Auto Manual Resource: 05/02/10

2001-08 Hummer H2 4WD Torsion Bar Leveling Kit Instructions

The net amount of ride height increase depends upon the age and use of the vehicle, wheel offset, and numerous other factors. Stated torsion bar ride height in- creases are based upon factory specifications. If the torsion bars were “cranked up” at some point in the past, expect a corresponding reduction in overall height increase with the new torsion keys. Note that torsion bars, like any other spring, are subject to fatigue and sagging over time. Also, torsion bars have different ratings depending on how the vehicle was equipped from the factory. In some cases, installing heavier rated bars (which can be purchased from a dealer) may be the only solution to regaining ride height lost from adding heavy aftermarket accessories, such as a winch bumper or snow plow.

Trail Master Suspension recommends a certified technician install this system. In addition to these instruction , professional knowledge of disassemble/reassembly procedures as well as post instructions checks must be known. Attempts to install this system without this knowledge and expertise may jeopardize the integrity and/or operating of the vehicle.

Please read all the instructions before beginning the installation. Check the kit hardware against the parts list. Be sure you have all the needed parts and understand where they go. If anything is missing , do not proceed with the installation, call Trail Master Suspension to obtain needed items.

Product Use Information
As a general rule, the taller a vehicle is the easier it will roll. We strongly recommend , because of rollover possibility, that seat belts and shoulder harness be worn at all times. Avoid situations where a side rollover may occur.

Braking performance and capabilities are decreased when significantly large/heavier tires and wheels are used. Take this into consideration while driving, also , speedometer recalibration is necessary when larger tires are installed.

Do no add, alter, or fabricate any factory or after-market parts which increase vehicle height over the intended height of the Trail Master Suspension product purchased. Mixing with suspension lift voids all warranties. Trail Master Suspension makes no claims regarding lifting devices and excludes any and all implied claims. We will not be responsible for any products that are altered. The only exception to the above policy is combining a Trail Master Suspension torsion key leveling kit with a Performance Accessories body lift system.

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06-07 Hummer H3/2005-2007 Colorado/Canyon 4wd Level Lift Installation Instructions

Step I:
Position truck on a flat surface and lift vehicle by the frame so that the front wheels are off the ground using a floor jack and jack stands or a (2) two post lift if available.
First, remove driver side front wheel, then unbolt upper shock mounting nut.(A) Next remove lower shock mounting nut and bolt.(B) Remove shock. Install shock stem spacer provided and reinstall bushings and shock.(C) & (D) Verify that all fasteners have been tightened to the proper torque specs and reinstall wheel.
*Be sure to torque the lug nuts to the proper OEM settings.

Step 2:
Replace Torsion Key
Remove stock torsion key. Bolt is located in cross-member beneath the doors. Please note that the factory keys are a left and a right and you need to match up the offset key to each one. Install Level Lift7” torsion key. (F)
Step 3:
Repeat steps 1 & 2 on the Passenger Side of the vehicle. Follow each step closely making sure to double check the torque on all fasteners.
Step 4:
Wheel Alignment; a Certified Alignment Technician that is experienced with lifted vehicles is recommended to perform the alignment.
*lt is recommended that you have your vehicle’s alignment checked whenever installing new tires.
*lt is also recommended that you adjust your headlights whenever your vehicle’s ride height is altered.

Before Level Lift™
Vehicle Handling Warning
Vehicles with larger wheels and tires will handle differently than stock vehicles. Take time to familiarize yourself with the handling of your vehicle. DRIVE SAFELY and WEAR YOUR SEATBELT.

After Level Lift™
Installation Warning
Always wear proper safety equipment and use the correct tools when installing any suspension upgrade. Make sure vehicle is on a flat surface and you are using jack stands or a lift rated for the weight of the vehicle.

Warning! This Level Lift1″ Leveling Kit is designed and engineered to level out a stock vehicle with no prior modifications. The use of this kit along with items such as rear lift blocks or spacers, add a leafs, airbags, suspension lifts, body lifts or any other type of lifting accessory shall be done at the vehicles owners risk and will void any and all warranties in effect or implied by Level Lift1″

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2004-08 Chevy Colorado/Canyon/Hummer H3/H3T 4WD Torsion Bar Leveling Kit

Daystar recommends a certified technician install this system. In addition to these instruction , professional knowledge of disassemble/reassembly procedures as well as post instructions checks must be known. Attempts to install this system without this knowledge and expertise may jeopardize the integrity and/or operating of the vehicle.
Please read all the instructions before beginning the installation. Check the kit hardware against the parts list. Be sure you have all the needed parts and understand where they go. If anything is missing, do not proceed with the installation, call Daystar Products to obtain needed items.

