Auto Manual Resource: Chevrolet

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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.

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

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

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

2005-2008 Chevy Cobalt Exhaust System Installation

Prior to installation, be sure your vehicle is parked on a level surface, and the exhaust system is cool. For safety purposes and ease of installation, we urge you to take your vehicle to a qualified service center or muffler installer that employs the use of a lift.

Exhaust System Removal:
1. Measure the exhaust pipe 7-1/2 inches forward of the rear axle and mark a line.
2. Using a saw or chain style pipe cutter, cut the stock system.
3. Using a 15 mm socket remove the two flange nuts.
4. Remove the front hanger from the rubber isolator and remove the front section of the stock exhaust system.
5. Remove the rubber isolator after the axle from both the vehicle and the exhaust system (See Fig. D).
NOTE: Be sure to save all rubber isolators removed from the vehicle. They will be used to install the CORSA Performance exhaust system in later steps.
6. Support the exhaust system, and remove the rubber isolators after
the rear muffler from both the vehicle and the exhaust system.
7. Remove the remaining section of the exhaust system.
8. Install all rubber isolators back onto the vehicle.

CORSA Performance Exhaust System Installation:
1. Remove all exhaust system components from the shipping cartons, including clamps. NOTE: There are three 2-1/2 inch clamps supplied. NOTE: Apply the anti-seize lubricant (supplied) to the threads ONLY of all the TORCA band clamps and flange bolts. Failure to follow this procedure can cause nuts to seize on clamps and potentially damage threads.
After applying anti-seize lubricant, be sure to thoroughly clean hands as lubricant will tarnish stainless steel.
2. Locate the front muffler assembly, flange gasket, nuts and bolts
3. Place the flange gasket over the flange after the catalytic converter, and using a 15mm socket and a 5/16” allen wrench install the front muffler assembly. Tighten the flange bolts to 40 ft-lbs (See Fig. G).
4. Locate the intermediate pipe assembly and place a TORCA clamp on the inlet.

Get pdf 2005-2008 Chevy Cobalt Exhaust System Installation

1996-00 Chevrolet, GMC Truck & SUV 5.7L V-8 ECONOAID Throttle Body Plate Instructions

1. Disconnect the negative battery cable! Remove the plastic wing nut on the air intake hat behind the throttlebody. Loosen the hose clamp that secures the flexible intake tube to the throttle body hat. Disconnect the crankcase breather hose. Roll the air intake hat towards the front of the vehicle to remove it, and set it aside.
2. A.) Remove the three bolts that secure the throttlebody to the intake manifold. B.) Remove the bolt that secures the throttle cable bracket to the throttlebody. C.) Lift up the tabs, and disconnect the two wiring harnesses of the drivers side of the throttlebody. Lift the throttlebody off of the intake manifold and set it to the side.
3. Install the ECONOAID Plate against the intake manifold with the logo facing the throttlebody. Next install the supplied gasket between the plate and the throttlebody.
4. Reinstall the throttlebody onto the intake manifold and tighten all three bolts securely. Reconnect the two wiring harnesses. Reinstall the bolt thru the throttle cable bracket and into the throttlebody. Before starting the engine, open and close the throttlebody to make sure there are no obstructions.
5. Reinstall the intake hat and tighten the wing nut. Reconnect the crankcase breather hose. Reconnect the intake tube and tighten the clamp.
6. Double check your work. Make sure there is no foreign material in the intake tract. Make sure all clamps, hoses, nuts, and bolts are secure. Reconnect the negative battery cable.

