Automotive Manual PDF

FRONT SUSPENSION INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. With the vehicle on level ground set the emergency brake and block the rear tires. Jack up the front end of the truck and support the frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE! Remove the front tires.
2. Locate the torsion bar adjusting cams and threaded bolts. Measure exposed threads of torsion bar adjusting bolts and record for reinstallation. Mark torsion bars indicating driver and passenger. Using a torsion bar removal tool unload the torsion bars and remove the torsion bar adjusters. Retain the hardware for reinstallation. NOTE- Do not attempt to unload or remove torsion bars without the proper torsion bar tool. Torsion Bars are under extreme spring load.
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PROCEDURE:
1. Remove push type retainers from lower splash shield. Remove plastic splash shield to access to mounting location.
2. Locate and remove bolts that hold the frame brace and bumper brackets to vehicle.
3. Install frame bracket between lower radiator support and frame brace using (3) existing bolts. As shown.
4. Cut plastic splash shield to allow brackets to pass through. See Cutting Instruction sheet for guidelines on cutting. Reinstall plastic splash shield over brackets in this same order removed.
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Read and understand these instructions BEFORE attempting to install this product.
1. Make sure vehicle is parked on a level surface.
2. Set parking brake.
3. Disconnect negative battery terminal.
4. If engine has run within the past two hours let it cool down.
5. The following items will be removed from the vehicle.
(a) The OE inlet tube
(b) The air filter case
(c) Intake air noise resonators (Fig A)
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Removing the stock air inlet system
a) Pry loose the retaining buttons on the lower splash shield.
b) Remove all retaining buttons on the fender liner around the fender well.
c) Carefully pull back the fender liner and splash shield to gain access to the fender well and stock resonator box.
d) Remove the battery from the engine bay.
e) Remove the plastic battery tray.
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Removal
1) Disconnect negative battery cable and ground strap at transaxle. Disconnect positive battery cable. Remove battery and battery base. Remove drain plug, and drain transaxle fluid (remove fill plug to speed draining). Install drain plug with NEW washer, and tighten plug to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article.
2) Disconnect wiring for starter motor, transaxle lock-up control solenoid and shift control solenoid. Remove starter. Disconnect mainshaft and countershaft speed sensor connectors. Remove complete air cleaner case assembly. Disconnect and remove throttle control cable at transaxle bracket.
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STEP 1. Remove the contents from the box and check for any damage. Verify all parts against the parts list.
STEP 2. Read and understand instructions completely before beginning installation.
STEP 3. Determine passenger and driver mount brackets from figure above.
STEP 4. Remove the (16) push type retainers and (2) 6mm bolts from the lower splash shield. Remove plastic splash shield to gain access to mounting locations.
STEP 5. Locate the (4) 14mm holes in the lower radiator support. Attach the mount brackets using the (4) 1/2-13 x 1.00” hex head bolts, (4) 1/2” external-internal tooth lock washer, (4) 1/2” flat washer, (4) 1/2” lock washer, (4) 1/2-14 hex nuts, (2) 5/16-18 x 1.75” hex head bolts, (2) 5/16” lock washer, (2) 5/16” flat washers and (2) 5/16-18 flange lock nuts. Leave loose.
CAUTION: Wheels must be supported to support sub-frame to the unibody to avoid misalignment for re- attachment.
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STEP 1. Remove the contents from the box and check for any damage. Verify all parts against the parts list.
STEP 2. Read and understand instructions completely before beginning installation.
STEP 3. Determine passenger and driver brackets. SEE FIGURE 1.
STEP 4. Remove (16) push type retainers from lower splash shield. Remove plastic splash shield to gain access to mounting locations.
STEP 5. Locate bolts that hold the frame brace and bumper brackets to vehicle. Remove bolts using a 17mm and 14mm socket and ratchet.
STEP 6. Install bracket between lower radiator support and frame brace using (2) 1/2” flat washers on top of bracket’s frame brace slots and replace bolts. Install (1) 3/8-16 x 1.00” hex head bolt, (1) 3/8” lock washer and (2) 3/8” flat washers. Leave loose. SEE FIGURE 1. NOTE: It may necessary to loosen body mount bolt holding the frame brace to gain enough clearance to slide brackets in place.
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FLARE INSTALLATION PROCEDURES
Step 1: Painting (Optional)
(A) Bushwacker only approves installing the flares according to these written instructions with the hardware provided. WARNING: Failure to install according to these instructions will invalidate the warranty. This includes, but is not limited to, using alternative installation methods, hardware, or materials. DO NOT USE: Loctite, SuperGlue, or similar products on the hardware or the flares.
(B) It is recommended that painting be done prior to installation.
(C) Sand (optional) before application of paint.
(D) Clean outer surface with a high-grade degreaser. DO NOT USE LACQUER THINNER OR ENAMEL REDUCER AS A DEGREASER. Wipe outer surface thoroughly with a tack rag prior to painting.
(E) Paint flares using a high quality lacquer, enamel, or polyurethane automotive paint. Application of a primer coat is optional.
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FRONT INSTALLATION
1. Park the vehicle on a clean, level surface and block the rear wheels for safety.
2. Safely raise the front of vehicle and support with jack stands for safety.
3. Remove the wheels.
4. Measure and record the length of the exposed thread on the torsion bar adjusting bolts for later reference.
DRV__________ PASS__________
5. Remove the torsion bar assembly.
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