Installation Step:
1. Place the vehicle on a level surface. Prior to beginning, record ride height on each side of the vehicle by measuring from the center of the spindle to a consistent point on the wheel well. Record these measurements for future reference.
2. Put the transmission in Park or 1st gear (manual transmissions) and chock the rear tires.
3. Raise the front of the vehicle using a jack. Raise it enough to completely unload the front suspension. Place a jack stand under each frame rail just behind the lower control arms for the front suspension. Ease the frame down on to the stands, but leave a slight load on the jack as a safety precaution.
4. Verify the front tires are off the ground and that the suspension is unloaded, or at full extension travel.
5. Locate the torsion bar crossmember. There is a bolt on each side of the crossmember that adjusts torsion bar preload. Measure or mark the exposed length of the adjuster bolt for reference during re-assembly. See Figure 1.
6. Position the appropriate torsion bar puller tool on the crossmember. Be sure the top of the puller tool engages the recess present in most crossmembers. Also be sure the lower end of the puller tool engages a recess on the torsion key near the adjuster bolt. See Figure 2.
7. Locate the torsion bar crossmember. There is a bolt on each side of the crossmember that adjusts torsion bar preload. Measure or mark the exposed length of the adjuster bolt for reference during re-assembly. See Figure 1.
8. Position the appropriate torsion bar puller tool on the crossmember. Be sure the top of the puller tool engages the recess present in most cross-members. Also be sure the lower end of the puller tool engages a recess on the torsion key near the adjuster bolt.

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06-09 Hummer H3 3,” 4″ and 4-1/2″ Cradle Mount Sidebar Installation Instructions

PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
2. Starting on the driver side of the vehicle, locate the two threaded holes toward the front of the frame. Select the driver side Front Mounting Bracket and bolt it to the threaded holes with (2) 10-1.5mm x 30mm Hex Bolts, (2) 10mm Flat Washers and (2) 10mm Lock Washers, (Figure 1). Snug but do not tighten hardware at this time. Repeat this step for the rear Mounting Bracket installation, (Figure 2).
3. Carefully place the passenger Sidebar up to the Mounting Brackets and use the included (4) 8mm x 25mm Hex Bolts, (4) 8mm Flat Washers and (4) 8mm Lock Washers, (Figure 1). Do not tighten at this time.
4. Level and adjust Sidebar properly and then tighten all hardware.
5. Repeat steps 2 – 4 for passenger Sidebar installation.
6. 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 Sidebar. For gloss black finishes: Mild soap may be used to clean the Sidebar.

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2003-06 Hummer H2 4wd w/ 6″ Fabtech System FTS57000 Multiple Front Shock System

INSTALLATION:
1. Disconnect the negative terminal on the battery. With the vehicle on level ground, set parking brake and block rear tires. Jack up front of vehicle and support under frame with jack stands. Remove the tires and wheels.
2. Working from driver side of vehicle, locate and remove the nut and washer that retains the stock lower control arm pivot bolt towards the rear of the vehicle. Do not remove the bolt, only the nut and washer. Locate the factory steering box bolt on the outside of the frame and remove. Save all the removed hardware.
3. Locate the Driver side upper shock hoop and place the rear leg mount over the stock rear lower control arm bolt and attach with the original nut and washer. Leave loose. SEE PHOTO BELOW.
4. Place the front leg of the shock hoop over the removed steering box bolt and reinstall the stock bolt, nut and washer. Leave loose.
5. Pushing on the top of the hoop, mate the upper mounting tabs to the top of the upper control arm pocket and centerpunch the holes. Drill out to 3/8” diameter. Install the supplied 3/8” x 1-1/4” bolts, nuts and washers. When installing the 3/8” bolts, they MUST be installed from the bottom of the pocket up as shown in the picture below. Torque to 35 LBS.
6. Using the short urethane bump stop as a template place above stock upper control arm bump stop bracket. Mark the center stud to be drilled out to 3/8” diameter Attach to stock bracket and torque to 5 LBS. If the dual shock hoop is being installed after the Fabtech Lift has been installed than the upper control arm will need to be disconnected from the steering knuckle again in order to drill the hole for the new bump stop.
7. Locate the lower shock mount with the shock tabs and place on top of upper control arm. Locate lower bracket with tubes and place under control arm. Secure using 3/8” x 3” bolts, nuts and washers. Torque to 35 LBS.
8. Locate and install Fabtech shocks (not included in this kit) to the upper and lower tabs using ½” x 6” bolts, nuts and washers. Torque bolt to 35 LBS.
9. Torque the steering box bolt to 110ft. lbs and the lower control arm bolt to 90 ft. lbs

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G T Simulated Beadlock Installation Instructions

With simulated beadlock wheels, you must mount your tires before installing the simulated beadlock ring, and conversely, you must remove the simulated beadlock rings prior to demounting and changing your tires. Included with your wheels are hardware packs that include 16 short, stainless button head Allen bolts, 6 long, stainless button head Allen bolts, and 22 stainless flat washers with each wheel. The 16 short bolts and washers should be installed on the ring in the 16 threaded holes prior to mounting the ring to the wheel.

Once those are installed, you’ll have 6 non-threaded holes left open and those are the holes used to install the beadlock ring onto the welded on ring.

The simulated beadlock ring is attached to the ring that is welded to the wheel by the 6 long bolts and washers, and there are six holes in the simulated beadlock ring that are not threaded which these bolts go through and into the threaded inserts that are already pressed into the welded on ring.
You will have to rotate the simulated beadlock ring, on top the welded ring, in order to align the mounting holes in sequence with the threaded inserts, since the holes are not in an equal pattern. Once lined up, install the long bolts and washers through the holes, and into the threaded inserts, and tighten down. Do not over tighten, as you can, with enough pressure, spin the threaded inserts inside the aluminum mounting ring.
After all bolts and washers are installed, check the tightness of each bolt to make sure the ring is secure.