Get pdf 1996-00 Chevrolet, GMC Truck & SUV 5.7L V-8 ECONOAID Throttle Body Plate Instructions

2007-2008 Chevy 4.8, 5.3, 6.0 Silverado/Sierra VPI Cold Air Performance Intake System Installation

Installation Instructions:
1. Disconnect negative battery cable. Then loosen all three factory hose clamps located at the Mass Air Flow (MAF) meter and both factory intake tube.
2. Remove black cover on throttle body by pulling up and sliding towards front of truck. It is held by two grommets. Gently pry the radiator hose bracket from the factory intake tube assembly and remove the tube from the vehicle. A flat head screwdriver may be used.
3. Remove the factory air filter base and lid as an assembly. There are no bolts, just friction mounts, so just pull straight up on the air filter base to remove. Then remove the plate that held the base and lid. There are (5) 10mm bolts to unscrew to remove the plate. After everything is removed it should look like the picture above.
4. Install the black plastic filter adapter ring using the (3)1/4 20 Screws and washers provided.
5. Position the VPI Intake Box over the inner fender cavity and secure with the (3) factory bolts you removed from the bottom plate.
6. Slide the factory MAF meter back onto the black plastic filter adapter ring. Important: Factory clamp/rubber bushing must be in place on the inlet to the MAF meter.
7. Install the hump hose provided onto the VPI Intake Tube with the supplied hose clamps.
Note: Slide the hump hose all the way onto the end of the tube.
8. Insert grommet and fitting into hole on VPI tube. Connect intake tube (with the now attached hump hose) to the MAF. Tighten clamps. Connect 3/8 hose from VPI tube to valve cover.
Note: It may be necessary to lubricate fitting with water to slide the breather hose on.
9. Connect intake tube end into the throttle body using factory GM coupler that is provided.
Final Steps
Check for any foreign objects or debris in the intake path. Double check your work, to make sure all nuts, bolts and clamps are fastened securely. Reconnect the negative battery cable.

Get pdf 2007-2008 Chevy 4.8, 5.3, 6.0 Silverado/Sierra VPI Cold Air Performance Intake System Installation

99-02 Full Size Chevy / 99-04 GMC Hoods Installation

STEP 1: Adjust hood until proper alignment with matching panels is achieved. There are two rubber bumpers located in the inner fender jam, they will need to be removed.
STEP 2: Adjust primary latch until it fits into the latch bar on the hood without hitting any perimeter edges of the opening. Make sure when the hood is closed you can hear the latch “click” onto the hood.
STEP 3: After you here it click, test it to be sure it’s working properly by grabbing the front edge of the hood and slowly pulling upward with a steady even pressure. If the hood opens it’s not adjusted properly; repeat STEP 2 until hood cannot be pulled open after it’s closed.
STEP 4: To ensure the safety catch is working properly, close the hood, pull the hood release from inside the car and the hood will partially open. Slowly pull upward on the hood and jiggle it at the same time. If it opens without pulling the safety catch lever then it needs to be readjusted. The safety catch prevents the hood from opening in the event the primary latch fails.
STEP 5: Locate the hood stoppers located on each side of the radiator support. Adjust upward until they apply a small amount of pressure to the underside of the hood when it is closed. This will prevent the hood from shaking or rocking.

Get pdf 99-02 Full Size Chevy / 99-04 GMC Hoods Installation

2001-2007 Chevy/GMC Duramax Diesel Installation Instructions

Pump mounting
We have found the best location if using a tank in the bed is in this location. Drill 4 holes
Remove Intake
On LMM LBZ
Loosen all bolts and nuts labeled with red arrows
On LLY
Loosen 6, 12mm bolts/nuts on the intake manifold. Remove the intake manifold. (Note: it will not be easy to get at all the bolts and remove the manifold, but it can be done just moving the cables out of the way) Be careful not to lose the 2 EGR gaskets and 1 intake manifold gasket.
Loosen BOTH ring clamps on flexible boost tube connector, pull the boost tube down and backwards with the intention of separating the boost tube from the intake manifold at the top most joint.
Nozzles
Take the intake and put on a flat surface and Drill 11/32 hole on the flat portion of the intake that faces towards the firewall when installed in the truck. Now run a 1/8npt-27 tap thru the drilled holes.
Then Thread Nozzles into intake. These should tighten down till the O-ring just starts to sit flat on intake don’t over tighten to the point the O-ring starts to push out.

