Ford - F 250 - Workshop Manual - 2011 - 2013

TM411N, TM412N, TM413N, TM414N Revised 7.11.13 400 W. Artesia Blvd. Fax: (310) 747-3912 Compton, CA 90220 Ph: (877) 695-7812 www.trailmastersuspension.com FORD SUPER DUTY F-250 4WD GAS SUSPENSION LIFT KIT 2011– 2013 KIT# TM412N FORD SUPER DUTY F-350 4WD GAS SUSPENSION LIFT KIT 2011– 2013 KIT# TM414N FORD SUPER DUTY F-250 4WD DIESEL SUSPENSION LIFT KIT 2011– 2013 KIT# TM411N FORD SUPER DUTY F-350 4WD DIESEL SUSPENSION LIFT KIT 2011– 2013 KIT# TM413N WARNING WARNING Installation of a Trail Master suspension lift kit will change the vehicle’s center of gravity and handling characteristics both onand 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 WARNING The installation of larger tires may reduce the effectiveness of the braking system. 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. WARNING Always wear eye protection when operating power tools. 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 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. 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. 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 1 threads of all kit nuts and bolts unless specified otherwise in these instructions. TM411N, TM412N, TM413N, TM414N Revised 7.11.13 2 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Before Starting Installation Torque Specifications: NOTE Tire & Wheel Information: 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. 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. 4. Park vehicle on a clean, dry, flat, level surface and block tires so vehicle cannot roll in either direction. 5. 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. Due to differences in manufacturing, dimensions and inflated measurements, tire and wheel combinations should be test fit prior to installation. Tire and wheel choice is crucial in assuring proper fit, performance, and the safety of your Trailmaster equipped vehicle. For this application, we recommend a wheel not to exceed 10” in width with a maximum backspacing of 5 3/4” must be used. Additionally, a quality tire of radial design, not exceeding 37” tall X 12.50” wide is also recommended. Violation of these recommendations will not be endorsed as acceptable by Trailmaster Suspension and will void any and all warranties either written or implied. See factory service manual for torque values when reusing OE fasteners. See factory service manual for torque values when re-using OE fasteners. NOTE Bolt Size 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. Wheel & Tire Requirements The factory wheel and tire combination will fit once this kit is installed. 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 3/4”-16 175 225 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Front Installation: IMPORTANT!: THE ENTIRE INSTALLATION PROCESS MUST BE DONE WITH HAND TOOLS TO ENSURE PROPER INSTALLATION. DO NOT USE IMPACT TOOLS. 1. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or asphalt). Block the rear tires and set the emergency brake. 2. Measure and record the distance from the center of each wheel to the top of its fender opening. Record below. 11. Install new pitman arm on sector shaft. Oil the sector shaft threads to ensure a proper torque reading. Install Pitman arm retaining nut and tighten until snug. See Illustration 1. 3. Place the vehicle in neutral. Place your floor LF: RF: LR: RR: 12. Insert the key and unlock the steering wheel. 13. Install the Pitman arm torque tool (96-5002) to the Pitman arm using one of the previously removed OE 14mm track bar bracket outer retaining bolt and nut plate. See Illustration 2. jack under the front axle and raise the vehicle. Place jack stands under the frame rails and lower the frame onto the stands. Remove the jack and place the vehicle back in gear, set the emergency brake, and place blocks both in front and behind the rear wheels. 