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2003-2005 Hummer HII Edelbrock Lower Trailing Arms Installation Instructions

1. Raise vehicle and support with jackstands on a stable surface.
Note: Vehicle must be supported with vehicle’s normal weight on rear axle. Do not support vehicle by its trailing arms.
2. Remove only one of the stock lower trailing arms.
3. Install the Edelbrock lower trailing arms with the spherical ball at the rear axle mounting point and the grease fitting on top of the arm. It may be necessary to spread the rear end mounting tabs slightly to install trailing arm.
4. Re-install stock trailing arm bolts and torque bolts to 140 ft. lbs.
5. After one side has been completed, repeat steps 2, 3, & 4 on other side of vehicle.
6. Edelbrock trailing arms are greased during assembly, but we recommend you grease them after installation and during normal service.
7. Check bolt torque periodically.

NOTE: To lube the spherical ball end of the trailing arm, the vehicle’s full weight must be on all four tires. This will allow you to grease the zerk fitting that is located on the top rear of the arm. If the suspension is hanging, you will not be able to access the zerk fitting. To lube the front trailling arm bushing, you will need to remove the plastic cover at the front of the trailing arm. Re-install plastic cover after lubing.

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2003-2008 Hummer II 6.0L V8 without A.I.R. or E.G.R Edelbrock Header Installation Instructions

These components are designed to improve the exhaust efficiency of the GM C.P.I. (Central Port Injection) V8 engine. This system does not require welding for installation and retains all O.E.M. emissions equipment. These Edelbrock headers are street legal in all 50 states.
Suggested Tools Needed for Installation. This vehicle has metric fasteners:
- 3/8″ ratchet socket set with extensions and universal 13mm and 15mm swivel sockets
- Set of combination wrenches
- Jackstands, screwdrivers, pliers, crescent wrench, etc.
- Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695) or available equivalent.

SPECIAL NOTICE: This Edelbrock part has received an Executive Order number (E.O.#) from the California Air Resources Board (C.A.R.B.) making it legal for street use in all 50 states. To assist you with emission equipment certification, we have included a silver fan shroud decal to help testing personnel verify the this part is a legal replacement on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed next to the existing emission and engine specifications decal. Do not cover any part of your original emission decal.

WARNING: The use of “Thermal Wrap” or any aftermarket coating process will void the warranty on your Edelbrock Headers. Those products will cause excessive heat and moisture buildup resulting in corrosion and failure of the header.
NOTE: High temperature spark plug wires and boots are recommended to withstand heat from Headers.

DISASSEMBLY
1. Disconnect negative battery cable.
2. Unbolt exhaust pipes from manifolds.
RIGHT SIDE
1. Disconnect and remove spark plug wires.
2. Unbolt and remove dipstick tube.
3. Unbolt and remove manifold from top.
4. Install flange gasket and header from top. Install header bolts, lock washers, and thick flat washers supplied. Note: Ensure proper alignment on slotted holes of port flange and only snug bolts at this time.
5. Re-install spark plug wires.
6. Re-install dipstick tube.
7. Some models may require the aluminum heat shield under the A/C receiver dryer to be re-positioned, adjusted or bent to gain some clearance between header and heat shield.
LEFT SIDE
1. Disconnect and remove spark plug wires.
2. Unbolt and remove manifold.
3. Install flange gasket and header from top. Install header bolts, lock washers, and thick flat washers supplied, ensure proper alignment and only snug bolts at this time.

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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.

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03-05 Hummer H2 P/N 200-183 Installation Instructions

Installation Instructions. Read Me!
I) DISCONNECT NEGATIVE (-) BATTERY CABLE.
II) Remove the Factory Air Box
a) Loosen Mass Air Meter hose clamps and set meter aside.
b) Unbolt the three air box hold down fasteners and save the bolts. See Fig#1
c) Lift out & remove the factory air box assembly from vehicle.
d) Remove and save the three rubber grommets, inserts and bolts. See Fig#2
III) Assemble the Airaid Cool Air Dam
a) Align Airaid top and bottom panels as show in Fig#3, and fasten together with saved grommets and inserts from Fig#2.
b) Install the black plastic filter adapter with provided hardware. See FIG#3
c) Mount the Airaid Premium Filter onto the black plastic adapter and secure with the hose clamp provided. See Fig#3
d) Press the supplied weather strip onto the upper rim of the Airaid Cool Air Box.
(Hint: for easy installation of weather seal, start on a corner) See Fig #3
IV) Install the Airaid Cool Air Dam
a) Position the Airaid system over the three factory mounting points & fasten with the saved factory bolts.
b) Reconnect MAF to inlet tube and adapter then tighten clamps.
c) Reconnect MAF wire harness
V) Finishing Up
a) Check for any foreign objects or debris in the intake path.
b) Reconnect the negative battery cable & double-check your work.