Reinstall Intake
Tighten all bolts and nuts labeled with red arrows
Map Sensor Wire
DevilsOwn Progressive Controller injects water methanol according to MAP sensor signal. On the Duramax the MAP sensor signal wire is a Lt. Green and is located as the center pin of the three pin connector. Use one of the supplied Posi-Tap connectors to tap onto this the MAP SIGNAL wire from the controller harness. If you are running any type of power module, make sure you tap onto the signal wire before the power module.

Get pdf 2001-2007 Chevy/GMC Duramax Diesel Installation Instructions

2002 Chevy Trailblazer / GMC Envoy Air Intake Installation Instructions

These instructions will take you through the installation of your new air intake system for your vehicle. We always recommend that you keep your stock air intake system in storage in case you might need it later.
Kit includes: air filter, air intake tube, bracket, (2) 3” hose clamps, red connecting hose and rubber grommet.
Tools required: Phillips head screwdriver and 5/16” nut driver.

1) Removing stock air intake system
Remove the 3 screws holding the air box with a phillips head screwdriver (fig.1, 2, 3). NOTE: You will need one of these screws later in the installation.
Remove the air box extender (fig.4) and the oxygen sensor (fig.5).
Loosen stock hose clamp and remove entire intake tube and filter (fig.6)
2) Installing your new intake tube
Stretch the red connecting hose over throttle body outlet and afix hose clamp over it (fig.7).
Fix rubber grommet into intake tube (fig.8).
Place other hose clamp on red connecting hose and install new air intake (fig.9).
Put oxygen sensor into intake tube at rubber grommet.
3) Installing the air filter
Loosen the hose clamp at the base of the air filter and slide onto end of the intake tube (fig.10). Do not tighten down the hose clamp yet.
Slide the curved end of the bracket between the hose clamp and the filter base (fig.11). Line the hole on the other end of the bracket with the hole the original air box was secured by. Use one of the original screws to secure your new bracket.

Get pdf 2002 Trailblazer / Envoy CGS Air Intake Installation Instructions

Stake Pocket Pop-Up Installation Instructions

1. Read and understand these instructions before proceeding. If you drop a screw down in some stake pocket holes it is difficult to retrieve. Some installers prefer to apply masking tape around the stake pocket holes to prevent scratches. Remove the tape before tightening the assembly screws.
2. Select the correct stake pocket insert. The flat model is used for the 88-98 Chevy & GMC models. All other trucks use the insert with the bent flanges. The bent flange style should be oriented with the bent wings pointing up like this: [__________]
3. Slide the rubber gasket, then insert, onto the Stake Pocket Pop-Up to dry fit the pieces together. Line up the holes in all the parts. You must understand what is the front and back orientation of the insert to install the parts correctly.
4. Place the correct insert in the stake pocket hole. Use strips of tape or short lengths of thin wire to hold it up and in place.
5. Slide the main Stake Pocket Pop-Up piece with the rubber gasket installed through the hole in the insert.
6. Start 2 of the provided screws through the Stake Pocket Pop-Up, gasket, and into the insert.
7. Remove the tape or wire used to hold the insert.
8. Start the other 2 screws through the Stake Pocket Pop-Up, gasket, and into the insert.
9. Pull the assembly up so the insert is centered in the stake pocket hole, and alternately tighten opposing screws until the assembly is pulled up but not tight.
10. Tighten the other 2 screws until they are flush with the top of the Stake Pocket Pop-Up.
11. Tighten all 4 screws, being careful to not distort any vehicle sheet metal.
To release the Stake Pocket Pop-Up, use your thumb, finger, or a coin in the slot to twist the center ¼ turn in either direction. To close the Stake Pocket Pop-Up, push the center piece back down into the hole until it is flush then rotate ¼ turn in either direction.

