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Silverado 1500Hd/2500Hd 2Wd & 4Wd 8-Lug Torsion Bar

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Silverado 1500Hd/2500Hd 2Wd & 4Wd 8-Lug Torsion Bar TM107 Revised 7.22.13 400 W. Artesia Blvd. Fax: (310) 747-3912 Compton, CA 90220 Ph: (877) 695-7812 www.trailmastersuspension.com SILVERADO 1500HD/2500HD 2WD & 4WD 8-LUG TORSION BAR SUSPENSION LIFT KIT 1999– 2010 KIT# TM107 WARNING WARNING Installation of a Trail Master suspension lift kit will Many states and municipalities have laws restricting change the vehicle’s center of gravity and handling char- bumper heights and vehicle lifts. Consult state and local acteristics both on- and off-road. You must drive the ve- laws to determine if the changes you intend to make to hicle safely! Extreme care must be taken to prevent vehi- the vehicle comply with the law. cle rollover or loss of control, which could result in seri- ous injury or death. Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants WARNING have their seat belts fastened. The installation of larger tires may reduce the effective- ness of the braking system. WARNING Before you install this kit, read and understand all in- WARNING structions, warnings, cautions, and notes in this instruc- tion sheet and in the vehicle owner’s manual. Always wear eye protection when operating power tools. CAUTION WARNING Proper installation of this kit requires knowledge of the factory recommended procedures for removal and instal- Before you install this kit, block the vehicle tires to pre- lation of original equipment components. We recommend vent the vehicle from rolling. that the factory shop manual and any special tools needed to service your vehicle be on hand during the WARNING installation. Installation of this kit without proper knowl- edge of the factory recommended procedures may affect DO NOT combine suspension, body, or other lift devices. the performance of these components and the safety of Use of vehicle with combined lifts may result in unsafe the vehicle. We strongly recommend that a certified me- and/or unexpected handling characteristics. chanic familiar with the installation of similar components install this kit. NOTE WARNING Lift height may vary depending on vehicle configuration, This kit should only be installed on a vehicle that is in engine size, additional accessories, the factory suspen- good working condition. Before you install the kit, thor- sion package, and vehicle’s condition. oughly inspect the vehicle for corrosion or deformation of the sheet metal. If the vehicle is suspected to have been in a collision or misused, do not install this kit. Off-road NOTE use of your vehicle with this kit installed may increase the stress applied to the factory components. Failure to Trail Master recommends using thread locking com- observe this warning may result in serious personal in- 1 pound on the threads of all kit nuts and bolts unless jury and/or severe damage to your vehicle. specified otherwise in these instructions. TM107 Revised 7.22.13 2 TM107 Revised 7.22.13 Before Starting Installation Ride Height 1. Carefully read all warnings and instructions com- 6. Measure ride height with the vehicle supporting its pletely before beginning. own weight on level ground. To settle the suspension, NOTE the vehicle should be driven forward at least 10 feet immediately prior to taking these measurements. Ride Kit parts are prefaced by the word kit and appear in height is the measurement from the center of the axle bold print. straight up (vertical) to the fender lip. Record this measurement for all four wheels. 2. Verify all parts have been received in this kit by checking the parts list at the end of this document. Torque Specifications 3. Only install this kit on the vehicle for which it is specified. If anytime during the installation you en- See factory service manual for torque values when re-using counter something different from what is outlined in OE fasteners. the instructions, call technical support at (877) 695- Bolt Size Grade 5 (ft.-lbs.) Grade 8 (ft.-lbs.) 7812. 1/4”-20 10 10 4. Special tools needed: 1/4”-28 10 12.5 a. Torsion bar tool (67971) 5/16”-18 17 22.5 5/16”-24 20 25 b. Welder or access to a professional welding 3/8”-16 30 40 shop. 3/8”-24 35 45 c. Die grinder or similar tool capable of cutting 7/16”-14 50 65 metal. 7/16”-20 55 70 d. Transmission jack 1/2”-13 75 100 e. Rust resistant metal paint 1/2”-20 80 115 9/16”-12 105 135 5. Park vehicle on a clean, dry, flat, level surface and 9/16”-18 115 150 block tires so vehicle cannot roll in either direction. 