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2008 Hummer H3 Alpha, 5.3L, 4wd Cat-Back Split Rear Exhaust Installation Instructions

2008 Hummer H3 Alpha, 5.3L, 4wd Cat-Back Split Rear 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, 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, cut just in front of the stock resonator. (see picture) Disengage the welded hangers from the OEM rubber grommets. Use WD-40 to aid in the process. Do not damage or remove the rubber grommets as they will be reused to mount the new system. Now, cut off tailpipe and remove exhaust.
3. Slide muffler #A onto headpipe 1―”-2”. Use a jack stand to support the muffler. Make sure muffler outlets are level. Use clamp #G to secure the muffler to the headpipe. Do not tighten.
4. Slide driver side over axle tailpipe #B into muffler 1.5-2”. Use clamp #F to secure tailpipe to muffler. Do not tighten. Insert welded hanger into rubber grommet.
5. Slide the second driver side over axle tailpipe #C onto pipe #B 1.5-2”. Secure pipes using clamp #F. Do not tighten. Insert welded hanger into rubber grommet.
6. Slide the passenger side tailpipe #D into muffler 1.5-2”. Insert welded hanger into rubber grommet. Use clamp #F to secure tailpipe to muffler. Do not tighten.
7. Install stainless steel tips. Clamp down. When you have everything in place, firmly tighten all bolts and clamps down securely. Use stainless steel or aluminum cleaner to polish tips. Inspect all fasteners after 25-50 miles of operation and re-tighten as necessary.

Dual Battery Cradle Fitting Instructions

For many years the number of plates per cell was taken as a guide to the engine cranking power provided by the battery. However, over time this criteria proved to be misleading. Starting power is a function of the area of plate surface exposed to acid. If all plates were the same size (and therefore the same area) plates per cell would be a useful comparative guide. However, plate dimensions vary dramatically from one manufacturer to another. To overcome this difficulty, in1985 the Australian battery manufacturers adopted the SAE (Society of Automotive Engineers) standard for cranking capability. Under the SAE standard, battery cranking power is specified in CCA’s (cold cranking amps).

To make a valid comparison from one battery to another, it is absolutely vital for both battery performances to be quoted against the same standard test. Performances quoted at higher temperatures, shorter durations or to higher end voltages, can be manipulated so as to appear superior to SAE ratings.

ACCESSORIES POWER (AMP Hour Capacity)
The power available from a fully charged battery to operate accessories is a function of the weight of reactive lead contained on the battery plates, below the acid level. The weight of reactive material depends on the thickness of plates, area of plates below the acid level and the number of plates in each cell.

For many years the power available for accessories was quoted as ‘amp hours’. In the case of automotive batteries, the amp hour rating was a statement of the amps that could be provided continuously for 20 hours. Whilst the amp hour rating did provide a rough guide to the weight of reactive lead available, it completely failed to indicate the ability of the battery to power the full vehicle accessory load. Some battery distributors use less severe tests conducted at higher temperatures to disguise low performance batteries. The Australian Standard specifies a standard measure for reserve capacity.
The reserve capacity rating for a battery is an attempt to specify in minutes how long a battery could keep the vehicle running in the case of a complete alternator failure with a notional level of accessories in use.
COLD CRANKING AMPS (CCA)
The international recognised battery performance test: the discharge load in amperes which a new fully charged battery at 18C (0F) can deliver for 30 seconds and maintain a voltage of 1.2 volts per cell or higher.
RESERVE CAPACITY (Minutes)
The time in minutes that a new fully charged battery will supply a constant load of 25 Amps at 25°C without the voltage falling below 10.5 volts for a 12 volt battery and 5.25 for 6 volt battery.

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2001-2009 Chevy 2500HD 2&4wd G.M. Heavy Duty Outer Tie Rod System Instructions

INSTALLATION 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. Remove the front tires. NEVER WORK UNDER AN UNSUPPORTED VEHICLE!
2. Starting on the driver’s side of the truck, remove the nut securing the tie rod end to the spindle. Using a large hammer strike the spindle to break loose the tie rod end. Save the factory hardware. USE CARE TO NOT HIT THE THREADS OF THE TIE ROD END.
3. Locate the inner tie rod end nut were it connects to the center link. Using a large Crescent wrench remove the inner tie rod end from the center link and remove the inner and outer tie rod end from the truck as one piece.
4. With the tie rod off the truck measure the over all length of the inner and out Tie Rod assembly. Record the length.
5. Repeat steps two through four on the passenger side of the truck.
6. Using a clean rag and a grease dissolving solvent clean all the grease out from the threads were the inner tie rod ends connect to the center link.
7. Locate FT20211-1 and FT20211-2 inner and outer Tie rod pieces. Connect them together, make sure to assemble the jam nut onto the inner tie rod end before assembling the outer tie rod to it. Adjust the tie rod assembly to the previously recorded tie rod lengths. Assemble the supplied grease fitting to the top of the outer tie rod end.
8. Working from the drivers side if the truck, attach the previously assembled inner/outer tie rod assembly to the factory center link. When installing the inner Tie Rod end you will need to put a small amount of the supplied thread locking compound on the threads on the inner Tie Rod end before installing it to the center link. You will need use a large Crescent wrench to tighten the new tie rod end to the center link. Torque to 100 ft. lbs. SEE PHOTO BELOW.
9. Slide the outer Tie Rod end into the spindle and torque the nut to 35 FT LBS.
10. Repeat steps eight and nine on the passenger side of the truck.
11. USING A GREASE GUN, GREASE ALL THE GREASE FITTINGS ON THE IDLER ARM, PITMAN ARM, CENTER LINK, AND TIE ROD ENDS
12. With both sides of the truck completely finished and the truck still off the ground, cycle the steering left to right from stop to stop. Make sure there is plenty of clearance between the ABS lines and all other components.
13. Reinstall the tires onto the truck and torque the lugs to factory specifications, which can be found in the owner’s manual. Set the truck back on the ground and cycle the steering left to right from stop to stop. Make sure there is plenty of clearance between the ABS lines and all other components, including the wheel and tire to the new tie rod end.
14. Recheck all nuts and bolts for proper torque tightness before driving. Align the truck to the factory specifications before driving. Recheck after 50 miles.
15. Check front-end alignment and set to factory specifications.

