock Chevrolet crank pulley; for double groove use GM part# 37744043. We use early (5/8”cc) groove spacing on pulleys.
1. Straight up thermostat housings work the best for most installations.
a) Murray # 277689 (54-72 GMC & Chevy light trucks)
b) Super Sunny #S6002 straight up billet aluminum housing
2. Engine driven fans:
a) Permacool 15” or 17” fan: this is polished, stainless steel.
b) Blades may have to be trimmed slightly
Note: most fans will require the use of a special fan spacer; they are available from us
3. The following hoses work well with this kit:
a) Dayco 70-477 upper hose
b) Dayco 70-457 lower hose
4. Water pump to Riser housing gasket: GM Part# 90190983
*use ULTRA BLUE silicone if you do not have a gasket
5. Pump furnished with kit is German Opal, with 7mm mounting holes clearance drilled
to 11/32 or “R” size 6. Rear fins on pump housing must be clearanced slightly when used with some manifolds that have their thermostat housing pushed forward. ie; 48 IDA Weber or dual four BBL manifolds
IMPORTANT NOTES: some engines trap air in the top of the Riser pump housing when the radiator is initially filled with water. Bleed trapped air through 1/8” brass air bleed at the top of Riser housing…run engine for a minute and rebleed. We do not use a bypass hole on the Riser pump; bypass is used for fast car heater warm-up and to circulate water in the block when the thermostat is closed. You must provide a means for water to circulate in the engine with a closed thermostat.

Drill bypass holes in thermostat: (SEE Below)
a) Drill one to three 1/16” holes in thermostat plate
b) OR: knock out center valve and use the plate only
c) If you do not have a car heater; run a hose from one of the front ―” holes on intake manifold to the heater hose nipple on the water pump inlet, however you must:Restrict the flow of water to the pump by placing a restrictor plug in the hose with a 3/16 or 1/4 inch hole.

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2007 Chevrolet Silverado/GMC Sierra 2WD and 4WD Superlift 6″ Lift System Installation

Installation requires a professional mechanic. Prior to beginning, inspect the vehicles steering, driveline, and brake systems, paying close attention to the suspension link arms and bushings, anti-sway bars and bushings, tie rod ends, pitman arm, ball joints and wheel bearings. Also check the steering sector-to-frame and all suspension-to-frame attaching points for stress cracks. The overall vehicle must be in excellent working condition; repair or replace all worn parts. Read instructions several times before starting. Be sure you have all needed parts and know where they install. Read each step completely as you go.

NOTES:
• Prior to beginning the installation, check all parts and hardware in the box with the parts list below. If you find a packaging error, contact Superlift directly. Do not contact the dealer where the system was originally purchased. You will need the control number from each box when calling; this number is located at the bottom of the part number label and to the right of the bar code.
• 2007 1/2-ton GM vehicles are equipped with the StabiliTrak traction control system, commonly refered to as ESC. Premature system engagement and an associated warning light on the dash may be encountered after installing this or any other lift system. ESC function is impacted by tire size and a multitude of other factors. It will be necessary to take the vehicle to the nearest GM dealer and have the system re-programmed or “re- flashed” with the tire diameter listed in GM’s system closest to the actual diameter of the tires installed on the vehicle. Be aware, however, that the vehicle may still exhibit premature system engagement even after it has been re-programmed under certain driving conditions. Note that the ESC system will be impacted if the steering wheel is not properly centered and that the system can be disabled by depressing the traction control button located in the center stack of the dash; refer to the owner’s manual for more information about what systems are impacted by depressing the traction control button. Superlift is working on an ESC recalibration system; check the website for the latest information.
• This system will accommodate the factory wheels equipped with larger-than-stock tires as well as the factory spare tire / wheel.
• Rear lift is sold separately and includes its own instructions. Refer to those instructions before proceeding with the installation.
• A special tool is required to disassemble / assemble the front struts. Other special tools are recommended to detach/attach the pitman/idler studs. Refer to the factory service manual.
• Front end realignment is necessary.
• An arrow on diagrams indicates which direction is toward the front of the vehicle.

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Stake Pocket Rail Installation Instructions

Before installing any bed rail on any vehicle, you must insure there is adequate clearance for the installation. Some vehicles do not have a protective “inner bed wall”, and rough treatment can result in a distortion created from within the truck bed. Daws Manufacturing Co. Inc. will not be liable for any installation damages created by the installation or installer. Prior planning and care are the installer’s responsibility.

