ford f-150 4wd 6” suspension lift kit 2004– 2008 kit# tm407n

400 W. Artesia Blvd.
Fax: (310) 747-3912
Compton, CA 90220
Ph: (877) 695-7812
www.trailmastersuspension.com
FORD F-150 4WD 6” SUSPENSION LIFT KIT
2004– 2008
KIT# TM407N
WARNING
WARNING
Installation of a Trail Master suspension lift kit will
change the vehicle’s center of gravity and handling characteristics both on- and off-road. You must drive the vehicle safely! Extreme care must be taken to prevent vehicle rollover or loss of control, which could result in serious injury or death. Avoid sudden sharp turns or abrupt
maneuvers and always make sure all vehicle occupants
have their seat belts fastened.
Many states and municipalities have laws restricting
bumper heights and vehicle lifts. Consult state and local
laws to determine if the changes you intend to make to
the vehicle comply with the law.
WARNING
Before you install this kit, read and understand all instructions, warnings, cautions, and notes in this instruction sheet and in the vehicle owner’s manual.
CAUTION
Proper installation of this kit requires knowledge of the
factory recommended procedures for removal and installation of original equipment components. We recommend
that the factory shop manual and any special tools
needed to service your vehicle be on hand during the
installation. Installation of this kit without proper knowledge of the factory recommended procedures may affect
the performance of these components and the safety of
the vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components
install this kit.
WARNING
This kit should only be installed on a vehicle that is in
good working condition. Before you install the kit, thoroughly 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
use of your vehicle with this kit installed may increase
the stress applied to the factory components. Failure to
observe this warning may result in serious personal injury and/or severe damage to your vehicle.
WARNING
The installation of larger tires may reduce the effectiveness of the braking system.
WARNING
Always wear eye protection when operating power tools.
WARNING
Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.
WARNING
DO NOT combine suspension, body, or other lift devices.
Use of vehicle with combined lifts may result in unsafe
and/or unexpected handling characteristics.
NOTE
Lift height may vary depending on vehicle configuration,
engine size, additional accessories, the factory suspension package, and vehicle’s condition.
NOTE
Trail Master recommends using thread locking compound on the threads of all kit nuts and bolts unless
specified otherwise in these instructions.
TM407N
Revised
6.14.13
2
TM407N
Revised
6.14.13
Ride Height
Before Starting Installation
6. Measure ride height with the vehicle supporting its
own weight on level ground. To settle the suspension,
the vehicle should be driven forward at least 10 feet
immediately prior to taking these measurements. Ride
height is the measurement from the center of the axle
straight up (vertical) to the fender lip. Record this
measurement for all four wheels.
NOTE
Kit parts are prefaced by the word kit and appear in
bold print.
1. Carefully read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by
checking the parts list at the end of this document.
Wheel & Tire Requirements
3. Only install this kit on the vehicle for which it is
specified. If anytime during the installation you encounter something different from what is outlined in
the instructions, call technical support at (877) 6957812.
The factory wheel and tire combination will not fit
once this kit is installed. The following are specifications for choosing a proper wheel and tire combination:
Minimum wheel diameter = 17” x 8”
Maximum wheel backspacing = 5”
Maximum tire diameter = 315/70R17
4. Special tools needed:
a. Torsion bar tool
b. Welder or access to a professional welding
shop.
Torque Specifications
c. Die grinder or similar tool capable of cutting
metal.
d. Transmission jack
See factory service manual for torque values when re-using
OE fasteners.
e. Rust resistant metal paint
Bolt Size
5. Park vehicle on a clean, dry, flat, level surface and
block tires so vehicle cannot roll in either direction.
NOTE
Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the factory service manual. When re-assembling the vehicle it
is recommended by the vehicle manufacturer that certain fasteners are replaced in order to maintain proper
retention characteristics. This system may not include
all replacement hardware as recommended by the factory service manual. Additional replacement hardware
should be obtained prior to installation of this system
to meet the requirements of the factory service manual.
3
Grade 5 (ft.-lbs.)
Grade 8 (ft.-lbs.)
