2003-2008 Hummer H2 SUV & SUT 6″ Performance Suspension System
FRONT SUSPENSION INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. With the vehicle on level ground set the emergency brake and block the rear tires. 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. Locate the torsion bar adjusting cams and threaded bolts. Measure exposed threads of torsion bar adjusting bolts and record for reinstallation. Mark torsion bars indicating driver and passenger. Using a torsion bar removal tool unload the torsion bars and remove the torsion bar adjusters. Retain the hardware for reinstallation. NOTE- Do not attempt to unload or remove torsion bars without the proper torsion bar tool. Torsion Bars are under extreme spring load.
3. Remove the sway bar link ends from the sway bar and lower control arm. Discard links and bushings
4. Remove the stock shocks and discard.
5. Remove the stock lower rubber bump stops from the frame and discard.
6. Remove the front factory differential skid plate and splash shield and discard. Remove the factory transmission guard and save. Retain the hardware for the transmission guard.
7. Disconnect the tie rod ends from the steering knuckle by loosening the nut and striking the knuckle to dislodge the tie rod end. Use care not to damage the tie rod end when removing. SEE PHOTO NEXT COLUMN.
8. Remove the brake hose bracket from the top of the steering knuckle. Unplug the ABS wire connection from the frame and control arm. Remove the caliper from the rotor and place above the upper control arm during this portion of the installation.
9. Remove the brake rotor from the steering knuckle. Remove the axle nut, washer, and the 4 hub bolts on the backside of knuckle. Remove the bearing hub assembly including O ring from knuckle. Retain the parts and hardware for reinstallation.
10. Remove the upper and lower ball joint nuts. Disconnect the upper and lower ball joints from the steering knuckle by striking the knuckle with a large hammer next to each ball joint on the knuckle to dislodge the ball joints. Use care not to hit the ball joints when removing. Retain the nuts and discard knuckle. SEE PHOTO BELOW.
11. Disconnect the CV half shafts from differential housing and remove the axle assembly.
12. Remove the lower control arms from the frame along with the torsion bar and retain the arms, torsion bar, and hardware for reinstallation. SEE PHOTO BELOW.
13. Disconnect the front drive shaft from differential housing and transfer case, and retain the bolts and u joint clamps for reinstallation, discard drive shaft. NOTE: A new C.V. drive shaft will be install later (included in this kit).
14. Disconnect the differential housing electrical connection and vacuum line from the differential housing.
15. Remove the stock differential rear crossmember and discard. Remove the differential housing assembly from vehicle. To ease removal, turn the steering wheel to the left for better centerlink clearance.
16. With the differential housing out of the truck locate the mounting bushing eye on the upper front side of the differential housing and mark the housing with a cut line smooth to the housing. Using a sawzall, cut the entire ear off the housing. Take care not to cut into the flat portion of the housing.