14. Secure the torque tool (96-5002) to the existing hole in the frame crossmember using the supplied 7/16” X 1 1/4” bolt and hardware. See Illustration 2. NOTE: The steering wheel may need to be turned in order for the hole in the torque tool and the frame crossmember to line up. Once the bolts are tightened the torque tool will align it’s self properly. 4. Remove the track bar bolt from the driver side frame mount. Save this hardware for re-use. 5. Remove the cast track bar mount on driver side of frame. Save the bolts and pal nuts. Hardware will be reused. NOTE: The use of the torque tool is to keep the Pitman arm from moving right or 6. Unbolt the sway bar from the sway bar end links on both sides of the vehicle. Save the hardware for reuse. Illustration 1 7. Mark the orientation of the sway bar and unbolt it from the frame of the vehicle. Save the hardware for reuse. Pitman Arm Assembly Sector Shaft Nut 8. If the vehicle is equipped with a factory steering stabilizer unbolt it and remove it from the vehicle. Cotter Pin 9. Remove the cotter pin and nut from drag link, at the pitman arm. Save the nut for reinstallation. Use a tie rod separator to separate drag link from Pitman arm. 10. Remove the sector Pitman arm retaining nut and save for reinstallation. Use a Pitman arm puller to remove the OE pitman arm. The threads of the sector shaft and the Pitman arm retaining nut must be cleaned of all factory dry adhesive. Drag Link 4 FD-800 Pitman Arm TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Illustration 2 Existing Hole Frame Crossmember 96-5002 Torque Tool Pitman Arm Torque Tool Pitman Arm OE 14mm Track Bar Retaining Bolt Pitman Arm OE 14mm Nut Plate 96-5002 Torque Tool Frame Crossmember 7/16” X 1 1/4” Bolt 17. Use the entire supplied thread locking compound to thoroughly cover the entire surface of the threads on the Pitman arm retaining nut. left, but allow for movement up the sector shaft. If you do not have this tool, a length of chain or a flat bar with two holes is a suitable replacement. 18. Reinstall the Pitman arm retaining nut to the sector shaft and torque to 350 ft./lbs. NOTE: Whether re-using the existing pitman arm retaining nut or replacing with a new nut, the supplied locking compound must be used. 15. Torque the Pitman arm retaining nut to 375 ft./lbs. 16. With the torque tool (96-5002) still in place remove the pitman arm retaining nut. The threads of the sector shaft and the Pitman arm retaining nut MUST be cleaned using brake cleaner or another suitable method to remove the previously applied oil. 19. Unbolt and remove the Pitman arm torque tool (96-5002) from the vehicle. Illustration 3 OE Pal Nut Track Bar Bracket Assembly (1) 9/16” X 1 1/2” Gr. 8 Bolts (2) 9/16” X 3” Gr. 8 Bolts 9/16” Hardware OE Bolt 82-9290 Track Bar Drop Bracket OE Track Bar Bolt OE Bolt OE Track Bar Hardware Track Bar 90-9295 Cam Plates 5 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Illustration 4 Front Radius Arm Drop Bracket Assembly 3/4” X 1 1/2” Gr. 8 Bolt Frame Pocket 3/4” X 1 1/2” Gr. 8 Bolt 3/4” X 5” Gr. 8 Bolt The Notched Bracket Goes on the Bottom 3/4” Stover Nut and Washers 82-3166 Radius Arm Drop Bracket 82-3167 Radius Arm Drop Bracket 90-2507 Spacer Tube vacuum line from inside of the axle bump stop plate. NOTE: Save this Pitman arm torque tool to add to your toolbox for any future Pitman arm installations. 25. Remove the transfer case skid plate. Also remove the rubber grommets, sleeves and clips from the frame. NOTE: Trimming of the transfer case skid plate is necessary for reinstallation. On the passenger side, use the supplied transfer case skid plate cut template (52802B-Supplement) as a guide. Line up the holes and trace the template onto the skid plate. carefully trim the skid plate. This modification is needed to clear the catalytic converter . On the driver side, carefully trim off the rounded kick out in the side of the skid plate. These modification is needed to clear the transfer case. These are only starting points and additional trimming may be necessary. 