Get pdf 2001-2009 Chevy 2500HD 2&4wd G.M. Heavy Duty Outer Tie Rod System Instructions

Hummer H2 Powerstep Installation Instructions

Step One
REMOVE CANISTER PURGE VALVE BRACKET AND ROCK RAIL
Remove the Canister Purge Valve Bracket from the Rock Rail. Set the bolt aside to be reused later. Then remove the ten bolts that secure the Rock Rail to the vehicle. Set these bolts aside also. Some of them will be used again later
Step Two
INSTALL NEW CANISTER PURGE VALVE BRACKET
Locate the 4th set of holes from the front on the inner sill. Place the Canister Purge Valve Bracket from the Parts Kit over the holes and install it with the bolt that was removed in Step One. Install the Canister Purge Valve on the bracket using an M8 x 20 Bolt, Nut and Washer.
Step Three
INSTALL FRONT ARM
Locate the second set of holes from the front of the sill. Use an 18mm Socket to remove the bolts and use them to install the Front Arm. Tighten the bolts on the Arms to 16 ft./lbs. (22 Nm).
Step Four
INSTALL REAR ARM
Locate the fith set of holes from the front of the sill. Use an 18mm Socket to remove the bolts. Place the rear holes in the arm over the holes in the vehicle and reinstall the bolts. Tighten the bolts on the Arms to 16 ft./lbs. (22 Nm).
Step Five
MOUNT POWER STEP
Slide the Step onto the arms so that the T-Nut aligns with the holes in the arms. Install four Socket Head Bolts. Use a 3/16″ Allen Wrench to tighten the bolts to 10 ft./lbs. (13.5 Nm).
Step Six
INSTALL CONTROL BOX
Locate the remove the Hood Support Bolt on the far left of the engine compartment. Install the M8 x 40 Bolt in the hole. Place the Control Box under the ledge and use a nut to secure it to the bolt.

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Hummer H3 Rear Stabilizer Bar Installation Instructions

THIS ANTI-SWAY BAR IS DESIGNED TO REPLACE THE FACTORY INSTALLED REAR SWAY BAR AND UPGRADE THE FRONT SWAY BAR BUSHINGS.
1. Remove the factory installed rear anti-sway bar from factory mounts and end links.
2. Lubricate the D-shaped poly bushings and install on the sway bar in approximately the same location as the factory mounts. To ease installation of bushing, use coined end of sway bar to spread bushing at split and slide bushing onto bar. Install using supplied U-plates and serrated flange bolts. LEAVE LOOSE AT THIS TIME . Attach the factory end link assemblies using factory supplied nuts. Torque all mounting hardware and end links to factory specifications.
3. Remove the factory installed D-shaped bushings and U-plates from the FRONT SWAY BAR. Lubricate the new D-shaped poly bushing and install them on the factory sway bar using supplied U-plates and serrated flange bolts. Torque bolts to the factory specifications.
4. Recheck your installation on a regular basis thereafter.

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Hummer H2 Rear Mud Guards Installation Instructions

It may be necessary to remove the wheels depending on the tools being used for installation.
1. Clean and degrease the mud guard location area on the fender before installation.
2. Remove factory fasteners from locations A and B (Figure 1).
3. Place mud guard against fender and install #10 screws and washers at locations A and B, through mud guard, through existing fender holes and into u-clips. NOTE: The u-clips are to be used as a nut and not to be clipped over fender. Check fit and level before tightening.
4. Using mud guard as a template, drill an 1/8” hole at location C and install a #10 screw.

PAINTING INSTRUCTIONS
1. Clean mud guard with a soap and water solution to remove dirt and other contaminates.
2. Sand painting surface with 320 grit sand paper.
3. Apply a coating of flexible primer-adhesion promoter.
4. Apply a flexible paint as directed by the paint manufacturer

Tools Required
• Short Phillips screwdriver
• Center punch / Hammer
• Drill / 1/8” drill bit

Package Contents
• Driver (LH) & passenger (RH) side front mud guard
• #10 screw (qty. 6)
• Washer (qty. 4)
• U-Clips (qty. 4)
• Instruction sheet

Get pdf Hummer H2 Rear Mud Guards Installation Instructions

Hummer Air Valve Installation Instructions

To Install
1. Attach the CTI Line with the swivel nut to the air valve.
2. Remove the ―” X 20 Nyloc Nut from the Valve
3. Put the air valve in the valve hole and hold in place.
4. Place Stainless Washer on Inside of Wheel under the Nyloc Nut.
5. Hand tighten the ―” X 20 Nyloc Nut onto the air valve.
6. Put the 9/16” open- end wrench on the swivel nut.
7. Tighten the Nyloc nut with the Hand Ratchet and ū” socket while holding the swivel nut in place with open- end wrench.
8. Tighten the Nyloc nut until the O-ring on the air valve has been squeezed down to about ― or more of its width which means that you must tighten the nut down as far as possible, it’s designed to bottom out on the threads of the valve, so make sure it’s “tight”.
9. Once the Nyloc nut is tight, reverse the direction of the ratchet and hold that ratchet and Nyloc nut in place. Do Not Untighten the nut.
10. While holding the ―” X 20 Nyloc nut in place, use the 9/16” open-end wrench and the tubular steel line to simultaneously, un-tighten the swivel nut from the air valve.
11. When re-installing the CTI Line, hand tighten the swivel nut on to the air valve, and then tighten that nut with a maximum of about 1/32 to 1/16 of a turn.
12. DO NOT over-tighten the swivel nut, it is not necessary as it is very likely that a hand tight swivel nut will hold air pressure, but would not necessarily stay tight, so it must be slightly tightened as suggested above.