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2003 GMC/Chevrolet Vehicles with DRL Running Lights Carton 07400 Installation Instructions

Mounting the Meyer Daytime Running Lights:
1. Connect the 07104 Adapter Kit as per Nite Saber Instruction sheet (Form 1-757) Installation #4 (Installation of adapter set).
2. Turn on Vehicle and verify operations of the Vehicle Headlight, Daytime Running Lights and Snow Plow lamps. Replace and repair any defective parts, switches, etc. before installing the Daytime Running Light Module. NOTE: To test Daytime Running Light on Vehicle, make sure vehicle is outside in Daytime condition. The 99 & later Chevy is equipped with a photo sensor and will not operate under artificial light.
3. The Meyer Daytime Running Light (DRL) is mounted in the engine compartment close to the battery and near one of the front headlamps and parking lamps. When a location is found, make a mark with a pencil on the inside fender wall of the vehicle through the mounting tab of the DRL module. Drill two 1/8” holes on the marks and mount the unit with two #10 gauge screws provided.

Wire connections:
The ground wire connection is one of the most important connections to be done in the installation and must be done first. The black colored wire is the ground wire and must be connected to metal chassis that provides a path back to battery negative. Check with an ohmmeter if possible to insure it is properly grounded.

NOTE: DO NOT CONNECT THE WIRE HARNESS TO THE MODULE UNTIL ALL NECESSARY CONNECTION(S) ARE MADE.
1. Connect the black wire (Position G) to a metal surface that is clean of dirt, grease and paint. Drill a 1/8” hole and using the #10 screw provided, securely fastened the terminal of the black ground wire.
2. Route the White wire (Position B) to one HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the white wire to the white wire on cable “C”. Refer to form 1-757 (Item #5). NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
3. Route the White wire (Position E) to the other HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the white wire to the white wire on cable “C”. Refer to form 1-757 (Item #5). NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
4. Route the Blue wire (Position F) to one HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the blue wire to the blue wire on cable “C”. Refer to form 1-757 (Item #5). NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
5. Route the Blue wire (Position H) to the other HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the blue wire to the blue wire on cable “C”. Refer to form 1-757 (Item #5).
NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
6. Connect the Red wire to the positive terminal of the battery.

Test Procedure:
Ensure that the following connections have been made:
1. Black wire secure to ground
2. White wire to Cable “C” white with (Item 5) (Refer to Form 1-757)
3. White wire to other Cable “C” white wire
4. Blue wire to Cable “C” blue wire
5. Blue wire to other Cable “C” blue wire
6. Red wire to positive terminal on Battery.
7. Touch the end of the Green Wire to the positive terminal of the battery. The Snow plow lamps low beam should illuminate at low intensity. Remove the green wire connection to the battery.

The snow plow lamps low beam should shut off.
NOTE: To test Daytime Running Light on Vehicle, make sure vehicle is outside in Daytime condition. The 2003 Chevy is equipped with a photo sensor and will not operate under artificial light.
NOTE: It may be necessary to strip and bare a small portion of the insulation from the end of the green wire to insure good contact. If lights do not turn on, refer to the trouble shooting index.
NOTE: In most cases when the unit does not work as indicated, it is a poor wire connection. If all lights work, carry on with the final connection of the green wire.
Final Wire Connection:
Locate the OEM Daytime Running Light Lamp. Route the Green (Position D) wire to the DRL lamp and connect it to the positive wire of the OEM lamp (Dark Blue Wire) using the Tap Splice connector provided.