20. Install track bar drop bracket (82-9290) using (2) 9/16” X 3”, (1) 9/16” X 1 1/2” and (2) OE bolts. Use thread locker on the bolts. Torque OE the bolts to 129 ft. lbs. and the 9/16” bolts to 110 ft. lbs. See ILLUSTRATION 3. 21. Unbolt the front brake line bracket from the lower spring perch. Save hardware for reuse. 22. Unbolt and unclip the ABS wiring connected to the radius arm. Save hardware for reuse. 23. On the driver side, unclip the axle vent line from inside the frame. 24. On the passenger side unclip the axle hub 6 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Illustration 5 Front Radius Arm Drop Drill Picture Drill Out (2) Center Holes Using Assembled Drop Bracket as a 7/16” Hardware Transfer Case Skid Plate Transfer Case Skid Plate 7/16” Drill Bit 3/4” X 5” Gr. 8 Bolt 3/4” X1 1/2” Gr. 8 Bolt 3/4” X 1 1/2” Gr. 8 Bolt 7/16” X 1 1/2” Bolts (4) Front of Vehicle Radius Arm Drop Bracket Assembly 3/4” Hardware Illustration 6 Radius Arm Drop Bracket Assembly Factory Radius Arm Install OE Bolt Factory Radius Arm OE Nut 7 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Before Illustration 7 OE Brake Line Bracket Brake Line Drop Install OE Bolt OE Brake Line OE Hard Line Ferrule Brake Line Retaining Clip Bottom of Vehicle OE Brake Line frame. Use the supplied 3/4” X 1 1/2” bolts in the front hole with the heads of the bolts facing out. Do not torque at this time. See ILLUSTRATION 4. 27. Carefully rotate both radius arms down to provide adequate space to install the new drop brackets. 29. Use the spacer tube (90-2507) and the 3/4” X 5” bolt in the rear hole. Do not torque at this time. See ILLUSTRATION 4. 30. From the rear, slide the previously removed and modified OE transfer case skid plate or the new transfer case skid plate (91-7057) in between the frame and the rear of the radius arm drop bracket. Insert (2) 7/16” X 1 1/2” bolts through the outside holes in the rear of the drop bracket. Tighten these bolts and use the radius arm bracket holes as a drill template to drill out the (2) inside holes in the factory skid plate and frame. Drill the holes using a 7/16” drill bit. Insert the remaining (2) 7/16” X 1 1/2” bolts in the newly drilled holes. See ILLUSTRATION 5. 31. Raise the factory radius arm into the lower hole in the drop bracket and skid plate. Secure using the OE bolt. Do not tighten this bolt until vehicle is on the ground. See ILLUSTRATION 6. 32. Torque the 7/16” radius arm drop bracket hardware to 60 ft. lbs. and the 3/4” hardware to 200 ft. lbs. 28. On both sides of the vehicle, assemble the radius arm drop side plates (82-3166 on top) and (82-3167, with the notch in it, on the bottom) and bolt radius arm drop to the Illustration 8 Bump Stop Drop Assembly Drill Out Mounting Cup Hole To 7/16” Brake Line Drop Bracket 90-7722 drvr and 907723 pass Brake Line Retaining Clip 26. Place a jack under the pinion or radius arm. On both sides remove the rear bolts holding the radius arms to the frame of the vehicle. Existing Bump Stop Hole Drill Out To 7/16” After OE Bolt 7/16” Bolt and Washer 82-2511 Bump Stop Drop Factory Mounting Cup 7/16” Washer 7/16” X 6 1/2” Bolt 33. Raise the front axle enough to relieve tension on the shock hardware and remove the shocks from the vehicle. Factory Bump Stop 34. Lower the front axle enough to remove the coil springs from the front spring pockets. 8 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 the bump stop mounting cup. Pliers and a back and forth rocking motion will assist in removal of the bump stop. Save the factory isolators for re-use. NOTE: Be sure to support the axle while the springs and shocks are removed. 41. On the driver side, unbolt the bump stop mounting cup and drill out the factory hole in the frame and bump stop mounting cup to 7/16”. 35. Remove the front brake line retaining clip. Separate the brake line from the bracket. Save the OE clip for reinstallation. See ILLUSTRATION 7. 