1/4”-20
10
10
1/4”-28
10
12.5
5/16”-18
17
22.5
5/16”-24
20
25
3/8”-16
30
40
3/8”-24
35
45
7/16”-14
50
65
7/16”-20
55
70
1/2”-13
75
100
1/2”-20
80
115
9/16”-12
105
135
9/16”-18
115
150
5/8”-11
150
195
5/8”-18
160
210
3/4”-16
175
225
TM407N
Revised
6.14.13
See factory service manual for torque values
when re-using OE fasteners.
3. Remove lug nuts and front wheels from
vehicle.
Fasteners
4.Remove Sway Bar from vehicle.
a. On both sides of vehicle, remove Nut at
bottom of lower control arm connecting link to
lower control arm.
Adhere to recommendations when replacement fasteners, retainers and keepers are
called out in the factory service manual.
When re-assembling the vehicle it is recommended by the vehicle manufacturer that certain fasteners are replaced in order to maintain proper retention characteristics. This system may not include all replacement hardware as recommended by the factory service
manual. Additional replacement hardware
should be obtained prior to installation of this
system to meet the requirements of the factory service manual.
Engine Compartment
1.Disconnect both battery cables. Disconnect
negative cable first, then positive cable.
Lower Nut on bottom
side of Lower Control
Arm
b. Unbolt Sway Bar Clamps at Frame rail on
both sides of vehicle and remove Sway Bar
from vehicle.
Prepare to Install Front
Suspension
Front Suspension
5. Remove spindle from vehicle.
1.Loosen, but do not remove, lug nuts on
each front wheel.
a. Disconnect vacuum line attached to 4WD
vacuum assembly.
2.If working without a shop hoist, use a hydraulic floor jack to slowly lift front axle until
front tires are 3-5” off ground. Position jack
stands under frame behind lower control arm
perches. Lower vehicle onto jack stands
while maintaining hydraulic jack pressure underneath front axle.
b. Note the routing of the brake line, make
sketch if needed for routing of new brake line
later during installation.
c. Unbolt brake caliper and remove from spindle. Zip-Tie out of the way.
WARNING
Do not allow caliper to hang by brake line. Damage
to brake line and/or caliper could occur. Personal
injury could occur if brake caliper or line is damaged.
WARNING
Use extreme caution when lifting vehicle from
ground. To prevent serious personal injury, properly position the lifting device.
4
TM407N
Revised
6.14.13
g. Loosen nut securing tie rod end to spindle.
Use tie rod end puller to dislodge tie-rod end
from spindle and remove.
Sway Bar
Clamp
Tie Rod
End
d. Remove brake rotor from spindle.
e. Remove dust cap on center of spindle and
remove axle nut.
h. Loosen but do not remove nut securing upper ball joint to spindle. Use ball joint puller to
dislodge upper ball joint from spindle.
Axle nut
Upper
Ball Joint
f. Unbolt ABS sensor and tie up out of the
way.
i. Loosen but do not remove nut securing
lower ball joint to spindle. Use ball joint puller
to dislodge lower ball joint from spindle.
ABS Sensor
Lower
Ball Joint
5
TM407N
Revised
6.14.13
j. While holding spindle, remove nuts on upper and lower ball joints.
c. Remove large bolt securing lower end of
shock to lower control arm.
k. Slide axle out of spindle and lift spindle off
of ball joints and set aside
d. Slowly lower the lower control arm making
sure to grab the shock assembly to keep it
from falling.
l. Repeat previous steps on opposite side of
vehicle.
e. Repeat previous steps on opposite side of
vehicle.
6. Unbolt front Axle Half Shaft from differential on both sides of vehicle and remove.
8.Remove factory skid plate if equipped.
a. Remove 4 mounting bolts and remove skid
plate.
Half Shaft
Bolts
Factory
Skid plate
7.Remove front coil/shock assembly.
a. Support lower control arm with jack.
9.Remove both lower control arms.
b. Remove three nuts securing upper studs to
upper shock mount pocket.
a. Remove pivot bolts securing lower control
arm to frame and remove lower control arm
from both sides of vehicle.
Upper
Nuts
Pivot
Bolts
Lower
Bolt
6
TM407N
Revised
6.14.13
10. Remove front drive shaft from vehicle.
12. Remove differential.
a. Unbolt driveshaft from front axle pinion.
a. Support differential and remove three bolts
securing it to the vehicle.
Unbolt
Drive
Shaft
NOTE
There are two bolts securing the driver’s side differential and one bolt on passenger side.
b. Lower differential and remove from vehicle.
