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1) FRONT
LIFT: Place the truck on a flat surface.
Engage the emergency brake. Take the hydraulic jack and wheel
it underneath the frame behind the front tire. In this picture,
youíll notice we used 2 pieces of wood on top of the hydraulic
jack. These pieces of wood are used to raise the vehicle up further
to accommodate the new lift (our hydraulic jack doesnít go high
enough). Jack the truck up high enough to accommodate enough
room to put the wheels back on. Leave approx. 3-4" space between
the bottom of the tire and the ground. Place the tallest/biggest
jack stand underneath the frame as seen in the picture. Slowly
lower the hydraulic jack and let the truck rest on the jack stand.
Once the frame is securely resting on the jack stand, remove the
hydraulic jack. Do the same thing for the other side of
the vehicle. Now, the front end of the vehicle (both sides) is
resting on the jack stands, remove both wheels from the vehicle
(21mm socket)
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2)
Disconnect the Sway Bar. Only one side is needed, however,
for more flexibility, you can disconnect both sides. Youíll
need a 6mm hexhead/allen wrench to hold the stud and a 17mm open-end
wrench to remove the nut as seen below.
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3)
Locate
the 3 bolts on top of the coil assembly (as seen below). Loosen
these bolts but do not remove them. You will need these nuts to
hold the assembly in place while you are removing the lower strut
bolt. DO NOT TOUCH THE CENTER NUT!!
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4)
Once you have loosened
the upper 3 bolts, focus your attention on the lower portion of
the strut. This is where the strut is mounted on the A-arm.
Using a 19mm socket and a 19mm open-end wrench, loosen and remove
the bolt holding the strut in place.
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5)
After removing the bolt at the bottom, hold the
entire coil/strut assembly firmly while removing the top 3 nuts.
Then, carefully lower the assembly out of the vehicle. Make sure
you LABEL each coil assembly accordingly to make sure the coils
go back in the same side they came out of. As seen below,
the entire coil/strut assembly ready to be compressed!
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6)
Refer to your Cornbred Lift Spacer instructions
for the installation of the spacers in your coil assembly. I would
recommend taking your coil/strut assembly to the nearest garage
(or friend with a garage) that has a WALL MOUNTED spring compressor.
Compressing the coils can be a royal pain and can be extremely
unsafe and harmful if not done correctly. When taking the assembly
to a garage, make sure the holes (2nd generation spacer) or the
studs (1st generation spacer) are properly aligned with the strut
mount as seen in your instructions or HERE.
Below, you can see the final coil/strut assembly with the Rancho
RS5000 struts and 2.5" 2nd generation lift spacer.
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7)
Carefully lift the new coil/strut assembly and maneuver them
in place. Make sure you are putting the same coils on the same
side as they came out of. Install the new bolts only slightly
(2nd generation). This will give you more maneuverability when
installing the lower strut bolt.
8) Install
the lower strut bolt. You may need some help from some friends.
One person to push down on the lower a-arm, while another person
lines up the holes and installs the bolt.
9)
Tighten the lower
strut bolt and the 3 bolts at the top.
10)
Put your sway bar back on and tighten.
11)
Install your wheels & tires.
12)
Using the Hydraulic Jack, jack the truck up enough to lift the
frame off the jack stands. Remove the jack stands and
lower the vehicle. The front is done!!!
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1) REAR
LIFT: Put
the truck in gear, or in Park. Take a wheel chock (big block of
wood) and place in front of one of the front wheels to prevent
the truck from rolling in case it jumps out of gear. Disengage
the emergency brake.
2) Place
the hydraulic jack underneath the rear pumpkin and jack up the
truck as high as you can. Place a jack stand underneath the frame
similar to what you did earlier. Placing the jack stand under
the frame in front of rear wheels near the leaf spring eye (both
sides).
3)
Slowly lower the hydraulic jack until the vehicle is sitting on
the jack stands
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4)
Remove rear wheels. Remove Rear Shocks.
5)
Place another set of jack stands underneath the axle on both sides
of the pumpkin for now (precautionary safety feature). Leave
the hydraulic jack underneath the pumpkin.