42. On the passenger side, unbolt the bump stop mounting cup. Measure in toward the engine 5/8” from the center of the factory bump stop hole in the frame. Center punch and drill and the new hole 7/16” in the frame. Drill out the bump stop mounting cup to 7/16”. 36. Loosen the OE hard line ferrule, just enough, to be able to rotate it 180 degrees so the rubber line is facing toward the bottom of the vehicle and retighten. See ILLUSTRATION 7. 37. Unbolt and remove the OE brake line bracket from the frame. Save the OE bolt for reinstallation. 43. Use the supplied 7/16” X 6 1/2” bolt and hardware to bolt the bump stop drop (912511) and mounting cup to the bump stop hole in frame. See ILLUSTRATION 8. 38. Install the new brake line drop bracket (907722 Drvr and 90-7723 Pass) to the original hole in the frame rail using the previously removed OE bolt. See ILLUSTRATION 7. NOTE: Be sure to fit the tab from the mounting cup into the hole in the drop. 39. Secure the brake line to the new bracket using the previously removed OE clip. See ILLUSTRATION 7. 44. Reinstall the previously removed factory bump stop into the mounting cup on the new bump stop drop. See ILLUSTRATION 8. 40. Remove the factory front bump stop from Illustration 9 OE Studs OE Nut Sway Bar Install Sway Bar Drop Bracket 82-7029 pass OE Nut OE Nut OE Sway Bar End Link Steering Stabilizer Mounting Bracket 82-3823 OE Nut Sway Bar Drop Bracket 82-7026 drvr 7/16” X 1 3/4” Bolt Steering Stabilizer Sway Bar 12mm X 65mm Bolt OE Studs OE Sway Bar End Link Sway Bar Spacer Plate 82-3822 7/16” X 1 3/4” Bolt Front of Vehicle 9 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 45. Using the factory isolators install the supplied front coil springs (24514 Gas or 24515 Diesel) into the spring buckets and raise the axle into place. Make sure the coil spring seats properly on the lower spring perch. 55. Remove the ABS line from the inner fender. Drill a new hole, using a 15/64” bit, 3” lower in the fender to provide adequate slack for line and reattach the ABS line. 56. Reinstall the ABS wiring onto the radius arms using the factory clips. 46. Install the new shocks (TM75880W). Torque the upper mounting hardware to 46 ft. lbs. and the lower mounting hardware to 111 ft. lbs. Use thread locker on these bolts. 57. Refasten the lower brake line mount to the lower coil spring perch using the OE hardware. 47. Install draglink end into pitman arm and torque draglink nut to 148 ft. lbs. Reinstall cotter pin. 58. Reinstall the front wheels and lower the vehicle to the ground. Torque to manufacturers specs. 48. Install the sway bar drops (82-7026 drvr and 82-7029 pass) to the OE sway bar mounting studs on the frame using the previously removed OE hardware. See ILLUSTRATION 9. 59. Torque the OE rear Radius arm bolts to 222 ft. lbs. 60. Reinstall the track bar into the Trailmaster track bar bracket (82-9290) using the OE bolt and adjustable cam plates (90-9295). Torque to 406 ft. lbs. See ILLUSTRATION 3. 49. Carefully raise the sway bar back into place and on the passenger side insert the steering stabilizer bracket (82-3823) under the passenger side sway bar mount. On the driver side insert the sway bar spacer plate (823822) under the driver side sway bar mount. Secure the supplied 7/16” X 1 3/4” bolts and hardware. See ILLUSTRATION 9. NOTE: Be sure the steering stabilizer mounting hole in the stabilizer bracket is oriented toward the rear of the vehicle. NOTE: You may find that having someone inside the vehicle and moving the steering wheel from side to side will aid in the alignment of the track bar. DO NOT start the engine for this! You only have to move it enough to line the holes up on the track bar mount. 61. On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component. At full droop, cycle the steering from lock to lock while observing the reaction of these components. Reposition them if needed. 50. Reattach the sway bar to the OE sway bar end links using the previously removed OE hardware. 