Trail Master Suspension TM104N CHEVEROLET/GMC 1/2 TON 4WD SUSPENSION LIFT KIT - Manual (Page 15)

15
TM104N
Revised
1.27.14
25. Carefully install the front caliper assemblies to each side of the truck.
26. Remove the factory brake line brackets from the frame. Using the supplied brackets
(PN 90-1868) and the previously removed factory bolt attach the new bracket in place of
the stock bracket with the bends facing down. Attach the stock brake line bracket to the
new bracket using the new hardware (PN 90-6299).
27. Install the ABS sensor wiring and secure them to the brake lines with “zip-ties”. Again,
the harness must be routed to prevent breakage or chaffing. Move the A-arm assembly
up and down to its limits several times to check for binding and to ensure that there are
no interference or pinching problems with the brake lines and ABS wiring.
28. Assemble sway bar end link extensions using hardware from packs (PN 90-6065 and
PN 90-6024) as shown in Illustration 12.
29. Install the sway bar end link extension (PN 82-2122) to the lower control arm. Using the
OEM bushings and hardware from packs (PN 90-6065 and PN 90-6024). See
IIllustration 12.
30. Secure the end link assembly to end of sway bar. See Illustration 12.
31. Install the torsion bar cross member drops by locating the new parts (PN 82-5700) in
place as shown in Illustrations 13, 14, 15, & 16, and clamping them in place to the
bottom and face of the frame rail. The location is determined by centering the new
adapter holes around the OEM mounting rivets as shown in the detail views. Drill the
four mounting holes per side for clearance of 7/16” bolts. Using the supplied 7/16” X 1
1/4” bolts, fasten the drops to the frame rails and torque to specifications.
32. From the factory, there are at least two different configurations for the torsion drop
brackets. Included in the kit are adapters made specifically for these differences. The
primary difference between the cross members is the width. Models with a torsion cross
member width of 40 1/2” (bolt center to bolt center) will use torsion drop adapters PN 90-
1638. cross members with a width of 39” will use PN 90-1636. they are mounted to the
universal adapters previously installed using four 3/8” X 1 1/4” bolts from parts pack PN
90-6223.
33. Install the Torsion bars by reversing the order in which they were removed. Again, be
very careful to install them with the same orientation that they were removed (I.E. left
front to left front, right front to right front)! Reset the preload bolts to the same
measurements previously taken.
34. With the truck still on jack stands and the suspension hanging at full extension, cycle
the steering from lock to lock to check that all components have clearance and operate
freely. Pay very close attention to the ABS wiring and brake lines.
35. Lower the truck to the ground to preload the suspension and unload the upper A– arms.
Tighten the lower A-arm pivot bolts to specifications. It is necessary to rotate the upper
A-arm alignment cam bolts to a neutral position (in the center of the alignment slot) and
then tighten the cam bolts to specifications. This step is necessary to allow you to get to
a professional alignment shop only! Do not assume that this setting is “close enough”
and skip the alignment.