NOTE:
We found it easier
to work on the passenger side first while leaving the driver side
intact. The drivers side of the axle holds the brake line - it
is critical to 'watch' the brake line during this installation.
It is possible to over stretch the brake line if you are not paying
attention.
Passenger Side:
6)
Disconnect the emergency brake cable from the drum. This
is done by simply removing the pin and pulling the bracket off.
7) Using
a 19mm socket, loosen and remove the nuts holding the U-bolts
in place. Remove U-bolts, bottome plate, & bump stop.
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8)
Slowly lower the rear axle. The leaf springs will separate from
the axle. Lower the axle enough to give about 2-3 inches
clearance between the perch and the springs. **It is important
to work on one side at a time. This ensures the pumpkin stays
in position (doesn't pitch up or down) and helps prevent the brake
lines from over-stretching**
9) Using a small set
of C-clamps or a pair of vice grips, clamp on the leaf springs
(not the overload) at the outer edges temporarily to ensure they
do not separate when the pin is removed.
10) Remove
the centering pin (this picture was taken from the drivers side).
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11)
Remove the overload leaf from the leaf pak.
12) Install
the Add-a-leaf using a new (longer) centering pin that should
be supplied with the kit. Make sure the over-load leaf and the
Add-A-Leaf are in the proper orientation before placing the
centering pin in place.
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13)
Use 2 -C clamps on each side of the centering pin to clamp down
on all the leafs including the Add-a-leaf and overload leaf.
Carefully crank down on the C-clamps. This will help bring the
leafs together and help you get the centering pin in place.
14)
Place the nut on the centering pin at the top and tighten it
down slightly - closing all the leafs together. Remove
your C-clamps.
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15)
After fully tightening the centering pin & nut, check to
make sure your bump stop fits over top the centering pin.
In some kits, the centering pin is too long and may require
you to cut off the excessive length.
16) Now, you'll need
to align the centering pin head with the hole in the leaf spring
perch on the axle. This may take some maneuvering and
may require you to raise or lower the axle.
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Note:
Make sure your leafs are properly
aligned in the centering hole.
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17)
Install your bump stop, U-bolts, and bottom plate.
Make sure your bottom plate is in the proper orientation for the
shock mount. Tighten everything down. Install the Emergency
brake cable.
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Driver Side:
18)
Remove the emergency brake cable from the drum.
19) Installation
of the drivers side will be similar to the passenger side, however,
because the brake line is stretched, we took a different approach.
Remove the U-bolts, bottom plate, and bump stop. Instead
of lowering the axle further like we did for the passenger side,
we decided to remove the front eye bolt of the leaf pak. This
will prevent further stretching of the brake line. Using
a 19mm socket & wrench, we removed the front leaf eye bolt
(end without the shackle). This allows the entire leaf pack
to pivot, giving us more room to work.
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20)
Similar to what you did on the other side (Step # 9) - clamp
your leafs in place (not overload leaf), and remove the centering
pin (Step # 10). Install the new Add-a-leaf, overload leaf and
centering pin similar to the passenger side using C-clamps (Steps
# 11, 12,13). This may take some maneuvering. Have some friends
help you.
21) Once
again, install the centering pin nut and tighten down to pull
the leafs together (Step # 14).
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22) Once
again, check to see the bump stop fits - you may need to cut the
centering pin (Step # 15).
23) Align
the centering pin in the hole on the spring perch (Step # 16).
24) Ensure
the leaf centering pin & nut are tight and the centering pin
is in the hole on the leaf spring perch on the axle. Install
your bump stop, U-bolts, and bottom plate. Tighten.
25) Now
is the time to Re-install the drivers side leaf pak
back into the frame mount. This will take some work.
We used a crow bar to flex the shackle back and forth to position
it in place while someone else installed the bolt through the
holes.
26) Install
emergency brake cable.
27) Install
rear shocks (as seen to the right).
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Other: If
you have a Brake Proportioning Valve relocation bracket, now
is a good time to install it while there's plenty of room under
the truck. Follow the instructions on the BPV bracket
you have purchased.
28) Remove
the jack stands from under the axle. Install your wheels.
Raise the vehicle enough to get the frame off the jack stands
- remove jack stands and slowly lower vehicle.
You're done!!!
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