Automotive Manual PDF

1. Park the vehicle on flat level ground. Set the emergency brake and properly block the tires.
2. Raise the front of the vehicle and support the frame rails using jack stands. Remove the front tires.
3. Remove the bushing and washer from the upper portion of the factory shock. Place the new upper frame bracket over the factory bracket. (See Photo #1). Now reinstall the upper bushing and washer onto the factory shock.
4. Push the bracket up flush against the frame. The outside mounting hole on the top plate will now line up with the factory hole in the upper mount. Drill out the factory hole using a 13/32” drill bit. Install the 3/8 x 1 fine thread bolt with washers and locknut at this location. (See Photo #2).
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STOCK EXHAUST SYSTEM REMOVAL
1. Remove frame cover.
2. Remove right side footpeg assembly held in place by two bolts (Figure 1).
3. Remove exhaust port nuts.
4. Remove bolts securing rear muffler to exhaust system mounting bracket.
5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required).
6. Check condition of stock exhaust gaskets. Replace if damaged or worn.
7. Remove two bolts attaching stock exhaust mounting bracket to frame.
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These shocks are pressurized with nitrogen to 250 psi. Normally there is no reason to change the nitrogen pressure in the shocks. It is not intended as an air shock which can be made stiffer or softer with changes in pressure. The use of standard automotive-type air chucks and gauges will allow the oil in the non-reservoir shocks to escape. Attempts to recharge the shocks should only be performed by trained service persons with the necessary high-pressure nitrogen handling equipment.
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Remove the contents from the box and check for any damage. Verify all parts against the parts list.
Read and understand instructions completely before beginning installation.
Remove 10mm bolts from bumper brace located on back side of front body mount if present. For each side, place Mount Bracket up to the backside of the body mount and secure using existing 10mm bolts removed in step 3. (On trucks without existing bolts, use the 10mm hardware provided in the bolt kit).
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Remove of the interior door panel
Steps:
#1 Use flat head screwdriver to remove the plastic panel along side the window. A 6-mm -socket head screw is now visible to remove.
#2 Use flat head screwdriver to remove speaker grille, (4) 6-mm socket head screw are now visible to remove speaker. You must remove the (4) white nut bosses by pushing from the backside to pop them out.
#3 Use a flat head screwdriver to remove the window control switch panel. Inside the door panel to the left is located 10-mm socket head bolts. Use 10-mm -socket w/ ratchet and 3” long extension to remove.
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1) Remove 4 bolts beside tow hooks to remove factory bumper. Retain bolts and tow hooks for use in step 7. ( see figure 1)
2) Remove fog lights from factory bumper keeping plastic pins and adjusting screw assembly in tact for future installation.
3) Remove casing from factory fog lights and discard. Install fog lights to brackets located on backside of new bumper using hardware removed in step 2.
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Simple step to front bumber replacement:
1) Remove hood release latch from factory assembly on factory bumper. Set aside and retain factory hardware for future installation.
2) Remove 4 bolts beside tow hooks to remove factory bumper. Retain bolts and tow hooks for use in step 7.
3) Remove fog lights from factory bumper retain plastic pins and adjusting screw assembly for future installation.
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1. Before working, please make sure the vehicle power is off (please keep in mind when pulling out the key, only monitor supply would be off but whole vehicle power supply would be off 5 minutes later)
2. Starting with separating of the monitor and the connecter removed in working may causes a error code. Do not start until the work is done.
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