1. Read and understand these instructions before beginning the installation.
2. Attach the adjustable feet to the rail making sure the beveled side of the foot matches the bevel of the flat head screws. You must use 2 screws per foot to keep the foot straight. Use the chart on the reverse side of these instructions to set the correct length or gently set the bed rails in position being careful not to scratch the truck. Use the plastic gaskets for protection. Adjust the flat feet so the mounting hole is centered over the stake pocket hole. Tighten the screws securely.
3. Look at the truck from both sides and the rear to be sure you are satisfied with the appearance. NOTE: Ford F150 ’97 to current and 2001 Tundra will need to have the stake pocket covers marked for hole location where the bolt will pass through. When you are satisfied with the rail position, mark the hole location on the stake pocket cover.
4. Place the button head bolt through the protective plastic washer, rail foot, and rail gasket (now is the time to install the ’97 Ford or 2001 Tundra stake pocket cover if necessary). Thread the proper locking bar onto the bolt, just a few threads deep. You will need to keep the locking bar loose at this time.
5. Carefully place the rail on the truck bed while inserting the locking bars into the stake pocket hole. The locking bars must fit under the lip of the stake pocket hole so when the bolt is tightened, they hold the rail to the top of the truck’s bedrail.
6. Refer to the warning note at the top of the page. The locking bars must not contact the outer fender wall of the vehicle, or they may create a distortion in the metal when tightened. To help prevent this from happening, tension can be applied to the locking bar by lifting up the bed rail while tightening the button head bolt. This tension must be held to prevent the locking bar from turning in the hole and contacting the outer skin of the fender.
7. Tighten the bolts enough to secure the rail to the truck without unnecessary torque. Excessive tightening on the button head bolts can distort the fender top.

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Bolt-On Shave Door Handle Kit Installation

1. Assemble your motor/bracket assembly. Your actuators came with two Phillips head screws. Use these to secure your the actuator to the bracket.
2. Remove the door panel and 3 torque screws that hold the latch. For most GM vehicles, screw size is T30.
3.Using a pick or similar tool, un-snap the plastic retaining clip that holds the rod to the back of the inside handle. Be careful not to damage the rod; you will reuse it.
4. Remove the clip that holds the wiring to the door and push it through. This step is not required if your vehicle doesn’t have power door locks.
5. Permanently remove all rods except the interior door handle rods connected to the latch. For non-power door vehicles, 2 rods should be removed. Power door vehicles: 3 rods should be removed.
6.To easily remove the door latch, unbolt your window track bolts. There should be two 10mm bolts on the right side of your door, one on top and one on the bottom. Do not bend the window track or door latch.
7. Power door lock vehicles will have wiring plugged into the latch. Unplug the wiring that goes to the latch.
8. Make sure the latch is in the unlocked position. Slide the bracket over the same lever, then line up the three holes on the bracket with the three holes on the latch.
9. With a screwdriver, hand-tighten the Phillips screws from the bracket to the latch. Don’t use power tools/overtighten.
10. Line up the motor with the latch lever. Then insert the bolt.
11. Now install the washer and the nut. Only tighten enough so the tip of the bolt is flush with the nut.
12. This step is not required for non-power vehicles. Plug in the two top plugs. Don’t plug in the plug that goes to the power lock motor. Zip tie or strap it off out of the way of the window.

This kit will fit the following vehicles:
•1994-2003 Chevy S10/S10 Blazer
•1994-2003 GMC Sonoma/Jimmy
•1999-2006 Chevy Silverado
•1999-2006 GMC Sierra
•2001-2006 GMC Yukon (Front doors only)
•2001-2006 GMC Yukon (Front doors only)
•2000-2006 Chevy Monte Carlo
Note: This kit is universal for the above years/makes/models. These instructions are given as a guide. Your door latch may vary from what is pictured in this instruction guide.

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Low Profile Light Bar Mounting Instructions

Preparing:
1. Two people will be needed to complete this task.
2. Place ONLY THE MOUNTING END CASTING into the rain-gutters of your vehicle.
3. Level each Mounting End Casting so that the top flat area is parallel to the horizon.
4. Take a tape measure and measure the distance between each open end of each Mounting End Casting .
5. Add 2 inches to that dimension.
6. Subtract that total from the total length of the bar, which is 56″.
7. Take the difference and divide it by two.
8. The amount divided by two is the amount you will cut off each end of your bar.

Installation:
1. Please read the Light Bar Cutting Instructions on the other side carefully.
2. Measure and mark a line using the information from the Light Bar Cutting Instruction on both ends of the steel bar.
3. Clamp the end of a bar into a vise. (Be careful not to scar the finish of the light bar).
4. Using a hacksaw, cut carefully along the marked lines. If a vise is not available, put the bar on a table, secure tightly and cut.
5. Place the black plastic booties on the feet of each casting.
6. With the holes in the bar, in the up position, take the casting and by squeezing the end of the bar, place the casting on the bar, until the inside top wall of the casting is flat against the inside of the bar.
7. Take a 5/16″ Allen head screw and put it through the hole in the casting, and the slot in the bar, with the head of the screw in the up position. (If there is no slot in the bar after cutting the bar to the length, place both castings on the bar, position the entire bar on the truck in its final position so that each casting sets completely in the rain gutters. Use the top holes in the castings as a guide and mark the holes on both ends of the bar. Take the castings off the bar and drill out the marked holes with 5/16” drill bit).
8. Take the larger washer and put it inside the bar, with the 5/16″ Allen head screw, going through the washer.
IMPORTANT: Be sure that the large washer is completely underneath the casting.
9. With the larger washer in position, take a nylon lock nut and Allen wrench provided, and lightly tighten the bar to casting.
10. Follow the same procedure in steps 5 - 9 to attach other casting to the bar.
11. With both of the castings lightly tightened to the bar, take the entire bar and place the bar, with the castings, into the rain gutter of your vehicle. Note: If your vehicle does not have rain gutters, please refer to the SPECIAL NOTE on the other side of this page.
12. Loosen, DO NOT REMOVE hardware on bar and casting.