Get pdf 2003 GMC and Chevrolet Vehicles with DRL Running Lights Carton 07400 Installation Instructions

2003 Chevrolet/GMC 2500HD RECON 3-Piece Cab Roof Light Installation

This document covers the installation of RECON Truck Accessories 3-Piece running lights on a 2003 Chevrolet/GMC Silverado/Sierra 2500 HD. RECON 3-piece Chevy/GMC Cab Roof Light Kit Boasts The Following:
Provides Maximum Visibility
Meets S.A.E. specifications
Adapts to Curved and Flat Roofs
Replaceable 194-Style Bulbs
Kit includes 2 Corner Clearance Lights and 1 Three Lamp Cluster Center Marker Light
Complete Wiring Harness with Quick Wire Connectors
Great Retail-Friendly Packaging
All Necessary Hardware

The light kit comes with everything required to install, except it is also recommended that you apply a little silicone/sealant to ensure a lasting seal around the holes & wires.

The installation takes approximately 2 to 3 hours and can be broken down into 5 main steps:
1. Drop front part of headliner
2. Measure/Mark holes for lights
3. Mount Lights
4. Wire Lights
5. Re-assembly

Drop Headliner
Remove sun visor assemblies and sun visor clamp (Torx 15 & 20 required)
Disengage passenger side grab handle. Insert small flat screwdriver to pull out covers/lock mechanism then pull out on handle until you feel it disengage. There is no need to remove handle from headliner.
Disengage DS and PS pillar covers. Pull out at top and away from pillar. Lower panel(s) down so you can drop headliner about 4-6”.
Remove overhead console. Remove front screw. Slide console forward a little and pull down in rear as is a clamp on each side that locks it into the overhead. Disconnect On-Star speaker plug (if equipped) and map light plug. Remove console. At this point you should be able to pull the front part of the headliner down around the front of the windshield. It will only drop about 2” to 3” which should be enough to carefully reach the wires.

Mount Lights
The side marker lights require 2 holes and the center light 5 holes IIRC. Take your time and measure everything twice to make sure you don’t drill any extra holes. You only have one chance.

Side lights:
On driver and passenger side, it is 4 1/4 inches from near edge of black rubber door rubber gasket to the near edge (side) of the roof marker lamp gasket 4 1/8” from near edge of black rubber windshield gasket to front edge of the roof marker lamp gasket

Center Light:
3 1/8 from near edge of black rubber windshield gasket to near edge of the center roof marker lamp gasket. Make sure you measure across to find center of roof and center light accordingly. IIRC, center is around 27 ž” measuring of the windshield top corner moldings. Place the lights at the approximate locations and place masking tape on roof so you can mark/drill without damaging the paint. It’s best to start with the center light so you’re not leaning over the outside lights during the installation process.
Measure all lights and mark holes. Once the lights are in place and measured, use a sharp tipped round scribe to mark the holes as you will need to place it down thru the light holes which are about 1” tall. This made marks on my tape which are visible once the lights are removed.

Get pdf 2003 Chevrolet/GMC 2500HD RECON 3-Piece Cab Roof Light Installation

2000-2007 Classic Chevy/GMC 2WD C1500 P/U 7″ Performance Suspension System

INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. With the truck on level ground measure the trucks ride height from all four corners. Record the heights for use in the installation of the kit.
2. 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.
3. On both sides of the truck, remove the hardware securing the brake line to the spindle, discard hardware. Remove the bolts attaching the brake caliper to the spindle, save hardware. Remove the caliper and tie is up out of the way. DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE LINE! Remove the brake rotor. Remove the front sway bar end links and discard. Also, disconnect the ABS wire from the frame.
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 hardware from lower shock mount and discard 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, as shown above, DO NOT HIT THE THREADS ON THE TIE ROD END. Save hardware. SEE PHOTO IN NEXT COLUMN.
5. Locate the three factory bolts on the back side of the spindle attaching the bearing assembly to the spindle. Remove bolts and bearing assembly and save.
6. Remove the nut holding the upper ball joint to the spindle. If the ball joint shaft spins inside the spindle, insert an allen wrench in the bottom of the ball joint and loosen the nut with a wrench. Do not remove nut at this time
7. Separate the ball joint from the spindle by hitting the side of the spindle with a hammer. DO NOT HIT THE THREADS ON THE BALL JOINT. Remove the ball joint nut from ball joint than remove upper ball joint from the spindle and save hardware. Remove the nut from the lower ball joint and separate the spindle from the lower ball joint, you may need to hit the side of the spindle with a hammer to free the lower ball joint from the spindle, save nut. BE SURE NOT TO HIT THE THREADS OF THE BALL JOINT. Discard factory spindle.
8. 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 make sure to remove the upper and lower spring insulators. DO NOT DISCARD THE COIL INSULATORS, THEY WILL BE REINSTALLED ON THE NEW COILS.
9. Remove the factory lower control arms from the truck. Save the factory hardware as you will reuse it during installation.
10. Locate the factory lower control arm bump stop on the frame. Remove and discard.
11. Repeat steps three through nine on the passenger side of the vehicle at this time.
12. If equipped, remove the factory strut tubes and discard.