13. Cut driver side of rear crossmember tab.
a. Mark vertical line on front face of the driver
side rear crossmember tab 2-3/4” from the
outside edge.
b. Unbolt driveshaft from front side of transfer
case.
Mark line to
cut as
shown.
Driveshaft un-bolted
from Front side of
Transfer case
About 1/2” up from
bottom mark notch to
clearance for fin on
differential as shown.
b. Mark vertical line on rear face of the same
crossmember tab 3-3/4” from outside edge
and then across the top connecting the two
lines.
11. Unbolt and remove factory rear crossmember.
Line marked 3-3/4”
from outside edge
and connected
across top to previous marked line on
other side.
Remove
Crossmember
7
TM407N
Revised
6.14.13
c. Cut frame using saw-z-all, cut off wheel,
plasma, or other appropriate tool.
(90-8009) and kit rack & pinion bracket (901964).
Kit 5/8” x 5
1/2” Bolt
Kit Rack &
pinion
Spacers
90-2726 &
90-8009
Rack &
Pinion
Rack &
Pinion
Install Front Suspension
1. Relocate rack & pinion assembly.
a. Remove bolts securing rack & pinion assembly to vehicle and remove factory mounting brackets. Keep horizontal bolts for re-use.
Kit Rack
& pinion
bracket
90-1964
Rack & pinion
assembly
NOTE
NOTE: The goal of this kit is to get as close to a
1” rack drop as possible without steering shaft
hitting the frame and band clamps.
Horizontal
& vertical
mounting
bolts
c. After installing the kit rack & pinion spacers to achieve a 1” drop, inspect for steering
shaft and steering U-joint clearance at the
frame.
d. If no contact is made and the steering shaft
has no interference, proceed with step h.
e. If the steering shaft and/or steering U-joint
has/have interference at the frame, reconfigure kit rack & pinion spacers to create
¾” drop
b. Secure the steering rack using the kit 5/8”
x 5 1/2” bolt, 1/2” kit rack & pinion spacers
(90-2726), (2) 1/4” kit rack & pinion spacers
8
TM407N
Revised
6.14.13
f. Inspect again for steering shaft and steering U-joint clearance at the frame. If no contact is made and the steering shaft has no
interference, proceed with step h.
3.Install kit driver side differential bracket.
a. Slide kit driver side differential bracket
into factory driver side differential mount.
Kit Drive side
differential
bracket
82-TM241007
g. If the steering shaft and/or steering U-joint
still has/have interference at the frame, reconfigure kit rack & pinion spacers to create
½” drop
h. Check for steering shaft clearance to frame
and band clamps, the dust boots and the
clamps may have to be repositioned or removed. Torque the kit 5/8” bolt to 150 ft./lbs.
and the OE bolts to manufacturers specifications.
b. Secure using OE bolt, do not tighten at this
time.
i. Repeat assembly on opposite side of vehicle.
4. Mount differential.
2. Install kit passenger side differential
bracket.
a. Position differential into kit brackets previously installed.
a. Slide kit passenger side differential
bracket into factory passenger side differential mount so that large tab with two holes on
bracket faces towards rear of vehicle.
Kit Passenger
side differential bracket
Kit Passenger
side differential
bracket
82-TM241008
differential
Kit Driver side
differential
bracket
b. Secure using OE bolt, do not tighten at this
time.
differential
9
TM407N
Revised
6.14.13
d. Drill 1/2” hole where the center mark was
placed.
b. Secure using kit 7/16” x 3-1/2” bolts &
hardware. Do not tighten at this time.
5. Drill hole for third differential mount in
frame.
1/2” Drilled
Hole
a. Notice on driver side of kit rear crossmember there is a 1/2” hole located approximately 1-3/4” to the side and a little above the
driver side mounting hole.
1/2”
Hole
e. Position differential in kit rear crossmember differential mounting tabs and install
7/16” x 4” bolt through hole previously
drilled, crossmember, and differential. Do not
tighten at this time.
Kit Rear Crossmember
82-TM241004
b. Take detailed dimensions of the 1/2” hole’s
location in relation to the mounting hole.