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1999-2007 Chevy/GMC 4.8/5.3/6.0L Mac Performance Installation Instructions

1. Start by loosening the hose clamp from the stock air tube to the throttle body as shown.
2. Remove the clip from the located on the coolant hose to the stock air tube as shown.
3. Loosen the hose clamp on the stock air tube that is attached to the stock air box as shown.
4. Remove the stock air tube as shown.
5. Remove the clip from the MAF sensor and unplug the sensor as shown.
6. Remove the stock air box by pulling it straight up as shown.
7. Once the stock air box is removed, remove the plate that held it in place and set aside hardware for reuse with the MAC system.
8. Remove the MAF meter from the stock air box for reuse with the MAC air system.
9. Install the rubber o-ring supplied in the kit onto the MAF meter as shown.
10. Install the MAF meter to the velocity adaptor through the MAC air dam as shown and tighten using the hardware provided.
11. Install the MAC air dam in the stock location using the stock hardware as shown.
12. Install the 35° elbow to the MAF sensor as shown and install the 80° elbow to the throttle body.
13. Install the MAC air tube and attach the clip for the coolant hose as shown. Note: Do not over tighten the hose clamps.
14. Install the MAC air filter to the velocity adaptor and tighten. Note: Do not over tighten the hose clamp on the MAC filter.
15. Reconnect the MAF sensor and reinstall the clip as shown. Check to make sure that everything is tight. Next Install the MAC cover to the air chamber using the 2 fitting provided in the kit.
You are Finished.

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1999-2005 Chevrolet Silverado 1/2-Ton 4WD Superlift Torque Max Traction Bar System Installation

NOTES:
• An arrow on diagrams indicates which direction is toward the front of the vehicle.
• A foot-pound torque reading is given in parenthesis ( ) after each appropriate fastener.
• Do not fabricate any components to gain additional suspension height.
• Prior to drilling or cutting, check behind the surface being worked on for any wires, lines, or hoses that could be damaged.
• After drilling, file smooth any burrs and sharp edges.
• Paint or undercoat all exposed metal surfaces.
• Prior to attaching components, be sure all mating surfaces are free of grit, grease, undercoating, etc.
• A factory service manual should be on hand for reference.

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2000-Up Chevrolet Tahoe/GMC Yukon 2/3 Torsion Bar/Coil Spring Complete Lowering Kit Instructions

This kit has been specifically engineered for the 2000 to current GMT 820 series ½ Ton Sport Utility Vehicles. Please note that this Belltech lowering kit will lower these vehicles approximately 2 inches in front and 3 inches in the rear. We DO NOT RECOMMEND using this lowering kit on vehicles where other aftermarket suspension components have been previously installed. If the vehicle’s suspension has been modified from stock, please return it to its exact original configuration prior to installing this kit.

In order to properly lower your vehicle and to improve handling performance, we recommend using only high quality Belltech Nitro-Drop® or Nitro-Active® shock absorbers. Note that shorter front and rear shocks are required during installation of this kit.

We recommend that you install Belltech front (#5406) and rear (#5506) Anti-Sway Bars to further improve your vehicle’s handling and performance.

KIT INSTALLATION
As this is a relatively involved installation, we recommend that a qualified mechanic at a properly equipped facility perform it. We also recommend that the installation be performed on a firm, flat and level surface, such as seasoned asphalt or concrete. The use of safe and properly maintained equipment is very important! In order to document any possible irregularities in the factory ride height of your vehicle, please take a few moments to fill out the Belltech Vehicle Inspection Record included with these instructions. We also recommend measuring and recording all stock driveline angles prior to installing this kit. This information may be helpful if vibration problems arise after installation.
1. Jacking, Supporting, and Preparing the Vehicle
a) Working from the LH front wheel opening, measure the LH ride height as described by the Belltech Vehicle Inspection Record. Repeat for the RH side of vehicle. Be sure to record these measurements so that proper ride-height can be set in subsequent Steps.
b) Block the rear wheels of the vehicle with appropriate wheel chocks. Make sure the vehicle’s transmission is in “Park” (automatic) or 1st gear (manual-if offered). Activate the parking brake.
c) Loosen, but DO NOT REMOVE, the front and rear wheel lug nuts.
d) Using a properly rated floor jack, lift the front of the vehicle off the ground. Lift the vehicle so that the front tires are approximately 6-8 inches off the ground surface.
e) Support the front of the vehicle using two (2) support stands, rated for the vehicle’s weight. The stands should be positioned, one on each of the frame rail, just rearward of the front wheel openings. Prior to lowering the vehicle onto stands, make sure the supports will securely contact the straight, flat portions of the frame rails.