51. Install the OE steering stabilizer to the new steering stabilizer bracket (91-3823) using the provided 12mm X 65mm bolt and hardware. See ILLUSTRATION 9. 62. With the vehicle fully on the ground, measure the clearance between each tire and inner fender. If the axle is not properly centered, readjust the track bar cam hardware. Torque to 406 ft. 52. Torque all sway bar hardware according to manufacturers specifications. 53. On the driver side, re clip the axle vent line on the frame providing adequate slack for the line at full droop. 54. On the passenger side, reposition the clip on the axle hub vacuum line to provide adequate slack to re-clip the line to the existing hole on the outside of the bump stop plate. NOTES:  On completion of the installation, have the suspension and headlights re-aligned.  After 100 miles recheck for proper torque on all newly installed hardware. NOTE: Be sure that the newly rerouted vent line does not interfere with the travel of the bump stop.  Recheck all hardware for tightness after off road use. 10 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Rear Installation: NOTE: DO NOT trim the excess center bolt on the driver side. The extra threads will be needed to attach the OE emergency brake line bracket. 1. Block the front tires and raise the rear of the vehicle. Support the frame with jack stands forward of the rear springs. 2. Remove the wheels and tires. APPLICATIONS: 3. Unscrew the rear axle vent tube to separate the rear brake line bracket from the rear axle. 4. Remove the shocks on both sides of the vehicle. It may be necessary that you slightly raise the axle to unload the shocks for removal. 5. On the driver side, unbolt the emergency brake line bracket from the upper spring plate. Save hardware for reuse. 6. If your vehicle is equipped with factory sway bar, unbolt it from the end links. Unbolt and remove the end links from the vehicle. 1. FOR F-250 MODELS, INSTALL THE ADD-A-LEAVES (13150-1 AND 13150-2) AND LIFT BLOCK 95407SD DRVR AND 95-406SD PASS. 2. FOR F-350 MODELS, INSTALL THE ADD-A-LEAVES (13150-1 AND 13150-2) AND LIFT BLOCKS 95556SD DRVR AND 95-557SD PASS. 9. While supporting the rear leaf spring, remove the factory spring mounting bolts and remove the leaf spring from the driver side only at this time. 12. Install the supplied lift block (F-250: 95407SD drvr and 95-406SD pass) or (F-350: 95556SD drvr and 95-557SD pass) depending on application. See the side note for proper applications. Make sure the pin fits into the hole on the spring perch. Use your floor jack to raise the axle to the spring making sure the pin on the factory leaf spring assembly fits into the hole on the lift block. Secure the assembly with the 5/8” U-bolts (F-250: 1390540 or F-350 13-90560 ) 5/8” hi-nuts (PN 20-65471) and washers supplied. Do not torque the hi-nuts at this time. See ILLUSTRATION 10. 10. Disassemble leaf spring and insert the add-aleaves (13150-1 and 13150-2). NOTE: Make sure the block sits flush on the axle perch. NOTE: The add-a-leaves will be added onto the bottom of the factory spring pack, progressively according to length. Do not install the add-a-leaves below the factory overload spring if the vehicle is equipped with one. See ILLUSTRATION 10. 13. Repeat the installation on the other side of the vehicle. 7. Support the rear axle with a floor jack and remove the U-bolts on the driver side. Slightly loosen the U-bolts on the passenger side. 8. Lower the rear axle and remove the factory block. NOTE: Be sure not to over extend the rear brake line and rear axle vent line. 14. On driver side, carefully bend down the emergency brake line bracket that secures the line to the frame and bolt the emergency brake line bracket back to the spring pack center bolt using the supplied 10mm-1.5 nut. 11. Using the C-clamps, bolt the leaf pack back together using the supplied center bolt with the head of the bolts facing down and the nut on the top. Reinstall the spring pack to the hangers using the OE hardware. Do not torque at this time. 15. Install your new Trailmaster shocks (TM75790W). Torque the upper mounting hardware to 46 ft. lbs. and the lower mounting hardware to 66 ft. lbs. Use thread locker on these bolts. 