NOTE
Check hole alignment for hole drilled in frame and hole in
crossmember. Ream to allow for bolt if necessary.
c. Install kit rear crossmember using OE
lower pivot bolts into frame and center as
best as possible in alignment slots. Transfer
measurements taken in previous step to the
Ford frame to locate a center mark to drill to
1/2”.
NOTE
To aid in installing kit 7/16” x 4” bolt through drilled
hole and crossmember previously installed differential
bolts may need removed to allow easier movemeant to
align holes.
Transfer measurements
for hole to be drilled.
OE Bolt
Kit 7/16” Bolt
through
10
TM407N
Revised
6.14.13
f. Check clearance between frame and differential inside pocket and around area of
frame cut. Clearance additional material if
needed to prevent rubbing.
Kit Front Crossmember
82-TM241003
Check Clearance all
around this area
7. Install four kit 7/16” x 1 1/2” bolts &
hardware on passenger side of rear crossmember above mounting tabs for brace just
installed. Holes are on both front and back of
frame/crossmember. The holes on the rear
of the crossmember will match with the passenger differential bracket. Do not torque at
this time.
6. Install kit front crossmember into OE
lower control arm pivot pockets and secure
using lower control arm pivot hardware. Do
not tighten at this time.
Rearward facing
bolts
NOTE
Minor trimming may be needed on OE rack and pinion
mount to fit crossmember into place.
Driver Side
Rack Mount
Trimming may be
necessary here
11
TM407N
Revised
6.14.13
9.Install kit sway bar drop brackets.
a. Install kit sway bar drop bracket to frame
with flat surface facing towards outside of
vehicle. Secure the bracket to frame using
OE hardware removed.
OE Hardware
Front Facing
Bolts
Kit Differential
Bracket
82-TM241008
8. Install lower control arms on both sides of
vehicle.
Kit Sway Bar
Drop Bracket
82-TM241006
a. Slide lower control arm into pockets on kit
front & rear crossmembers.
b. Repeat on opposite side of vehicle.
b. Mount lower control arm using kit 18mm
“D” bolts, cam washers, flat washers, and
18mm nuts.
c. Secure sway bar to kit sway bar drop
brackets using 7/16” x 1-1/4” bolts & hardware.
Kit Sway Bar
Drop Bracket
Lower Control
Arm
Sway Bar
Kit 18mm D Bolts
& Hardware
10. Assemble struts.
WARNING
Compressed coil springs can expand violently causing
serious personal injury. Before removing the coil
springs, lower the axle housing as far as possible to allow the coil springs to expand. Use caution when using
coil spring compressors.
12
TM407N
Revised
6.14.13
a. Place strut/coil assembly in spring compressor and compress spring enough to relieve tension from strut.
OE Strut
Spring
Compressor
Coil & Strut
Assembly
b. With tension on strut relieved remove nut
from top of strut.
Remove Nut
d. Note direction of bump stop and coil seat
and slide rubber shock bump stop and coil
seat off of OE strut to be reused on new kit
strut.
e. Install kit bushings & sleeve into new
strut using a lithium grease if not preinstalled.
c. Carefully slide strut out from center of coil.
13
TM407N
Revised
6.14.13
Upper mounting studs
& nuts Lower mount
using OE bolt
Kit Bushings
Kit Sleeve
Kit Strut
75700
Lower mount
using OE bolt
f. Install OE coil seat, kit striker pad and OE
bump stop onto new strut in same fashion as
originally removed from OE strut.
Kit Striker pad
Kit Strut
75700
12. kit knuckle on vehicle.
a. Insert upper and lower ball joints through
kit knuckle and secure using OE ball joint
nuts. Do not tighten at this time.
OE Bump stop
OE Spring Pad
Upper
Ball joint
g. Using coil compressor compress coil and
slide strut into position until threads are exposed through top. Secure with nut.
Kit
Knuckle
241001
Drvr and
241002
Pass
11. Install shocks
a. Install three upper studs into factory
pocket and secure using OE nuts removed
during disassembly.
Lower
Ball joint
b. Pivot lower control arm up and in line with
lower strut mount, secure with OE bolt removed.
14
TM407N
Revised
6.14.13
c. Install spindle assembly into new kit
knuckle in same fashion removed from OE
knuckle.
13. Assemble kit spindles.
Kit Knuckle
OE Spindle
Assembly
OE Bolts
for spindle
a. Remove three small bolts securing vacuum activated 4WD unit and the assembly
itself.
d. Install vacuum activated 4WD unit and secure using 3 OEM bolts removed from original. Make sure vacuum lines face upwards.