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Bed X-Tender Assemblies Installation Instructions

STEP 1. Remove the contents from the box and check for any damage. Verify all parts against the parts list. Read and understand instructions completely before beginning installation.
STEP 2. Position and hold template on passenger side for square bracket as shown (See Figure 1). (FOR TOYOTA, NISSAN, CHEVY S-10, GMC up to ‘94, and MAZDA up to ‘94 Use template for “L” bracket as shown in Figure 4). Using a center punch, punch each hole. NOTE: If the truck has a bed liner, center punch the bed liner. DO NOT CUT THE BED LINER! Repeat for driver side.
STEP 3. Verify hole locations before drilling (See Figure 2). Drill mounting holes for square brackets using 9/64” drill bit (See Figure 2). For “L” bracket mounting, drill mounting holes using 7/32” drill bit (See Figure 4). Repeat for driver side.
STEP 4. Mount passenger side square bracket using (3) phillips head sheet metal screws.( If the truck has a bed liner, mount square bracket on top of bed liner) (See Figure 3). For ”L” bracket use, use (2) phillips head bolts, (2) lock washers and (2) hex nuts (See Figure 4). Repeat for driver side
STEP 5. Insert center tubes into each side of curved tubes as shown (See Figure 5). NOTE: For Flare Side trucks, cut 4” off each inside end of curved tubes to allow X-TENDER to fit within truck bed (See Figure 5).
STEP 6. Insert upright bosses into bed brackets. NOTE: X-TENDER must be vertical to allow bosses to fit into brackets (See Figure 6).
STEP 7. Adjust center tubes so that each side is inserted equally into each end of curved tubes (See Figure 5).
STEP 8. Install wedges into uprights. Install the thick wedges to the out side of the upright and the thin wedges to the inside as shown (See Figure 7).NOTE: Wedges fit flush against surface of uprights.
STEP 9. Insert stanchion adjustment torx head screws into uprights (one side only) and move center upright over curved tubes by tapping with rubber mallet (See Figure 7).
STEP 10. Push down on buckle to insert onto tailgate latch. To release, pull tailgate handle (See Figure 8). NOTE: It may be easier to insert buckle by first pushing latch inboard with buckle.

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Fuel Injections Performance Kits Installation Instructions

TO START:
1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
2. Loosen and remove the air cleaner wing nuts, then remove the air cleaner lid.
3. Disconnect the cold inlet tube and then remove the air cleaner base assebmly as shown.
NOTE: Some vehicles are equipped with and air injection check valve which is vented to the air cleaner assembly. On these vehicles, remove the rubber hose and clamp the provided filter to the check valve.
4. Loosen and remove the two bolts that secure the air inlet/resonator, then remove the assembly as shown.
NOTE: K&N recommends that you do not discard your factory air intake.
5. Remove the crank case vent line from the valve cover as shown.
6. Remove the throttle body spacer as shown.
7a. On 92-95 vehicles, remove the two factory throttle body studs as shown.
7b. On 88-91 vehicles, remove the factory “Z” stud.
8. Remove the three factory torx screws as shown.
9. Install the three provided throttle body studs into the three holes from step 8.
NOTE: Apply two drops of Loc-tite to the throttle body studs and torque them to 30 inch-pounds. Failure to follow the above instructions may damage the throttle body.
10. Install the three provided nylock nuts onto the throttle body studs approximately 3/4” down as shown.
11. Install the three flat washers onto the throttle body studs as shown.

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Bed Extender Bracket Installation Instructions

BRACKET MOUNTING INSTRUCTIONS
Step 1. Remove contents from box and check for damage. Verify all parts against parts list. Read and understand instructions completely before installation.
Step 2. Position and hold template on passenger side for quick latch bracket as shown (See Figure 1). (FOR TOYOTA, NISSAN, CHEVY S-10, GMC up to 94, and MAZDA up to 94 a separate bracket kit must be ordered). Using a center punch, punch each hole. NOTE: If the truck has a bed liner, center punch the bed liner. DO NOT CUT THE BED LINER! Repeat for driver side.
Step 3. Verify hole locations before drilling and make sure quick latch bracket will not interfere with closed tailgate. (See Figure 2). Drill mounting holes for quick latch brackets using 9/64 drill bit (See Figure 2).
Step 4. Mount passenger side quick latch bracket using (3) Phillips head sheet metal screws. (If the truck has a bed liner, mount quick latch bracket on top of bed liner) (See Figure 3). Repeat for driver side.

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2007 Cadillac Escalade 6.2L AWD Cat-Back Dual Extreme Exhaust Installation Instructions

When installing this exhaust system make sure to use proper safety precautions. Use jack stands when working under the vehicle, set parking brake, block tires and use safety glasses and gloves. Allow exhaust to cool before attempting installation. Severe injury or burns could occur if safety measures are not taken.

SUGGESTED TOOLS: 1/2″, 9/16″, 15mm wrenches & sockets, WD-40, hacksaw, and jack stands