11 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Illustration 10 F-250:13-90540 U-bolts F-350: 13-90560 U-bolts Rear Spring With Add-A-Leaf Assembly Front of Vehicle 10mm-1.5 Nut Upper Spring Plate Factory Overload Spring And plate, F-350 only. Add-A-Leaf (13150-1) Add-A-Leaf (13150-2) OE Brake Line Mount Factory Overload Spring if Equipped Brake Line Supplied Center Bolt 97-716 or 97-165 3/8” X 1” Bolt F-250 models: 95-407SD drvr and 95-406SD pass Lift Block F-350 models: use 95-556SD drvr and 95-557SD pass The goal of the offset rear block is to shift the axle forward to center the wheel. Rear Axle 90-7031 Brake Line Mount NOTE: Install the (13150-1 and 13150-2) add-a leaves onto the bottom of the factory spring pack. Do not install below the factory overload spring if the vehicle is equipped with one. 5/8” Hi-Nuts Add-A-Leaf Rear Spacer Options: 1. F-250: Add-a-leaves (13150-1 and 13150-2) and lift block 95-407SD drvr and 95406SD pass. 2. F-350: Add-a-leaves (13150-1 and 13150-2) and lift blocks 95-556SD drvr and 95557SD pass. See Inset box after step 11, page 11. 12 12 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 21. Torque the spring mounts at this time. The front bolts are torqued to 250 ft. lbs. and the rear bolts are torqued to 185 ft. lbs. Torque the 5/8” U-bolts to 120 ft. lbs. 15. Remove the (2) bolts that secure the center drive shaft bearing. Lower bearing and install 1/4” of shim thickness for each inch of rear lift. Use new 7/16” X 2 1/4” bolts and torque to 55 ft./lbs. NOTE: 1/4” of shim for each inch of lift is only a starting point. Only by driving the vehicle and adding or removing shims can the high speed vibration be totally eliminated. The off the line vibration is caused by axle wrap up and cannot be eliminated with these products. 16. If vehicle came equipped with a rear sway bar, assemble the rear sway bar end links (82-2446) using the bushings (45359) and sleeves (60859H). 22. Re-check the wheel lug torque on all four wheels at this time. 23. Re-check all hardware (both the front and the rear) for proper installation and torque!! 24. If you wish, you may trim the excess u-bolt thread length. If you do this you should leave approximately one inch of thread exposed after the U-bolts are torqued. 25. On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component. Reposition them if needed. 17. Secure the new rear sway bar end links (822446) to the frame and the sway bar using the provided 12mm-1.75 X 70mm. Torque the bolts according to the torque chart on page 19. NOTES: 18. Secure the new rear brake line bracket (907031) to the rear axle by reinstalling the vent tube.  On completion of the installation, have the suspension and headlights re-aligned.  After 100 miles recheck for proper torque 19. Secure the OE brake line bracket to the new brake line bracket (90-7031) using the supplied 3/8” X 1” bolt and hardware. on all newly installed hardware.  Recheck all hardware for tightness after 20. Reinstall the wheels and tires and lower the vehicle to the ground. Torque lug nuts to manufacturer specification. off road use. 13 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 NOTES: Dynamic Vehicle Check 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. 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. 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. IMPORTANT!: 18” OR LARGER WHEELS MUST BE USED IN CONJUNCTION WITH THIS LIFT KIT! 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 14 information can result in damage to the vehicle and severe personal injury.  On completion of the installation, have the suspension and headlights re-aligned.  After 100 miles recheck for proper torque on all newly installed hardware.  