5/8”-11 150 195 5/8”-18 160 210 NOTE 3/4”-16 175 225 Adhere to recommendations when replacement fas- teners, retainers and keepers are called out in the fac- Fasteners tory service manual. When re-assembling the vehicle it is recommended by the vehicle manufacturer that cer- Adhere to recommendations when replacement tain fasteners are replaced in order to maintain proper fasteners, retainers and keepers are called out in retention characteristics. This system may not include the factory service manual. When re-assembling all replacement hardware as recommended by the fac- the vehicle it is recommended by the vehicle tory service manual. Additional replacement hardware manufacturer that certain fasteners are replaced should be obtained prior to installation of this system in order to maintain proper retention characteris- to meet the requirements of the factory service man- tics. This system may not include all replacement ual. hardware as recommended by the factory service manual. Additional replacement hardware should 3 be obtained prior to installation of this system to meet the requirements of the factory service man- ual. TM107 Revised 7.22.13 Install Front 5. Completely remove the torsion bar key bolt from the key assembly. Suspension 6. With the bar unloaded, slide it for- ward out of the OE torsion bar key 1. Be sure you are working on a level and remove the key from the vehicle. surface. Block the rear tires and NOTE: If the bar seems stuck, raise the front of the vehicle. Support use a hammer and punch through the frame with jack stands. the hole in the rear of the cross member to dislodge it. 2. Remove the front wheels. 7. Install the Trailmaster Forged torsion 3. Measure the torsion bar adjusting key (94-4268) and slide the torsion screw depths and record this dimen- bar back into position. Be sure to sions for later use on reassembly. line up the previously applied orien- Mark the orientation of the torsion tation marks. bar in relation to the front A-arm. IMPORTANT! Make sure Tor- LEFT: RIGHT: sion Bar is extended at least ¼” inch through the Torsion Key. 4. Starting on the driver’s side, remove 8. Using the torsion bar unloading tool, the torsion bar adjusting screw. Ap- apply pressure with the torsion key to ply a small amount of lubrication allow the torsion key keeper to be grease to the torsion bar puller reinstalled. threads (67971 is recommended) and 9. Install the supplied adjusting bolt the puller shaft-to-adjuster arm con- (90-2863) (2009 models will reuse tact point. Load the puller and tor- factory bolt) to the keeper, and reset sion adjuster arm until the torsion bar the torsion bar preload bolts using the keeper can be removed from the measurements previously taken. cross member. Release the puller to IMPORTANT! – On 2009 mod- unload the torsion bar. els DO NOT run the adjustment bolt in farther than 1/4” or damage to the ball joints may occur. IMPORTANT!: Be sure that at least ¼” of bolt threads extend be- yond torsion key keeper. Torsion Bar Tool 67971 NOTE: Each ¼” of adjustment on the bolt equals approximately 1” at the wheel. To avoid over-cranking the suspension and negatively affecting ride quality, perform steps 11 and 12. 4 TM107 Revised 7.22.13 12. Now would also be a good time to inspect the shocks for damage or 94-4268 Torsion Bar Key fluid leakage. Replace if necessary. Adjusting NOTE: For improved perform- Bolt (90-2863 ance Trailmaster shocks are recom- 2000-2008 models) or mended. factory Bolt 1/4” (2009 model only) If reusing OE shocks or OE length 1/4” shocks ONLY!. A. Remove front lower shock mounting bolt and unbolt the OE lower mount from A-Arm. 10. Measure the distance between the B. Install the provided lower shock lower A-arm and the rubber bump mounts (91-5159) using the previ- stop. The distance should be no ously removed OE hardware. more than 3/4”. IMPORTANT!: 2009 models will 11. Measure the distance between the up- reuse the factory lower shock mounts. per A-arm and the metal bump stop. The distance should be no less than 3/4”. OE Lower Shock Mount OR 91-5159 Lower Shock Mount OE Rubber Bump Stop Lower Control 13. Repeat steps 5 through 12 and the Arm shock box on the Passenger Side of the vehicle. Upper A-Arm 14. Install the front tires/wheels and lower the vehicle onto the ground. 15. Check ride height of the vehicle by Measuring the distance between the OE Metal tires and fenders making sure both Bump Stop sides of the truck are even. Adjust as needed. 16. Torque all bolts to factory specifica- 5 tions. Re-torque all bolts after 500 miles. TM107 Revised 7.22.13 Engine Compartment Troubleshooting 1.Connect both battery cables. Connect positive 1. Once the vehicle has been lifted, some vehicle cable first, then negative cable. vibration may become more apparent to the Miscellaneous driver.
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