1. Disconnect the negative battery cable before removal of OEM exhaust. This will allow the computer to reset and recognize the new exhaust. Lay out the exhaust on the floor so it looks like the drawing and compare parts with manual.
2. To remove the stock exhaust, unbolt it at the 2-bolt flange located in front of the muffler. Disengage the welded hangers using WD-40 from the OEM rubber grommets. Do not damage stock nuts and bolts or remove the rubber grommets as you will re-use them to mount your new system. Now, cut off tailpipe and remove exhaust.
3. Install headpipe #A onto your existing stock flange and attach using stock hardware. Do not tighten. Insert welded hanger into rubber grommet.
4. Install muffler #B onto headpipe 1.5-2” with the louvers facing towards the converter. Use a jack stand to support the muffler. Use clamp #G to secure the muffler to the headpipe. Do not tighten. Muffler inlet is looking into louvers.
5. Next, remove your spare tire and spare tire heat shield. Kit will only fit with those items removed.
6. Install passenger side tailpipe #C into muffler 1.5-2”. Use clamp #H to secure pipes together. Do not tighten. Insert welded hanger into rubber grommet.
6. Install tailpipe #D into muffler 1.5-2” and secure with clamp #H. Do not tighten. Insert welded hanger into rubber grommet.
7. Install rear tailpipe hanger #I. Remove hitch bolt as seen in picture. Insert rubber grommet on hanger.
8. Install exit pipe #E onto the tailpipe 1.5-2” and secure with clamp #H. Do not tighten. Rotate pipe to best suit your vehicle. Insert welded hanger into rubber grommet. Adjust pipes to fit your vehicle with tips on so you make sure there is proper clearance.
9. Install stainless steel tip. Clamp down. When you have everything in place, firmly tighten all bolts and clamps down securely. Use stainless steel cleaner and a Scotch Brite pad weekly to prevent tip from discoloration. Inspect all fasteners after 25-50 miles of operation and re-tighten as necessary.

Get pdf 2007 Cadillac Escalade 6.2L AWD Cat-Back Dual Extreme Exhaust Installation Instructions

Hallman Boost Controller Pro Series Installation Instructions

The HBC (Hallman Boost Controller) that you just purchased is cnc machined of high quality billet Aluminum and Stainless Steel. This high performance boost controller has features not found on any other manual boost controller, such as:
• Fast Spool-up (This is not a bleeder valve type controller)
• Non-Locknut Adjustment System (Easy adjustment, no tools required, no locknut required)
• Over-Boost Protection (Internals and adjustment knob of valve cannot be lost)
• Expandability (Cockpit control ready with addition of an add-on kit) Before you install your HBC you must already have a performance exhaust system, a low restriction air filter and an after market boost gauge. An after market boost gauge is a must because most stock gauges will not read correctly at higher than stock boost levels. Raising your boost level will void your warranty and it can also destroy your engine if not done correctly.

This kit includes much of the necessary hardware and instructions to install and mount the HBC on almost any turbo-charged application. Note: Not all of the hardware will be used with each application. In some applications the lines may be hard to install on the actuator. A tiny drop of motor oil on your finger and then applied to the fitting will allow for easier installation of the lines. Lines can be cut to any length that will allow for a suitable installation. Read through the instructions to find an application for your particular turbo setup.

Section 1, The Basics:
Our boost controller functions by interrupting the pressure line running to the wastegate actuator. The boost controller creates a differential in that line. If your actuator is a 10 psi actuator and our controller is adjusted to create a 2 psi differential then you will have 12 psi of boost. Since you can control the differential, you can add boost beyond what your stock actuator is capable of producing. Referring to figure 1 will show a diagram of the valve and the proper connections for installation.

First, locate your wastegate actuator. It is typically mounted to the turbo unless you have an external wastegate. You can refer to figure 2 for a diagram of the wastegate actuator. The actuator has a port on the canister; this port will have a vacuum line connected to it. The line will run to a boost source that is used to operate the actuator. If you trace the line from the actuator it will go to one of the following boost sources: the compressor housing of the turbo, the intercooler plumbing, or somewhere on the intake manifold. This is the line that you will want to remove or cut and install our controller inline between the boost source and the wastegate actuator. Again referring to figure 1 will provide a diagram as to which line connects to the appropriate barb. You may encounter a “T” in the line running between the wastegate actuator and the boost source. The vacuum line off of the “T” will run to a boost control solenoid. We recommend that you remove the “T” and the lines running to the solenoid but leave the solenoid plugged into the factory wiring harness.

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2007-09 Chevrolet/GMC HD Pickup GMT-900 Platform “LMM” 6.6L Duramax Diesel Instructions

Installation Step:
1. Disconnect the negative battery cable. Using a 5/16” socket or flat screwdriver, loosen the hose clamp that holds the factory airbox to the flexible intake tube.
2. Using a #20 Torx bit, remove 2 screws holding the Mass Air Flow sensor to the factory airbox tube. Remove the MAF and set it aside. Remove the factory filter minder and grommet from the factory airbox. Save them for later use in step #10.
3. Slide the flexible intake tube off of the factory airbox and then rock the airbox back and forth to free it from the mounting grommets, next lift it straight up and remove it from the vehicle.
4. Using a 10mm socket, remove 4 bolts from the factory airbox mounting plate. Remove the plate from the vehicle.
5. Assemble the two Cool Air Dam panels (#2) and (#3) as shown, using the five 6-32 screws (#10), washers (#11), and nuts (#12).
6. Install the Airaid intake tube (#4) into the Cool Air Dam using the three 1/4”-20×1/2” button head bolts (#6), and washers (#7) as shown.
7. Install the supplied rubber trim (#13) onto the Cool Air Dam as shown.
8. Install the Cool Air Dam into the vehicle where you removed the factory mounting plate in step #4, using the four supplied M6-1×25 bolts (#9), and flat washers (#7). Do Not Over Tighten the Bolts!
9. Reconnect the factory intake tube to the Airaid Intake Tube, and tighten the hose clamp.