Vacuum
Unit
b. Remove four bolts securing spindle assembly to knuckle and separate assembly
from knuckle.
14. Install front axle half shafts.
a. Position axle between spindle and differential.
b. Insert axle end into spindle and reinstall
OE axle nut removed during disassembly. Do
not tighten at this time.
15
TM407N
Revised
6.14.13
Axle Nut
Kit Bolts
c. Position kit axle spacer on half shaft. Notice there’s a male and female end to index
the spacer, install it appropriately.
Differential
Axle Half
Shaft
e. Rotate tie rod end so that threaded end is
facing down and install tie rod into knuckle
steering arm. Use OE nut to secure. Do not
tighten at this time.
Kit Axle Spacer
82-TM241015
Tie Rod
Axle Half
Shaft
Kit Knuckle
Steering Arm
d. Bolt axle half shaft & kit axle spacer to
differential using kit 12mm x 45mm Gr10.9
bolts & 12mm flat washers supplied.
16
TM407N
Revised
6.14.13
15. Install ABS sensor into kit spindle.
18. Install brake lines.
a. Pull ABS line down to fit into spindle assembly. The line will possibly need to be unclipped from above and rerouted to gain
enough slack to fit.
a. Install brake caliper to kit spindle using
OE hardware.
Brake
Caliper
OE Bolt
Caliper
Bolt
ABS Line
b. Remove OE brake line bracket from
frame. Carefully remount the brackets with
the supplied Kit front brake line drops in
between bracket and frame. Use OE hardware to fasten the shorter end of the bracket
to the frame. Position the drops, best for
your application. Use the Kit 5/16” x 1”
bolts, 5/16” washer and 5/16” nut to fasten
OE bracket to Kit front brake line drops .
16. Unclip vacuum line from above to gain
enough slack and plug into 4WD vacuum assembly.
17. Attach sway bar end links to lower control arms using OE hardware.
Sway Bar
End Link
19. Install kit drive shaft.
a. Install CV end of drive shaft (two U-Joints
next to each other) to transfer case end using OE bolts.
b. Install opposite end of drive shaft to front
differential using OE bolts.
Lower
Control
arm
20.Torque entire front suspension system to
specifications
17
TM407N
Revised
6.14.13
Install Rear Suspension
1.Loosen, but do not remove, lug nuts on
each two rear wheels.
2.Using a hydraulic floor jack under rear differential, slowly lift rear axle until rear tires
are 3-5” off ground. Position jack stands under frame just forward of lower control arm
perches. Lower vehicle onto jack stands
while maintaining hydraulic jack pressure underneath rear axle.
Shock
3.Remove lug nuts and rear wheels.
Lower
Shock
Mount
b. Remove upper bolt and nut on shock from
frame.
4.Remove four bolts and driveshaft from rear
differential. Tie driveshaft up beneath bed or
crossmember to prevent driveshaft from falling.
Upper
Shock
Bolt
Driveshaft
Rear
Differential
Shock
c. Remove shocks from frame and axle.
Bolts
d. Install kit rear shocks to the upper and
lower mounts using the previously removed
OE hardware.
e. Repeat on opposite side of vehicle.
5.Shock absorbers
6. Install brake line spacer bracket.
a. Remove lower bolt and nut on shock from
axle.
a. Remove vent line connected to brake line
block in middle of Driver side rear axle tube
b. Remove vent line fitting from brake line
block.
18
TM407N
Revised
6.14.13
Brake
Line
Block
7. Install kit parking brake cable bracket on
rear driver side of vehicle.
a. Disconnect parking brake cable for driver
side rear wheel at junction located just in
front of driver side front leaf spring mount.
Leaf
spring
Pivot Bolt
c. Carefully bend brake line out of the way
and install kit brake line bracket. Secure
using vent line fitting removed.
Driver Side Parking Brake
Cable Disconnected
Kit Brake
Line
Bracket
82-TM24012
Vent
Line
Fitting
d. Secure brake line block previously unbolted and moved out of the way to the remaining hole in the kit brake line bracket
using 3/8” bolt & hardware provided.
b. Push Parking Brake Cable previously disconnected out of bracket bolted to leaf spring
perch.