Get pdf 2000-2007 Classic Chevy/GMC 2WD C1500 P/U 7″ Performance Suspension System

2007-2008 Chevrolet & GMC Truck with a 5.3L, 6.0L & 6.2L V8 Mac Performance Instructions

1. Start by disconnecting the wire harness from the MAF sensor as shown.
2. Remove the cover from the intake manifold by lifting it up and then pulling it out as shown.
3. Unplug the vent air tube from the stock air silencer as shown.
4. Remove the clip holding the radiator hose to the stock air tube as shown.
5. Loosen the hose clamp on the stock air tube at the MAF meter and the throttle body and remove the stock air tube as shown.
6. Remove the cover of the stock air box as shown and set aside.
7. Pull up on the stock air box and remove it form the vehicle as shown.
8. Using a 10mm socket and ratchet remove the bolts (4) that hold the stock plate in place and remove as shown.
9. Install the MAC velocity adaptor to the MAC air dam as shown using the hardware provided.
10. Install the MAC air dam into the stock location as shown using the stock hardware.
11. Loosen the hose clamp that holds the MAF meter to the stock air box and remove as shown.
12. Remove the hose clamp and the rubber mount as shown from the MAF meter.
13. Install the straight silicone hose to the velocity adaptor and to the MAF meter and tighten as shown.
14. Install the 30° silicone hose to the MAF meter as shown. Note: Do not tighten the hose clamp.
15. Install the 70° silicone elbow to the MAC air tube as shown. Note: Do not tighten the hose clamp.
16. Install the MAC air tube to the throttle body and to the silicone hose on the MAF meter as shown.
17. Once the MAC air tube is aligned tighten the hose clamps on the air tube as shown.
18. Attach the clip on the upper radiator hose to the bracket on the MAC air tube as shown.
19. Install the vent air tube provided in the kit to the stock air tube as shown.
20. Install the vent air tube to the fitting on the MAC air tube as shown.

Get pdf 2007-2008 Chevrolet & GMC Truck with a 5.3L, 6.0L & 6.2L V8 Mac Performance Instructions

2004 Chevy HD Truck Duramax Diesel High Output “LLY” Installation Instructions

Tools Required For Installation:
Flat Head Screwdriver
8mm, 10mm Socket
Ratchet & Extension
3/32”, 5/32” Allen Wrench
#T20 Security bit (Included)
1. Disconnect the negative battery cable. Disconnect the Mass Air Flow (MAF) sensor wiring harness. Using the supplied T-20 Security bit, remove the two screws and the Mass Air Flow sensor from the tube (save the sensor for reuse). Loosen the hose clamps on each end of the factory intake tube assembly.
2. Remove the factory filter minder and grommet.
3. Remove the factory intake tube assembly from the engine. Rock the factory air box back and forth and remove it from the vehicle. There are only grommets holding it in, no bolts.
4. Using a 10mm socket, remove the five bolts and mounting plate from the engine compartment.
5. Assemble the Airaid Cool Air Dam panels (#2, #3) using five 6-32x 5/16” screws (#9), #6 flat washers (#10) and 6/32 keps nuts (#11).
6. Using three ž-20x 1/2” button head bolts (#12) and 1/4” flat washers (#13), install the filter adapter (#4) on the Airaid Cool Air Dam.