Get pdf 2007-09 Chevrolet/GMC HD Pickup GMT-900 Platform “LMM” 6.6L Duramax Diesel Instructions

GMC Envoy 5.3L/Chevrolet Trailblazer True Flow Intake Installation Instructions

Excess oil must be removed from filter before installation. Blot using paper towels on front and backside of filter until excess oil is removed.
1. Using a socket or an open-end wrench, disconnect the negative terminal connection on the vehicle battery.
2. Remove the factory rubber / plastic flex hose that connects the throttle body to the air filter box. Using a socket or an open-end wrench, remove the small black tubular brace that runs across the corner of the factory air filter box and connects the fender to the radiator shroud.
3. Using a Phillips screw driver, remove the air box lid. Remove the factory paper air filter. Remove the black rectangular muffler from the mass air meter assembly. Install the supplied rubber cap on the opening where the plastic rectangular muffler was removed. Install the supplied True Flow air filter onto the mass air meter assembly. Position mass air meter assembly with True Flow filter and rubber cap installed into the bottom half of the factory air box. Secure air box lid in place before proceeding to the next step.
4. Install the small black tubular brace back into its location.
5. Install the red 3-9/16” x 3-9/16” x 2-1/2” silicone coupler along with two 3-1/2’’ clamps to the air filter box outlet. Make sure coupler is aligned straight with the air filter box outlet then gradually slip the coupler on.
6. Slip the elbow coupler along with one 3-1/2’’ clamp and one 4’’ clamp over the throttle body.
7. Slide the supplied black air tube into the air box coupler. Slide the other end of the tube into the elbow coupler connected to the throttle body. You may have to move the elbow coupler to get the tube to fit. Before tightening, make sure tube is spaced away from radiator coolant line so they don’t rub. Also make sure elbow coupler is spaced away from fan shroud to allow clearance for the fan.
8. Once you have the ends of the air tube in both red couplers, make sure the clamps are positioned over the first ½” of the coupler so when tightened down, they apply pressure against the metal tube now inside each end of the coupler.
9. After alignment of the clamps, slowly tighten each clamp down using a standard screw driver and tighten them by hand until it becomes difficult to turn any further.
10. Stop and check all fittings and connections one last time. Now, put the cable back on the battery and tighten down and make sure it’s not loose.
11. Restart your vehicle and the ECM will reset properly and you should have no check engine light coming on inside the vehicle. If you do, repeat Steps 1 and 9 over again and then Step 10.
12. Place the C.A.R.B. label on or near the True Flow system in the engine compartment.
13. ENJOY!

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1967-72 GMC/Chevrolet Truck HydroBoost Instructions

This system is intended for “off road use only”
1. Please carefully inspect the entire braking system thoroughly, and replace any marginal items. Installation of braided steel, high performance brake lines is highly recommended, though not mandatory.
2. Please carefully inspect the entire power steering system thoroughly, and replace any marginal items. This system will not function properly unless the power steering system is 100%
3. Disconnect the battery.
4. Disconnect the brake pedal rod connection at the brake pedal.
5. Disconnect the master cylinder from its mounting, and secure it approximately 6 inches forward (if brake line integrity / routing permits – otherwise remove the master cylinder).
6. If equipped with factory power brakes, remove the power brake booster to firewall attachment nuts, then carefully remove the brake booster from vehicle, (you may have to gently pry the unit loose of the firewall), remove the rubber firewall boot also.
7. Assemble the brake pedal rod adapter onto the hydraulic assist unit’s threaded pedal rod, and apply a small amount of grease to the brake pedal rod eyelet of hydraulic assist unit.
8. Install the hydraulic brake booster carefully into the firewall, with the hydraulic fittings facing downward, accumulator to the driver’s side, while aligning brake pedal / pedal rod interface as required.
9. Using the 4 supplied attachment nuts and washers, securely fasten the hydraulic assist unit to firewall.
10. (Bench bleed master cylinder if removed from vehicle in prior steps / or replaced), then connect the master cylinder to the hydraulic brake assist unit firmly, using the supplied chromed replacement nuts.
11. Adjust the pedal height to the stock height / your liking, by spinning the threaded assist unit pedal rod in / out of the pedal rod adapter – 10 threads minimum engagement.
12. Double check for appropriate thread engagement at pedal rod adapter, (10 threads absolute minimum) then tighten the brake pedal rod jam nut. (Do not overtorque!)
13. Connect the pedal rod to brake pedal securely.
14. Remove the existing high side power steering line, allowing the system to drain into a suitable container.
15. Connect the shorter pressure line direct fit 3/8 flare style 90 degree hose end to the power steering pump, and then connect the other end of this line to the inlet/driver’s side AN style fitting of the hydraulic assist unit.
16. Install the supplied AN-6 line adapter into the steering box pressure inlet port.
17. Connect the longer pressure line, 90 degree AN-6 female hose end, to the steering box AN adapter, then connect the other end (direct fit 3/8 flare style 90 degree hose end) to the outlet / passenger side port of the hydraulic assist unit.
18. Inspect the existing power steering low pressure return line, from steering box to ps pump, replace if marginal.
19. Cut the existing power steering return line approximately 3” - 4” from the ps pump push on hose nipple, install the brass “T” STRAIGHT INLINE using the supplied hose clamps.
20. Connect the chromed hose nut end of the return line to the hose fitting on the assist unit, then run the hose from the brake assist unit hose nipple to the remaining brass “T” perpendicular nipple – trim hose to length as necessary and clamp to the “T” securely.