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2006-2009 Hummer H3 & 2005-2009 Colorado/Canyon 4WD Torsion Key Kit Installation Instructions

Step 1: Applies to H3 ONLY, for Colorado/Canyon please skip to step 2.
Position truck on a flat surface and lift vehicle by the frame so that the front wheels are off the ground using a floor jack and jack stands or a (2) two post lift if available.
First, remove driver’s side front wheel, then unbolt upper shock mounting nut. (A)
Next remove lower shock mounting nut and bolt. (B)
Remove shock. Install shock stem spacer provided and reinstall bushings and shock.
Verify that all fasteners have been tightened to the proper torque specs and re-install wheel.
*Be sure to torque the lug nuts to the proper OEM settings.

Step 2:
Replace Torsion Key Remove stock torsion key. Bolt is located in cross- member beneath the doors. Please note that the factory keys are a left and a right and you need to match up the offset key to each one. Install ReadyLiftо torsion key.

Step 3:
Repeat steps 1 & 2 on the Passenger Side of the vehicle. Follow each step closely, making sure to double check the torque on all fasteners.

Step 4:
Wheel Alignment; a Certified Alignment Technician that is experienced with lifted vehicles is recommended to perform the alignment.
*It is recommended that you have your vehicle’s alignment checked whenever installing new tires.
*It is also recommended that you adjust your headlights whenever your vehicle’s ride height is altered.

Get pdf 2006-2009 Hummer H3 & 2005-2009 Colorado/Canyon 4WD Torsion Key Kit Installation Instructions

2001-2007 Chevrolet Express Van Bracketron Phone Mount Instructions

Installation instructions for the 2003-2007 Express and Savana Vans
Use your 10-mm socket and ratchet to remove two (2) washer nuts from the inside of the small cubby hole under the radio and airbag switch. Set the washers aside. Remove two (2) 10-mm screws from the bezel below the steering column. Set the screws aside. Pull the bezel toward you releasing six (6) clips. On the pas- sengers side, remove two (2) 10-mm screws on the lower bezel below the glove box. Set the screws aside. Pull toward you to release two (2) clips and a pin that is connected to the larger radio bezel.

Remove the bezel that surrounds radio, climate control and instrument panel. Use the Dash Trim Panel tool in the upper right corner of the bezel releasing the first clip. Continue working the bezel loose to all the way to the left of the steering column for a total of twelve (12) clips. Tilt the bezel out just enough to gain access to the screw that is on the right side of the radio.

Remove the factory screw with a 9/32” socket & ratchet. Install the smaller part “A” onto the side of the radio, insert the factory screw and tighten. Reinstall all the dash bezels securing all clips, screws, and washers nuts. Connect the larger part “B” into the smaller part “A” aligning the studs with the holes on part “A”. Use the two (2) provided cap nuts and tighten part “B” to part “A” with a 5/16” open end wrench.
Install any Bracketron phone holder or Amps compatible device to your Custom Bezel Mount. Your installation is complete.

Get pdf 2001-2007 Chevrolet Express Van Bracketron Phone Mount Instructions

Hummer H3 & H3T 1″ Body Lift Instructions

Your new Daystar body lift kit will allow the installation of 35” tires. Larger tires can be fitted if paired with our 2” torsion bar key kit, and some trimming . The tools needed for installation are on the last page . A list of parts in the kit are under the BOM, verify that you have all parts prior to installing your new Body Lift Kit . Make sure you have all of the proper tools and understand these directions before proceeding. Place Vehicle on level ground. Be sure that the wheels are blocked and the vehicle is in park.

Fan Shroud
The Factory Fan Shroud is a two piece design; you will need to remove the lower half of the fan shroud so that it can be trimmed.

Fan Shroud Removal (Fig. 1-4)
1. Locate the two center push tabs on the shroud (upper fan shroud), depress these to loosen the lower portion of the shroud from the Top Portion
2. On the bottom of the fan shroud remove the push in style radiator hose supports, (careful not to damage these as you will re-use them) Pull the radiator hose back.
3. Depress the two tabs at the bottom of the fan shroud; with the shroud loose at the top and bottom pull the shroud down. The Fan Shroud at this time should be free and able to move.
4. Turning the Fan shroud up in a CCW position and pulling down on the shroud will allow for removal.

Trimming the Fan Shroud (Fig. 5-6)
1. With the fan shroud out and on a flat surface (lip facing up) you will want to make a line from the Top Part of the lip, on the Outside portion of the shroud. The line is to be a 1/4 inch out from the top lip.
2. The 1/4” line is to go all the way around the shroud; this is your cut line.
3. Trim the Shroud
4. A 3/8” hole will need to be drilled a half inch up from the bottom center of the fan shroud.
5. After you make the cut you will want to debur all edges
6. When cutting and deburing are finished, reverse the step of removal to reinstall the shroud.
7. When the Fan Shroud is re-installed place supplied push on hose support into the new hole that was drilled. This is an additional support for the radiator hose.
8. Place the radiator hose in and supports back on the shroud. To install the trimmed fan shroud reverse steps 1-4 of fan shroud removal.