Parking Brake
Bracket
Parking Brake Line
Removed from bracket
OE Brake
Line
Block
Kit 3/8”
bolt &
hardware
c. 2004-2005 models: Remove Nut from
front leaf spring pivot bolt next to brake line
previously disconnected and remove OE
bracket.
d. 2006 models: Remove nut from front leaf
spring pivot bolt next to brake line previously
19 disconnected.
TM407N
Revised
6.14.13
e. Drill out small hole just in front of spring
pivot bolt to 5/16”.
2004-2005 Models
Drill hole
to 5/16”
f. Install kit parking brake cable bracket
over leaf spring pivot bolt and secure with
pivot nut and kit 5/16” x 1” bolt & hardware.
Kit 5/16” x 1” Bolt &
hardware
Leaf spring
pivot bolt
2006 Models
8.Install rear lift blocks.
Kit Parking
Brake Bracket
82-TM241011
a. Making sure differential is supported by
jack loosen and remove U-Bolts on one side
of vehicle.
b. Slowly lower axle about 5”. Remove OE
lift block.
g. Install driver side parking brake cable into
kit parking brake bracket the same way it
was removed from OE and reconnect it.
c. Install kit rear lift block.
20
TM407N
Revised
6.14.13
Kit Rear
U-Bolt
13-90390
Kit Rear
Lift Block
241013
WARNING
Before driving the vehicle, pump the brakes several
times. If the pedal is soft or mushy, refer to the vehicle
service manual and verify the brake bleeding procedures.
Failure to do so may cause the brakes to malfunction,
resulting in property damage or serious personal injury.
OE Spring plate
d. Install kit U-Bolts & hardware over leaf
pack and around differential using OE spring
plate Torque to 115 ft. lbs.
e. Repeat on opposite side
9. From F4405BAG9: Install kit spacer, rear
driveshaft and rear driveshaft onto rear differential with four kit bolts, Gr. 10.9 (12mm1.75 x 45mm) and four kit washers, flat
SAE (12mm). TORQUE to specification.
Driveshaft
Kit Spacer Rear
Driveshaft
241016
Kit Bolts, Gr.
10.9 (12-1. 75 x
45mm), Kit
Washers, Flat
SAE (12mm)
21
TM407N
Revised
6.14.13
Engine Compartment
Troubleshooting
1.Connect both battery cables. Connect positive
cable first, then negative cable.
Miscellaneous
1.Apply kit label (warning) onto dashboard in plain
sight of all vehicle occupants.
2.Adjust headlights.
3.Check all fasteners to ensure they are tight.
4.Ensure all wires, hoses, cables, etc. are properly connected and there is ample slack.
1. Once the vehicle has been lifted, some vehicle
vibration may become more apparent to the
driver. The reason for the vibration may be due to
the angle at which the driveline operates. A suspension lift increases the operating angle of the
driveline and normal vehicle vibration is amplified.
Some vibration characteristics are as follows:
a. Acceleration vibration: vibration felt during
acceleration of the vehicle and caused by the
rear axle pinion angle being too high.
WARNING
If the engine cooling system is hot, the coolant will be
HOT and UNDER PRESSURE. To prevent serious personal injury, wait until the cooling system is completely
cool before removing the cap from the radiator.
b. Deceleration vibration: vibration felt during
deceleration of the vehicle and caused by the
rear axle pinion angle being too low.
5.Start engine and top off cooling system. Purge
air from cooling system according to manufacturer’s instructions. Install radiator cap.
6.Align vehicle
c. General vibration: vibration caused by rear pinion angle in relation to the transfer case output
shaft.
Dynamic Vehicle Check
WARNING
Re-torque all fasteners after 500 miles and after
off road use. All suspension lift components
should be visually inspected and fasteners retorqued during routine vehicle servicing.
1. Check steering and suspension in all positions
to ensure that there is no bind and adequate
clearance between all moving, fixed, and
heated members. Check operation of clutch,
brake system, and parking brake. Check operation of transmission and transfer case. Ensure there is full engagement in all gears and
4WD ranges. Check battery connections and
electrical component operations. Test-drive
vehicle.