Get pdf 1967-72 GMC/Chevrolet Truck HydroBoost Instructions

04-07 Chevy/GMC Colorado/Canyon Crew Cab Bracket Bar Installation

Installation Instruction:
1. Verify all the parts from the list above are present and accounted for. Please read instructions completely before starting.
2. Verify passenger and driver side bracket.
3. Locate the round holes on rocker panel for bracket installation. Insert M8 hex nut on the longer end of U-bolt. Insert U-bolt through the first hole and out through the second hole. Install M8 hex nut on shorter end of U-bolt after it comes through second hole in the rocker panel. This will help prevent the U-bolt from falling into the rocker panel. Remove the hex nut on the longer end of the U-bolt and position the top flange of the bracket onto the longer end of the U-bolt. Secure with M8 bolt set as shown. Lease loose. Remove the hex nut on the shorter end of the U-bolt. Position bracket and secure with M8 bolt set as shown. Repeat for all brackets.
4. Secure the backing plates to the bracket using M8 bolt set as shown and leave loose. The backing plate will clamp the bracket and pinch weld together. See Figure 1. 2. 3.
5. Place oval step bars on brackets. Each step bar is marked driver and passenger.
6. Assemble with M10 button head bolts and M10 washers. 2 bolts per bracket, 4 bolts per bar.

Get pdf 04-07 Chevy/GMC Colorado/Canyon Crew Cab Bracket Bar Installation

EasyLift Tail Gate Installation Instructions

Check to make sure your truck does not already have some type of tail-gate assisting device installed. Some 2004 and newer trucks have factory installed torsion bars. If you have made aftermarket modifications to your truck, check to make sure they won’t interfere with installation.

STEP 1
Chevy, GMC, Dodge 1500 (year 1994-2001), Dodge 2500 (year 1994-2002) Trucks: Measure 2 3/4” above the top of the left tailgate pivot post, where the tailgate mounts (Figure 1). Ford, Dodge 1500 (year 2002-present), Dodge 2500 (year 2003-present), Nissan and Toyota Trucks: Measure 3 3/4” above the top of the left tailgate pivot post, where the tailgate mounts (Figure 1).
Carry this line over to point A (shown by the dotted line, Figure 2). Mark hole A to the far left side of the truck end panel. On some early model Chevy and GMC trucks, the fit will be tight. Locate hole A to the far left side, in the gap between the pivot post and the truck end panel (Figure 3). On some late model Fords, the far left side has several tapered ridges. Stay to the right of the ridges, so end A will lay flat against the truck end pane (Figure 4).
Drill Hole A, using a 3/8” drill bit (Figure 5). To prevent eye injury from flying metal shavings, be sure to wear proper eye protection.
STEP 2
Lay your Tailgate EasyLift on top of your tailgate. End A should be placed in hole A (Figure 6). Mark the line for hole B directly above the white line on End B of the Tailgate EasyLift.

STEP 3
Remove your tailgate.
WARNING: Your tailgate is heavy. Do not attempt without the assistance of a friend. For safety purposes, consult your owner’s manual for tailgate removal instructions.
Nissan, Toyota, all Stepside Trucks: Mark hole B close to the bottom side of the underside of the tailgate (Figure 8).
Chevy & GMC Trucks: Years 1989-1999, mark hole B close to the bottom side of the underside of the tailgate (Figure 8). Years 2000-present, mark hole B in the center of the underside of the tailgate (Figure 9).
Ford & Dodge Trucks: Mark hole B close to the top side of the underside of the tailgate (Figure 10).
Drill hole B in the tailgate, using a 3/8” drill bit (Figure 11). To prevent eye injury from flying metal shavings, be sure to wear proper eye protection.

Get pdf EasyLift Tail Gate Installation Instructions

99-06 Chevy/GMC Silverado/Sierra 6.5 Bed GM-001 Armor Lid Installation Manual

This truck bed cover is designed for trucks that DO NOT have a bed liner. Trucks that DO have a bed liner may require some minor trimming or modification of the bed liner to insure proper placement for the brackets. Trimming or modification will vary between different brands of bed liners and model of your truck. Remember: Any modifications must be made to the bed liner and NOT to the installation hardware. Modifications to the installation hardware will result in a improper installation and will void your warranty. (See page 9 for do’s & don’ts regarding bed liners.

Step 1
Remove factory tail gate cap. Using a T30 bit.
Step 2
Install aftermarket tailgate cap to cover factory bolt holes
Step 3
Install front brackets using 4 M8X30 Bolts, 4 lock washers, 4 washers & 4 C clamps. If you have bed liner, this area may have to be notched or cut. (See page 9 for do’s & don’ts regarding bed liners)
Step 4
Install rear brackets using 4 M8X30 Bolts, 4 lock washers, 4 washers & 4 C clamps. If you have a bed liner, this area may have to be notched or cut. (See page 9 for do’s & don’ts regarding bed liners)
Step 5
Note: Make sure the front flap hangs over the bulkhead of the truck and is not rolled under the lid.
Make sure the tail gate is up & “Dry fit the lid.” Attach the lid to the front tabs & set it on the truck.