Body Measurement (Fig. 7-9)
Prior to installing your new Daystar Body Lift you will need to take body to frame, bed to frame rail measurements and measure the gap between the body and bed. These measurements are what you will need to adjust your body and bed back to after installing your Body Lift.
When measuring the body you will want to measure down the drivers side and passenger side in three different locations.
1. In front of the front tire
2. Middle of the vehicle (at the front door and rear door seam)
3. The back of the body (where the bed and body separate)

Get pdf Hummer H3 & H3T 1″ Body Lift Instructions

Hummer H3 Delta 6X Light Bar Installation Instructions

Step 1
Remove the driver’s side hood cover by prying upward with both hands.
Step 2
Remove the driver’s side windshield molding. Do not peel off the rubber seal or separate from roof molding.
Step 3
Remove 4 screws from driver’s side roof railing. Remove roof and windshield molding and set it down on the table.
Step 4
Measure 1” from the beginning of the roof railing and mark on the masking tape the spot to drill ―” hole for your harness.
Step 5
Install relays onto driver’s side engine compartment behind the battery, (See Step 6)
Step 6
Ground two short black wires leading from relays to screws holding the relays. Run yellow wires towards the corner of engine compartment.
Step 7
Run blue switch wire through the existing rubber grommet in the fire wall next to the relay’s location (Step 6).
Step 8
Pull both fuses out of fuse holders to protect from falsely activating the harness.
Step 9
Connect both red wires leading from relays to the battery’s positive terminal.
Step 10
Run both yellow wires with black wire alongside the windshield and up to the roof. Use electric tape to help hold down your wires.

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2002-03 Hummer Multiple Shock Instructions

1. Park the vehicle on flat level ground. Set the emergency brake and properly block the tires.
2. Raise the front of the vehicle and support the frame rails using jack stands. Remove the front tires.
3. Remove the bushing and washer from the upper portion of the factory shock. Place the new upper frame bracket over the factory bracket. (See Photo #1). Now reinstall the upper bushing and washer onto the factory shock.
4. Push the bracket up flush against the frame. The outside mounting hole on the top plate will now line up with the factory hole in the upper mount. Drill out the factory hole using a 13/32” drill bit. Install the 3/8 x 1 fine thread bolt with washers and locknut at this location. (See Photo #2).
5. Mark one of the outer holes on the front and rear of the bracket where it mounts to the frame. (Some models will line up with 1 factory hole in the frame). It is recommended to drill and install the front bolt first then move to the rear mount. Drill using a 5/16” drill bit. Once drilled, install the 3/8 x 1” thread cutter bolt. Once 1 bolt has been installed on the front and rear, drill the remaining outer holes and install the 3/8” bolts.
6. With all of the outer bolts installed. Mark and drill the center hole using a 1/2” drill bit. Be sure not to drill into any power steering lines or wiring. It will be necessary on some models to remove the factory exhaust heat shield from the backside of the frame to allow for installation. Once installed, reinstall the heat shield. Once drilled, install the 1/2 x 4” fine thread bolts with washers and nuts. Be sure to install the bolt from inside pointing out. (See Photo #4). The new brakeline bracket will attach under the bottom bolt in the front mount. Attach the factory brakeline bracket to the extension bracket using the 5/16 x 1” fine thread bolt, washers, and locknut.
7. Install the new lower bracket on top of the factory upper A-Arm. The two outside bolts will line up with factory holes in the upper A-Arm. Attach the bracket at these points using the
6 x 30mm bolts and washers. With the outer bolts installed, mark and drill the two inner holes using a 13/32” drill bit. Once drilled install bottom plate on the bottom of upper A-Arm. Attach to upper bracket using the 3/8 x 2 3/4” bolts, washers, and lock nuts. (See Photo #6).
8. With all brackets installed, install the new shocks using the 1/2 x 3” fine thread bolts, washers, and nuts.
9. After installation, reinstall front tires and lower vehicle onto the ground. Cycle the steering left to right and check tires and wheels for clearance.

Get pdf 2002-03 Hummer Multiple Shock Instructions

2003-07 Hummer H2 V8-6.0L K&N Kit Installation Instructions

1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
3. Disconnect the mass air sensor electrical connection.
2. Remove the 8mm bolt that retains then engine cover onto the engine then remove the cover from vehicle.
4. Loosen the hose clamp at the throttle body.
5. Loosen the hose clamp at the mass air sensor.
6. Detach the intake tube from the throttle body and mass air sensor then remove the intake assembly.
NOTE: K&N recommends that customers do not discard factory air intake.
7. Remove the 3 10mm bolts that retain the air box onto the vehicle.
8. Remove the air box from vehicle as shown.
9. Loosen the hose clamp that retains the mass air sensor onto the air box then remove the mass air sensor from the air box.
10. Install the mass air sensor and filter adapter onto the heat shield using the gaskets and hardware provided.
11. Install the edge trim onto the heat shield. Trim if needed.
12. Install the 1/2 long rubber mounted stud onto bracket as shown.
13. Install the 1” long rubber mounted stud onto bracket as shown.
14. Install the rubber mounted stud onto the vehicle as shown.
15. Install the 3 brackets onto the vehicle with the provided hardware as shown. Don’t tighten completely at this time.
16. Install the silicone hose (084053) onto the K&N intakes tube as shown using the supplied hose clamps.
NOTE: The synch bolt in the #400 hose clamp at the throttle body will need to be replaced with the longer synch bolt supplied.

