BMR Suspension RK002 - Manual (Page 3)

BMR MANUAL RACK CONVERSION KIT (Cont.)
PART# RK002
NOTE: the following steps (steps 17-21 are only necessary if you are using a stock K-
member. If you have a BMR K-member, proceed to step 22)
17. Locate the brake line that runs along the front of the K-member. Pry the brake line
retainer out of the K-member and slightly bend the line up out of the way to prepare for
clearancing the K-member.
18. Locate the drivers' side forward portion of the K-member. See Images 4, 5, and 6 below.
Measure approximately
1/2" from the front corner and mark the K-member. Mark a
triangular section in the K-member in such a way that it "squares off” the area when cut.
19. Using a Sawzall or similar cutting tool, cut the section out.
20. Sand and paint the area.
21. Bend the brake line back and re-insert the retainer.
22. Using the provided new bolts, bolt the rack and pinion to the K-
member. If you used Option 1 to remove the drivers' side bolt,
replace it from the top then lower the motor back down. Insert the
motor mount cross-bolts and re-tighten both sides. Re-install the
alternator. If you used Option 2 to remove the drivers' side rack bolt,
replace it from the bottom with the nut on top. Use red Loctite when
installing the nut.
23. Tighten the rack bolts to 80 ft/lbs with a 19mm wrench and socket
24. It is now necessary to modify the vehicles spindles in preparation
for installing the outer tie rods. Using a
1/2" drill bit, drill out the tie
rod mounting holes on the spindles.
25. Assemble the tie rod bolts and spacers as illustrated in Image 7
and bolt them to the spindles. Tighten the bolts to 55 ft/lbs.
26. Take the pre-assembled u-joint/shaft assembly that came with
your RK002 and slide the end with the hole inside the steering
column. Use the supplied 10mm nut along with the factory bolt and tighten them down.
27. Now take the other end of the shaft with the female splined u-joint and slide that over the
male shaft on the rack.
28. Tighten the set screw and jam nut on the u-joint.
29. Double-check all bolts and jam-nuts from the installation to make sure everything is tight.
30. Re-install the wheels and tires and lower the vehicle.
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