Get pdf 99-06 Chevy/GMC Silverado/Sierra 6.5 Bed Armor Lid Installation Manual

Hauler Rack II - Universal Truck Series Racks Assembly Instructions

Before you begin:
Remove all components from the shipping carton.
The rack should be assembled on a padded surface such as carpet to prevent scratching of aluminum surfaces. Remove bands securing components together.
Read the instructions thoroughly to familiarize yourself with the assembly sequence.
Note that you DO NOT tighten any nuts and bolts until the completed rack is installed on the vehicle unless specified. This allows for minor adjustments to the rack during the installation process.
Gather the following tools used to assemble and install the rack.

NOTE: If you have a 97-09 Chevrolet or GMC fullsize truck, you will need to change the feet with p/n
SPBKIT-1 due to possible stake pockets interference.

1. Connect front and rear sections
Each side rail side contains a front and rear section preassembled for easier assembly. The front and rear sections are banded together.
Remove the banding and separate the front and rear rail sections from packaging. On a flat surface, place boards under the front and rear rail sections as shown so that the rear ‘H’ bracket does not touch the ground. This will make aligning the front and rear rail sections faster. Insert the front rail section into the 5” bracket mounted on the rear rail section and line up the holes.
Note the orientation of the other carriage bolts on rail assemblies. For the top round tube, use a 3/8”-16 x 1-3/4” carriage bolt, 3/8” split lock washer and a 3/8”-16 nut, install hardware finger tight. Repeat for other side rail. For the lower rectangle tube, use (2) 3/8”-16 x 3” carriage bolts, (2) 3/8” split lock washers and (2) 3/8”-16 nuts, install hardware finger tight. Repeat for other side rail.

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1988-1998 Chevy/GMC 2WD C1500 P/U Ext. Cab V8 7″ Performance Suspension System

INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. Jack up the front end of the truck and support the frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE! Remove the front tires.
2. Working from both sides of the truck, remove and discard the factory sway bar end links from the truck. Remove the sway bar from the truck and save with hardware.
3. Remove the bolts attaching the brake caliper to the spindle, save the hardware. Remove the caliper and tie it up and out of the way. DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE LINE! Remove the brake rotor and save. Remove the ABS / Dust Shield from the spindle and set them aside and save along with the hardware.
4. On the driver side of the vehicle, support the lower control arm (LCA) with a jack and remove the front shock and discard, save the hardware from lower shock mount and discard the upper shock hardware. Remove the nut from the end of the tie rod and separate the tie rod from the spindle by hitting the end of the steering knuckle with a hammer. DO NOT HIT THE THREADS ON THE TIE ROD END. Save the hardware. SEE PHOTO BELOW.
5. With the lower control arm still supported by the jack remove the cotter pins and loosen the nuts holding the upper and lower ball joints to the spindle, do not remove the nuts completely at this time. Separate the ball joints from the spindle by hitting the side of the spindle near each ball joint with a hammer. DO NOT HIT THE THREADS ON THE BALL JOINTS. Remove the ball joint nuts from ball joints then remove the spindle from the truck and discard, save the ball joint castle nuts and discard the original cotter pins.
6. Slowly lower the floor jack supporting the lower control arm to release the coil spring. EXERCISE EXTREME CAUTION WHEN WORKING WITH COIL SPRINGS UNDER LOAD! Set the coil spring aside and remove the upper spring isolator and save them. DO NOT DISCARD THE COIL ISOLATOR, THEY WILL BE REINSTALLED ON THE NEW COILS.
7. Locate the factory bump stops on the factory lower controlarms and remove them. Discard the bump stops and the hardware.
8. Remove the factory lower control arms from the truck and save the factory hardware.
9. Remove the upper control arm from the truck and save the hardware. Inspect the control arm pockets to see if the alignment cam knock-outs have been removed out of the pockets. If they have not been removed, do so at this time. If they have been removed the pivot holes will be slotted.
10. Using a solvent like acetone, remove the black wax off the frame on the UCA mounts. Locate FTS1500GK and tack weld the UCA gussets into place as shown on the supplied drawing. Slide the UCA back into the frame mount and be sure there is adequate clearance between the UCA and the new gussets. Remove the arm once you have checked for proper clearance. Completely weld both sides of the gusset onto the frame and UCA mount. Inspect the factory UCA pocket for proper factory weld size and penetration. Many factory welds are undersized and do not have good penetration due to automation assembly process at GM. Should the factory weld on the UCA pocket appear to lack proper penetration and structure re-weld at this time. When all the welded areas have cooled, paint all exposed areas. Reinstall the upper control arm using the original hardware. When reinstalling the cam bolts in the upper control arm, set the cam in the middle of its adjustment.
11. Repeat steps four through ten on the passenger side of the vehicle at this time.
12. Following the diagram on the last page of this instruction sheet, mark and cut the factory front lower control arm pockets.

Get pdf 1988-1998 Chevy/GMC 2WD C1500 P/U Ext. Cab V8 7″ Performance Suspension System

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