Buyers 09001023 - Manual (Page 2)

Quality since 1946

member. With this cap screw already installed, slide one 2"
square washer plate (item 11) onto the threaded portion of
the screw. Install the driver's side mounting plate onto the
cap screw through the center .81" OD hole. Place one USS flat
washer, one 3/4" split lock washer, and one 3/4"-10 hex nut
Gr 5 onto the threads and hand tighten.
5. Position the front and rear angle iron cross members and
align with the outside of the formed ears of the side mount-
ing plates. Insert one l/2"-13 x 1-1/2" cap screw Gr 8 and one
1/2" USS flat washer through each slot in the side mount-
ing plate and the corresponding slot in the angle iron cross
members. A total of two l/2"-13 x 1-1/2" cap screws Gr 8 are
required for mounting both the front and rear cross members
to the driver's side mounting plate. Install one 1/2" USS flat
washer, one 1/2" split lock washer and one 1/2"-13 hex nut
Gr 8 onto each of the threaded ends of the cap screws and
hand tighten.
6. Insert one 3/4"-10 x 2-1/2" Gr. 5 cap screw and 3/4" USS
flat washer through the 3" x 5" frame spacer plate (item
12), and install from the inside of the truck frame member
through the 1-1/4" x 2" vertically oriented slotted hole and the
corresponding rear slot in the side mounting plate. Orient
the frame spacer plate vertically in the truck frame member.
Install one 3/4" USS flat washer, one 3/4" split lock washer
and one 3/4"-10 hex nut Gr 5 onto the threaded end of the
cap screw and hand tighten.
7. Place the emergency brake cable bracket over the
threaded portion of the 5/16" carriage bolt. Secure the
bracket with a 5/16" USS flat washer, 5/16" lock washer
and nut. Tighten to a torque of 20 ft-lbs.
8. Install passenger side mounting plate and hardware
in the same manner as detailed in Step #4-#6.
9. Verify that the mid-point between both front and rear
cross members is located no more than 4-1/2" forward of
the centerline of the rear truck axle. Then hand tighten the
fasteners.
10. If it was necessary to raise the truck bed, it is now time
to lower it back into its original position. Be sure not to move
the position of the cross members.
Make sure to replace all
of the truck bed mounting hardware and torque to recom-
mended settings.
11. From the underside of the truck, locate the four G9003/
G9005 folding ball hitch mounting holes on the horizontal
side of the cross members (two holes per cross member).
These four holes correspond to the holes marked “A” on the
cutting template included with this kit. Using a 1/8" bit, drill
one hole through the truck bed at the centerline of each of
the four cross member mounting holes. Be sure to drill each
1/8" hole at center of each predrilled holes in the cross member.
12. From inside the truck bed, locate the 1/8" pilot holes
drilled in Step 11. Place the cutting template so that the pilot
holes drilled are at the centerline of the corresponding tem-
plate holes (marked “A” on template). Temporarily attach the
template to the truck bed, using adhesive tape. Verify that
the template is properly positioned to allow the centerline
of the gooseneck ball to be located at the center of the truck
bed.
Be sure that the template is lined up with the appro-
priate holes! Template must be parallel with the truck cab!
13. From under the vehicle, verify that the area between
the front and rear cross members does not contact any fuel
lines, brake lines, electrical wiring, or objects that will get
damaged when this area of the truck bed is removed to
allow for the G9003/G9005 Folding Ball Hitch to set into
the truck bed.
14. From inside the truck bed and using the template, drill
four 1/8" pilot holes at the centerline of the holes marked
“B” on the cutting template. Remove the template once this
is complete. In the next step the area within the four pilot
holes (marked “B” on the cutting template) will be removed
to allow installation of the folding ball hitch.
15. Using a saber saw, cut a hole in the truck bed by con-
necting the 1/8" pilot holes (marked “B” on the cutting tem-
plate).
Be sure that there are no obstructions under the bed
of the truck that can be damaged by cutting.
16. Using a 1-3/4" hole saw, enlarge the mounting holes
(marked “A”) already drilled in the truck bed. Be sure to only
cut through the truck bed. Do not cut into or through the
front or rear cross members.
17. From inside of the bed, place the G9003/G9005
Gooseneck Ball Mount into the large hole (marked “C” on
template).
(Be sure the front of the G9003/G9005 is towards
the truck cab). The enclosed 7/8" SAE and 5/8" USS flat
washers are used as spacers between the cross members
and the bottom surface of the G9003/G9005. These spacers
allow the G9003/G9005 to be mounted flush with the truck
bed. Place one (or two, if required) 5/8" USS flat washer
on top of both cross members over each of the four G9003/
G9005 mounting holes. Place one 7/8" SAE flat washer on
top of each 5/8" USS flat washer. Place the G9003/G9005
through the large cut-out hole in the truck bed and set on top
of the washers. Note the 7/8" SAE flat washer has a larger
hole inside diameter to allow for the flush mount of the car-
riage bolt. Using four 5/8" x 2-1/2" G5 carriage bolts (supplied
with the G9003/G9005), secure the G9003/G9005 through
the truck bed and the front and rear cross members. From
the underside of the truck, install four 5/8" heavy-duty lock
washers (supplied with this Frame Mounting Kit), four 5/8"