Caution:
Larger wheel and tire combinations increase
stress and wear on steering and suspension
components, which leads to increased maintenance and higher risk for component failure. Larger wheel and tire combinations also alter speedometer calibration, braking effectiveness, center
of gravity, and handling characteristics. Consult
an experienced local off road shop to find what
wheel and tire combinations work best with your
vehicle.
WARNING
Retorque all fasteners after 500 miles and after off road
use. All suspension lift components should be visually
inspected and fasteners retorqued during routine vehicle
servicing.
22
TM407N
Revised
6.14.13
NOTE
All warranty information, instruction sheets, and
other documents regarding the installation of this
product must be retained by the vehicle owner.
Information contained in the instructions and on
the warranty card will be required for any warranty claims. The vehicle owner needs to understand the modifications made to the vehicle and
how they affect vehicle handling and performance. Failure to provide the customer with this
information can result in damage to the vehicle
and severe personal injury.
Kit Parts List:
Box TM407N-1
Box 1
82-TM241004
CROSSMEMBER, AFT
1
90-6255
HARDWARE PACK: Bag Kit, Rack & Pinion
Bolt, Gr. 8 (5/8” X 5 1/2”)
Nut, Stover Gr. 8 USS (5/8”)
Washer, Flat Gr .8 SAE (5/8”)
1
2
4
8
90-1964
BRACKET, RACK & PINION
2
F4405BAG1
HARDWARE PACK: Bag Kit, Crossmember
D-Bolt (18mm)
D-Washers
Nut, Stover (18mm-2.5)
Washer, Flat (18mm)
Bolt, Gr. 5 (7/16”-14 x 1 1/2”)
Nut, Stover (7/16”-14)
Washer, Flat SAE (7/16”)
Loctite
1
4
8
4
12
4
4
8
2
F4405BAG3
HARDWARE PACK: Bag Kit Sway Bar Mount
Bolt, Gr. 5 (7/16”-14 x 1 1/4”)
Nut, Stover (7/16”-14)
Washer, Flat SAE (7/16”)
1
4
4
8
F4405BAG4
HARDWARE PACK: Bag Kit, Axle Spacer
Bolt, Gr. 10.9 (12mm-1.75 x 45mm)
Washer, Flat SAE (12mm
1
12
12
241016
SPACER, REAR DRIVESHAFT
1
23
TM407N
Revised
6.14.13
82-TM201012
BRACE, CROSS MEMBER
1
82-TM241018
BRACE, AFT
2
90-6299
HARDWARE PACK: Front Brake Lines
Bolt, Gr. 8 (5/16” x 1”)
Nut, Stover (5/16”)
Washer, Flat (5/16”)
1
2
2
4
90-6393
90-3202
HARDWARE PACK: Front Brake Line Drop
FRONT BRAKE LINE DROP
1
2
Box TM407N-2
Box 2
90-6715
90-2726
90-8009
HARDWARE PACK
Spacer, 1/2” Rack & Pinion
Spacer, 1/4” Rack & Pinion
F4405BAG2
HARDWARE PACK: Bag Kit, Diff Mounts
Bolt, Gr. 8 (7/16”-14 x 3 1/2”)
Bolt, Gr. 8 (7/16”-14 x 4”)
Nut, Stover (7/16”-14)
Washer, Flat SAE (7/16”)
F4405BAG6
HARDWARE PACK: Bag Kit, X-member brace
Bolt, Gr. 8 (3/8”-16 x 2 1/4”)
Bolt, Gr. 8 (3/8”-16 x 1 1/2”)
Nut, Stover (3/8”-16)
Washer, Flat SAE (3/8”)
1
2
4-(not used)
4-(2 not used)
10-(6 not used)
F4405BAG8
HARDWARE PACK: Bag Kit, Brake Brackets
Bolt, Gr. 5 (5/16”-16 x 1” )
Bolt, Gr. 5 (3/8”-16 x 1 1/2”)
Nut, Stover (5/16”-14)
Nut, Stover (3/8”-16)
Washer, Flat SAE (5/16”)
Washer, Flat SAE (3/8”)
1
1
1
1
1
2
2
F4405BAG9
HARDWARE PACK: Bag Kit, Drive Shaft Spacer 1
Bolt, Gr. 10.9 (12mm-1.75 x 45mm)
4
Washer, Flat SAE (12mm)
4
82-TM241003
CROSSMEMBER, FORWARD
1
82-TM241011
BRACKET, PARKING BRAKE CABLE
1
82-TM241012
BRACKET, BRAKE LINE, REAR
1
24
1
4
4
1
2
1
2
5
TM407N
Revised
6.14.13
Box TM407N-3
Box 3
241001
KNUCKLE, DRIVER SIDE
1
82-TM241006
BRACKET, SWAY BAR
2
Box TM407N-4
Box 4
241002
KNUCKLE, PASSENGER SIDE
1
82-TM241015
SPACER, FRONT AXLE
2
82-TM241007
MOUNT, FRONT DIFFERENTIAL: Driver
1
82-TM241008
MOUNT, FRONT DIFFERENTIAL: Passenger 1
Box TM407N-5
Box 5
13-90390
U-BOLT, 9/16 X 3 3/16 X 1
4
241013
LIFT BLOCK WITH ARM
2
20-65302
U-BOLT HARDWARE PACK, Bag Kit 9/16"-18
1
Box TM407N-6
Box 6
75700
STRUT, FRONT
2
TM75550W
SHOCK, REAR
2
25
TM407N
Revised
6.14.13
Notice to Owner Operator, Dealer and Installer:
Vehicles that have been enhanced for off-road performance often have unique handling characteristics
