and nuts that retain the differential carrier.
(Diagram 4)
10.Remove the bolts retaining the axle tube cross member, and remove the cross member from the
vehicle. Next remove the two remaining bolts holding the front differential to the chassis.
(Diagram 5)
11. Next it will be necessary to remove the mounting tab on the driver's side on the vehicle. Cut the
tab off at the weld, as shown, using a die grinder with a cutoff wheel (or hacksaw). Grind or file
the remaining weld flush with the surface.
(Photo 6)
12.Lower the differential enough to install the new axle tube cross member. Use the polyurethane
bushings and sleeves included in the new cross member, and you will use all existing hardware
to install the cross member. The short end of the cross member is installed toward the front of the
vehicle.
Some models will require the short end of the cross member to be installed toward
the rear to allow for proper alignment of the differential.(Photo 7 & 8) Do NOT tighten any
of the bolts at this time.
13.Install the Upper differential lowering tubes as shown, using the 9/16" x 5" bolt, locknut and flat
washers provided. Be sure to insert the spacer tube between the two brackets, with a large flat
washer on each end.
(Photo 9) Do NOT tighten any of the bolts at this time.
14.Install the driver's side lowering bracket at this time. Use the 9/16" x 1 1/2" bolt, nut and washers
to hold the bracket in the existing hole behind the lower A-arm mount. Carefully mark the remain-
ing
1
/
2
" hole to be drilled. Remove the bracket, then carefully center punch and drill the remaining
hole. Mount the bracket as shown,
but do NOT tighten the bolts yet. (Photo 10)
15.Align the mounting bushings in the front differential housing with the brackets, and install the fac-
tory bolts, washers ad nuts now.
Tighten all factory bolts and nuts to 80 ft.lbs. Tighten
remaining
1
/
2
" bolts to 50-55 ft.lbs., and the
9
/
16
" bolts to 65-70 ft.lbs.
16.Install and load the torsion bars reversing the sequence of instructions in step #3, again being
very careful. If installing new torsion bars, do so at this time.
17.If so equipped, reinstall the skid plate using the factory hardware on the rear of skid, and in the
front of skid plate insert new spacer blocks between frame and skid plate and install new 10mm x
70mm bolts and washers provided. Tighten bolts into frame.
18.Shorten the anti-sway bar connecting link sleeves
3
/
8
" with a hacksaw or die grinder. Reinstall the
shortened sleeves using the supplied
3
/
8
" x 8" bolts, washers and nuts, re-using the factory rubber
grommets.
*NOTE: If '97 & Up model, install front brake lines at this time. Refer to brake line instructions
to install.
19.Check all nuts, bolts and hardware for tightness. Install new shock absorbers, reinstall tires and
lower vehicle to the ground.
REAR INSTALLATION:
20.Place a floor jack under rear axle and raise vehicle. Place jack stands under the frame to support
vehicle and remove the rear wheels.
3
#I-C256 (Rev. 4/04)