Get pdf 2004 Chevy HD Truck Duramax Diesel High Output “LLY” Installation Instructions

01-06 Chev/GMC 6.6L Duramax Diesel Extended Cab Short & Long Bed Installation Instructions

Removal of stock system:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. Using a 15mm socket or wrench, disconnect the factory exhaust system at the four bolt flange located behind the catalytic converter. If the vehicle is not equipped with a catalytic converter disconnect the four bolt flange located approximately under the passenger side seat.
3. Remove the exhaust system from the rubber insulators and remove from under the vehicle. If a hoist is not available for use, it may be necessary to cut the tail pipe behind the muffler for removal of the system.
4. Unbolt the OEM hanger from the transmission and remove.
5. Loosen the factory band clamp and remove the stock front pipe. Some vehicles are not equipped with a catalytic converter. Do not discard the band clamp as it is required for the installation.
6. Remove the spare tire. You may not be able to reinstall your spare tire after the installation of this exhaust system.

Installation of MBRP Inc. Performance Exhaust:
1. Install the Front Pipe onto the factory down pipe using the band clamp removed previously. Do not fully tighten to allow for adjustment. For regular cab models, 3” must be removed from the non flared end.
2. Install the hanger removed previously by sliding the outside hole in the rubber insulator over the hanger on the Front Pipe and re-connect to the transmission.
3. Install the 4″ to 5” Adapter over the Front Pipe. Then connect the Mid Pipe to the 4″ to 5” Adapter at the slip joint placing the bend around and under the cross member. Regular cab models do not have this cross member. The Mid Pipe does not require cutting to fit crew cab trucks. For extended cab trucks, approximately 9―” needs to be cut off the end with the longest straight section of pipe. For regular cab trucks remove 2” from the end with the shortest straight section of pipe and approximately 11―” from the end with the longest straight section of pipe. (Installation tip: Temporarily hang the Muffler and the Tail Pipe in place and measure to the Intermediate Pipe to verify the length required).
4. Rotate the Mid Pipe toward the drive shaft and loosely install the Hanger Clamp with the shortest hanger. This will support the Extension Pipe during the Muffler installation. Regular cab trucks do not require the installation of this Hanger Clamp.
5. Crew cab & extended cab long bed trucks require the use of the 18″ Extension Pipe provided. This is to be positioned between the Muffler and the Mid Pipe. The 18” Extension Pipe is not required with short box trucks.

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99-07 Chevy & GMC Full Size Part # 000937, 000938 Installation Instructions

REMOVAL:
1. Engage the steering column / ignition switch lock with the steering wheel & wheels centered. (NOTE It may be necessary to remove the upper and lower steering shaft bolts prior to locking for accessibility)
2. Remove the two bolts holding the upper shaft in place. One is located in the engine compartment; the second is located under the dash at the base of the steering column.
3. Compress factory shaft assembly and remove it from under the dash. Do not spin wheel with shaft removed.

INSTALLATION:
4. Insert the tubular end of the Borgeson shaft from under dash through the firewall. Insert the male end of the universal joint into the steering column base and reinstall bolt.
5. Extend the Borgeson shaft to mate with lower shaft assembly in the engine compartment and reinstall bolt.
6. Torque each of the bolts to 60 ft/lb…NOTE…Failure to torque these bolts may cause a loose feeling in the steering.

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2001-2004 Chev/GMC Duramax Diesel “Cool Duals” Installation Instructions

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)

Standard installation:
Install the slip joint to the front pipe. ( Four Bolt Flange )
Install extension pipe into the slip joint (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)
Install the Over axle pipe over the muffler outlet, the muffler outlets will be in a vertical position. Install the second half of the driver side tail pipe to the over axle pipe using the frame hanger provided. ( Crew Cab Long Beds may require drilling )
Install the passenger side tailpipe over the bottom muffler outlet from the rear of the truck using the frame hanger provided. ( Crew Cab Long Beds may require drilling )
Install clamps around pipes where needed, be sure exhaust is in place before tightening
clamps. Starting at the front-pipe, tighten all connections.