due to the higher center of gravity and larger tires. This vehicle may handle, react and stop differently than
many passenger cars or unmodified vehicles, both on and off–road. You must drive your vehicle safely!
Extreme care should always be taken to prevent vehicle rollover or loss of control, which can result in serious injury or even death. Always avoid sudden sharp turns or abrupt maneuvers and allow more time and
distance for braking! Trail Master Suspension reminds you to fasten your seat belts at all times and reduce speed! We will gladly answer any questions concerning the design, function, maintenance and correct use of our products.
Please make sure your Dealer/Installer explains and delivers all warning notices, warranty forms
and instruction sheets included with Trail Master Suspension product.
Application listings in this catalog have been carefully fit checked for each model and year denoted. However, Trail Master Suspension reserves the right to update as necessary, without notice, and will not be
held responsible for misprints, changes or variations made by vehicle manufacturers. Please call when in
question regarding new model year, vehicles not listed by specific body or chassis styles or vehicles not
originally distributed in the USA.
Please note that certain mechanical aspects of any suspension lift product may accelerate ordinary wear of original equipment components. Further, installation of certain Trail Master Suspension
products may void the vehicle’s factory warranty as it pertains to certain covered parts; it is the consumer’s responsibility to check with their local dealer for warranty coverage before installation of the lift.
Warranty and Return policy:
Trail Master Suspension warranties its full line of products to be free from defects in workmanship and
materials. Trail Master Suspension’s obligation under this warranty is limited to repair or replacement, at
Trail Master Suspension’s option, of the defective product. Any and all costs of removal, installation,
freight or incidental or consequential damages are expressly excluded from this warranty. Trail Master
Suspension is not responsible for damages and / or warranty of other vehicle parts related or non-related
to the installation of Trail Master Suspension product. A consumer who makes the decision to modify his
vehicle with aftermarket components of any kind will assume all risk and responsibility for potential damages incurred as a result of their chosen modifications. Warranty coverage does not include consumer
opinions regarding ride comfort, fitment and design. Warranty claims can be made directly with Trail Master Suspension or at any factory authorized Trail Master Suspension dealer.
IMPORTANT! To validate the warranty on this purchase please be sure to mail in the warranty card.
Claims not covered under warranty• Parts subject to normal wear; this includes bushings, bump stops, ball joints, tie rod ends and heim joints
• Discontinued products at Trail Master Suspension’s discretion
• Bent or dented product
• Finish after 90 days
• Leaf or coil springs used without proper bump stops
• Products with evident damage caused by abrasion or contact with other items
• Damage caused as a result of not following recommendations or requirements called out in the installation manuals
• Products used in applications other than listed in Trail Master Suspension’s catalog
• Components or accessories used in conjunction with other manufacturer’s systems
• Warranty claims without “Proof of Purchase”
• Trail Master Suspension accepts no responsibility for any altered product, improper installation, lack of
or improper maintenance, or improper use of our products.
E-Mail: info@trailmastersuspension.com
Website: www.trailmastersuspension.com
Ph: (877) 695-7812
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