Recheck all hardware for tightness after off road use. TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Part # Description Qty. Kit Parts List: Box TM411N-1 82-7026 SWAY BAR DROP: Drvr 1 82-7029 SWAY BAR DROP: Pass 1 82-3822 SWAY BAR SPACER 1 82-3823 STEERING STABILIZER BRACKET 1 90-6315 70-0431751800 73-04300034 72-04300100816 HARDWARE PACK: Sway Bar Drop 7/16” X 1 3/4” GR. 8 HEX BOLT 7/16” HARDENED FLAT WASHER 7/16” GR. 8 STOVER NUT 1 4 8 4 90-6803 HARDWARE PACK: Steering Stabilizer 70-0120651758800 12mm– 1.75 X 65mm 10.9 HEX BOLT 73-01217508812 12mm FLAT WASHER 72-01200832 12mm– 1.75 STOVER NUT 1 1 2 1 82-9290 TRACK BAR DROP BRACKET 1 90-6772 56C300HCS8Y 56C150HCS8Y 56CNUCZ 56NWHDY/SAE HARDWARE PACK: Track Bar Drop 9/16” X 3” HEX BOLT GR. 8 9/16” X 1 1/2" HEX BOLT GR. 8 9/16” STOVER NUT GR. C 9/16” HARDENED FLAT WASHER 1 2 1 3 6 FD-800-1 PITMAN ARM 1 82-2511 BUMP STOP SPACER 2 90-6390 70-0436501800 73-04300034 72-04300100816 HARDWARE PACK: Bump Stop 7/16” X 6 1/2” USS GR. 8 HEX BOLT 7/16” SAE FLAT WASHER 7/16” USS GR.8 STOVER NUT 1 2 4 2 90-6042 45359 60859H HARDWARE PACK:Rear Sway Bar Links 5/8” RUBBER HOURGLASS BUSHING 5/8” O.D. X 12mm I.D. X 1.480” SLEEVE 1 4 4 90-6572 .120C750HCS1Z .120CNNEZ .120NWHDY HARDWARE PACK:Rear Sway Bar Links 12mm-1.75 X 70mm HEX BOLT GR. 10.9 12mm-1.75 NYLOCK NUT 12mm HARDENED FLAT WASHER 1 4 4 8 82-2446 REAR SWAY BAR END LINKS 2 96-5002 PITMAN ARM TOOL 1 15 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Part # 90-6595 Description Qty. HARDWARE PACK: Pitman Arm Tool THREAD LOCKER 7/16" X 1 1/4" GR. 8 HEX BOLT 7/16" FLAT WASHER 7/16" NYLOC NUT BRAKE LINE MOUNT: Rear 1 1 1 1 2 1 HARDWARE PACK: Brake Line Mount 3/8” X 1” HEX BOLT GR. 8 3/8” NYLOCK NUT GR. 5 3/8” HARDENED FLAT WASHER 10MM X 1.5 PITCH NYLOCK: Rear E-Brake Bracket 1 1 1 2 1 90-7722 FRONT BRAKE LINE DROP BRACKET: Drvr 1 90-7723 FRONT BRAKE LINE DROP BRACKET: Pass 1 90-6918 90-9295 HARDWARE PACK: Cam Plates Cam Plate 1 2 90-6386 90-2507 HARDWARE PACK: Radius Arm RADIUS ARM SPACER TUBE 1 2 82-3166 RADIUS ARM DROP SIDE PLATE 2 82-3167 RADIUS ARM DROP SIDE PLATE (With Notch) 2 90-6370 70-0751501800 72-075100816 73-07500830 70-0755001800 70-0431501800 72-043100816 73-04300830 HARDWARE PACK: Radius Arm Drop 3/4” X 1 1/2” HEX BOLTS GR. 8 3/4” STOVER NUTS 3/4” WASHERS SAE GR. 8 3/4” X 5 HEX BOLTS GR. 8 7/16” X 1 1/2” HEX BOLTS GR.8 7/16” STOVER NUTS 7/16” WASHERS SAE GR. 8 1 4 6 12 2 8 8 0431251800 04300030 04300100512 90-7031 90-6773 0431251800 04300100512 72-01015008812 Box TM411N-2 16 90-1080 3/8” Driveline Shim 2 90-1081 1/4” Driveline Shim 2 90-1082 1/8” Driveline Shim 2 90-6013 70-04300100816 73-04300042 HARDWARE PACK: Driveline Shim 7/16” x 2 1/4” USS Grade 8 Bolt 7/16 USS Hardened Washer 1 2 2 TM75880W FRONT SHOCKS 2 TM75790W REAR SHOCKS 2 Box TM411N-3 16 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Part # Description Qty. Box TM411N-4 13150-1 ADD-A-LEAF 2 13150-2 ADD-A-LEAF 2 90-7130 98-00300-1 98-003002 97-716 8771-1 HARDWARE PACK: Add-A-Leaf 3” SPRING CLAMP 3” SPRING PLATE 7/16”X 4 1/2” CENTER BOLT 7/16”GR. 8 CENTER BOLT NUT 4 4 2 2 90-6337 97-165 72-01015008812 HARDWARE PACK: Add-A-Leaf 10MM X 165MM CENTER PIN 10MM-1.5 NUT (CENTER BOLT NUT) 1 2 2 COILS GASOLINE ENGINE 1 COILS DIESEL ENGINE 1 Box TM411N-5 24514 OR Box TM413N-5 24515 Box TM411N-6: F250 Only 95-407SD 4" REAR LIFT BLOCK: Drvr: F-250 1 95-406SD 4" REAR LIFT BLOCK: Pass: F-250 1 13-90540 U-BOLT: F-250 4 20-65471 HARDWARE PACK: 5/8” Hi nuts & Washers 1 Box TM413N-6: F350 Only 95-556SD 5 1/2” REAR LIFT BLOCK: F-350 1 95-557SD 5 1/2” REAR LIFT BLOCK: F-350 1 13-90560 U-BOLT: F-350 4 20-65471 HARDWARE PACK: 5/8” Hi nuts & Washers 1 17 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 Revision Page: 18 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 19 TM411N, TM412N, TM413N, TM414N Revised 7.11.13 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: [email protected] Website: www.trailmastersuspension.com Ph: (877) 695-7812 20