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TracVan Double Installation Manual

TracVan installation is straightforward, and should take you under 20 minutes to complete. You’ll attach the Crossbars to the Corner Brackets, then attach this assembly to the Gutter Rails of your van.
1. Verify that you have received the correct parts using the attached Assembly Drawing and Packing Checklist.
2. Fit the Rubber Strip on the lower edge of each Corner Bracket.
Do not install strip:
• On 2000+ Ford 150 Econoline vans.
• If using the Gutter Spans
3. Insert 2 (5/16” x 1 3/4 ” long) Socket Head Cap Screws through the Lock Washers and then into the holes in each Corner Bracket Tab.
4. Insert the J-Hooks with Neoprene Strips through the Assembly Slots at the base of the Corner Bracket. Then insert 2 Brass Nuts into the opening of the J-Hook clips. Thread each screw approx. 1/4 in. into the J-hook’s brass nut. (Do not completely tighten screws) Repeat for each Corner Bracket, (2 hooks for each Bracket). (See Fig. 1)
5. Now you’re ready to attach the Crossbars (see Shim Installation, page 6, if shims are required on front and rear racks). Insert the heads of four 1 1/2” T-Bolts into the Crossbar Slot on the bottom of each Crossbar (the bottom is the side with the Flat Recess) (see Fig. 2). Slide 2 T-Bolts to the left side and 2 T-Bolts to the right.
6. Attach a Corner Bracket assembly to the Crossbar by inserting the T-Bolts through the two holes in the Corner Bracket. Partially tighten and secure with the Self Locking Nuts – enough to hold the Corner Bracket in place. Repeat for each of the remaining three Brackets.
7. Slide the Crossbar Tiedowns onto the Crossbar by insert- ing the T-Bolts into the top Crossbar Slot.

Special Installation notes:
• All 1998+ Chevy Express / GMC Savanna (G-Series Vans) require the supplied Gutter Span, which are designed to span the putty filled rain gutter of the Van for maximum strength. If you use the supplied Gutter Spans, refer to “Roof Installation B” instructions on page 5 for proper installation.
• All 2000+ Ford Econoline Vans: DO NOT install the rubber strips to the Corner Brackets.
• When installing a TracVan Triple (SKU# 29056) to a Chevy Express / GMC Savanna (G-Series Vans) and Ford Vans with curved roofs you’ll need to add the supplied Shims, to compensate for the gutter’s curve.

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99-up Chevy/GMC Truck Tailgate Cap Instructions

1. Remove the factory plastic tailgate cap.
A. Remove any tape residue from the truck by wrapping a cloth shop towel or terry cloth rag tightly around knuckles and push firmly against remaining tape.
B. Remove any remaining glue or dirt with Naptha, Paint Thinner or Adhesive Remover. Then clean surface with Isopropyl alcohol and wipe clean.
C. If you have purchased the gray smooth paintable Tailgate Cap go to step 2; if you have purchased the black textured Tailgate Cap go to step 3.
2. Paint Smooth Tailgate Cap according to painting instructions on back of this page. Do not paint black textured Tailgate Cap - this one is meant to be left black.
3. To Install: Peel upper tape protective strip (see #1 below). Then peel back 1”-2” of lower tape protective strip (see #2 below) and fold downward to create a pull tab. Center the cap and push down onto the tailgate, holding the exposed tape on lower corner away from the tailgate until cap is in place. Now slowly pull down on tab and pull protective strip from under the lower edge of tailgate cap. Once the strip is removed, push firmly against cap to set the tape.
Warranty is void if factory tailgate is not cleaned according to instructions and if installation instructions are not followed.

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