Get pdf 2003-07 Hummer H2 V8-6.0L K&N Kit Installation Instructions

H2 Hummer Low Profile Light Bar Instructions

INSTALLATION:
1. Disconnect negative battery terminal. Remove phillips head screw from driver side marker light lens and remove lens assembly. Pull up the wire boot.
2. Remove driver side assist handle by pulling out locking tabs with a small flat blade screwdriver until they “click”. Next, remove the A-Pillar trim and place on dash.
3. Remove the fuse cover panel on the left side of dash. There are two clips at the top and one at the bottom.
4. Using a 13mm socket, remove 4 bolts, one plastic stud, and remove the driver’s side hood stop bracket for access to the main wire harness boot.
5. Slice a small slit in the marker light boot and run the black and white wires through the boot and down the A-Pillar and out the bottom of the dash through the fuse box area. To gain access under the roof, pull down the rubber trim and the headliner slightly so you can reach up under the marker light to grab the black and white wires.
6. Slide a piece of shrink tubing over the black and white wires that you pulled down the A-Pillar and crimp to the black and white wires from the main wiring harness. (Crimp black to black, and white to white). Shrink the tubing with a non-flame heat gun. Plug these wires into the main wiring harness. See FIG 10.
7. Locate the large Red and Black wires with a plug on one end. Plug these 2 wires into the main harness. Ground the Black Wire to the 8mm stud at the top of the emergency brake housing with the 8mm nut provided. Mount the relay under the dash with the self tapping screw provided. (The top of the emergency brake housing is one convenient place to mount the relay.)
8. Under the hood, remove the fuse box top cover and the fuse box enclosure as shown . See FIG 11.
9. Make a small hole in the main wire boot in the firewall and run the large Red wire from the main harness up to the fuse box. Be careful not to damage existing wires in the boot.

Get pdf H2 Hummer Low Profile Light Bar Instructions

H1 Hummer H.I.D. High/Low Projection Headlamp System Wiring and Installation Instructions

Installation Procedure
1. Remove Stock Headlamps by removing the three flathead screws securing headlamp bezel in place. Disconnect and discard stock headlamp.
2. Notch the back side of the housing to obtain additional clearance for HID wiring harness to pass through. (Please See Fig. 1)
3. Insert the projection HID lamps into the housing and reinstall Headlamp Bezel. Ensure that the top of the HID lamp is facing up before securing in place.
4. Install the two wiring harness to vehicle with both black wires secured to a common vehicle ground and the two red wires secured to the batteries positive terminal post located on drivers side engine firewall.
5. Secure the ballasts to hood using supplied self adhesive pads and sef tapping screws. IMPORTANT: Be sure to secure to the outer sides of the hood in the double wall section to ensure the screws do not puncture through to the outside of the hood.
6. Check fuses to ensure they are installed correctly.
7. Route wire harness to front of engine bay and plug the white fitting on the end of the harness to the white fitting on the back side of the projection lamp.
8. Route Red and Black fitting (36” in from end of harness) to a flat secure surface to mount ballast.
9. Plug the black ballast fitting into the ballast. Note: be sure that the fitting is plugged in correctly, the wire can be inadvertently forced into the receptacle backwards and will not operate correctly.
10. Secure the wire harness with the supplied zip ties.
11. Plug the stock headlamp wire harness into the supplied adapters and plug into projection headlamp harness.

Get pdf H1 Hummer H.I.D. High/Low Projection Headlamp System Wiring and Installation Instructions

2003-2006 Hummer H2 6.0L V8 Part #3060 Installation Instructions

1. Start by unplugging the MAF sensor by using a screw driver to remove the clip as shown.
2. Push fitting in and pull up to remove the wire harness from the MAF sensor.
3. Remove the bolts that hold the stock air box in place as shown and set aside for reuse with the MAC system.
4. Unbolt the engine cover by using a 10mm socket as shown and set the hardware aside for reuse.
5. Remove the cover to gain access to the hose clamp at the throttle body as shown.
6. Loosen the hose clamp on the stock air tube that attaches at the throttle body as shown.
7. Loosen the hose clamp that attaches the stock air tube to the MAF sensor as shown.
8. Remove the stock air tube from the throttle body and the MAF sensor as shown.
9. Loosen the hose clamp around the MAF meter and remove the meter form the air box. Note: The MAF meter will be reused with the MAC system.
10. Remove the stock air box by pulling it out of the fender as shown.
11. Install the MAC velocity adaptor on to the MAC air dam with the O-ring supplied in the hardware kit.
12. Install the MAF meter to the velocity adaptor through the MAC air dam as shown. Note: Do not over tighten the mass air meter.
13. Install the MAC air dam into the stock location as shown. Use the stock hardware to mount the air dam in place.
14. Remove the air meter from the stock air tube and install it to the MAC air tube as shown. Also install the silicone hoses to the MAC air tube.
15. Install the MAC air tube to the throttle body and to the mass air meter as shown using the silicone hoses provided in the kit and tighten the hose clamps. Note: Do not over tighten the hose clamps.

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