I was given one week to install this
kit before driving 1200 miles one way to Moab for the 2005 goneMOAB
event and as such I did not have time to screw around.
The axle mounts I had welded at a
local shop. The rest of the kit I did myself in my driveway. Total
time from start to finish was about 25 man hours.
Tools I used
- Dewalt Angle Grinder (with grinding
wheel and cut off wheels)
- Dewalt Recipricating Saw
- Tape Measure
- Hand Tools (Metric and Standard)
- 3 Ton Floor Jack and Jack Stands
- BFH (Big Fucking Hammer)
- Torque Wrench
- Spray Paint for frame
arm puller (only needed if you have the Calmini steering as the
kit uses a stock arm)
one : Remove the old junk.
includes upper and lower control arms (lower control arm mounts),
torsion bars, front differential, front driveshaft, brakes, cross
members ( leave the transmission cross member till you are ready
to swap it, then support the transmission for the switch), frame
side shock mounts and the steering linkages.
all the things to remove the lower control arm mounts will give
you the most trouble. I removed mine by way of the saw and grinder.
If you have access to someone with a cutting torch it goes MUCH
faster. Something of note. Be careful when you are removing the
shock mounts as it is a tight space. I was able to remove most of
the mount with the saw then the rest of the mount by careful use
of the cut off wheel. Everything else goes rather quickly.
all the crap is off the frame you should spend some time to clean
up the frame so that is looks nice. This means grinding any rough
spots and making things look like the IFS crap was never there.
you are done the front end will look like this (there are also some
good pics in the instructions for close up stuff)
two: Start putting on the kit
the instruction are good, but to be honest I looked at them once
and never looked back. The bolts and parts that are supplied are
rather self explanitory as to where they go and how they fit.
by putting on the shock hoops. As with all the other pieces in the
kit there is little tolerance for error. Either the part will fit
or it will not. Do not force it. If you find that a part is not
going in smoothly go back and check that all the old crap is out
of the way (this really only applies to the shock hoops)
the hoops are in place the rest of the front sort of falls into
place. You will put in the new cross members. NOTE: Remember to
support your transmission when you replace that crossmember with
the new one.
attach the long arms and move your axle into place (I had the wheels
and tires on my axle to help move it around)
you get the axle under the truck and have attached the long arms
you can attach the coil overs (follow instructions provided with
the coilovers so that they are set up properly) and install the
front drive shaft.
this point you are just about done with the front. You will still
need to attach the steering, bleed the brakes and adjust your ride
height and set your toe.
to the back half of the vehicle.
sells a replacement rear spring pack that is tuned for the lift
of the front end. To save yourself the trouble of doing all the
crap necessary to get a rear spring made it would be prudent to
get the springs from them. Same goes with the front coil-overs and
you have the rear springs replaced.and you have double checked to
make sure everything is tight then it is time to drive it around.