nissan frontier 2 & 4wd king & crew cab models … · nissan frontier 2 & 4wd automatic...

3651 N Highway 89 • Chino Valley, AZ 86323(928) 636-7080 • www.p-a-g.net

NISSAN FRONTIER 2 & 4WDAUTOMATIC & MANUAL TRANS.KING & CREW CAB MODELS3” BODY LIFT KITINSTALLATION INSTRUCTIONS2005-2011 KIT# 40083

WARNING

Installation of a Performance Automotive Group bodylift kit will change the vehicle’s center of gravity andhandling characteristics both on- and off-road. Youmust drive the vehicle safely! Extreme care must betaken to prevent vehicle rollover or loss of control,which could result in serious injury or death. Avoid sud-den sharp turns or abrupt maneuvers and always makesure all vehicle occupants have their seat belts fas-tened.

WARNING

Before you install this kit, read and understand allinstructions, warnings, cautions, and notes in thisinstruction sheet and in the vehicle owner’s manual.

CAUTION

Proper installation of this kit requires knowledge of thefactory recommended procedures for removal andinstallation of original equipment components. We rec-ommend that the factory shop manual and any specialtools needed to service your vehicle be on hand duringthe installation. Installation of this kit without properknowledge of the factory recommended proceduresmay affect the performance of these components andthe safety of the vehicle. We strongly recommend thata certified mechanic familiar with the installation of sim-ilar components install this kit.

WARNING

DO NOT combine suspension, body, or other liftdevices. Use of vehicle with combined lifts may resultin unsafe and/or unexpected handling characteristics.

WARNING

This kit should only be installed on a vehicle that is ingood working condition. Before you install the kit, thor-oughly inspect the vehicle for corrosion or deformationof the sheet metal around the factory body mounts. Ifthe vehicle is suspected to have been in a collision ormisused, do not install this kit. Off-road use of yourvehicle with this kit installed may increase the stressapplied to the factory body mounts. We do not recom-mend that any vehicle with a body lift kit installed beinvolved in any extreme off-road maneuvers such asjumping. Failure to observe this warning may result inserious personal injury and/or severe damage to yourvehicle.

WARNING

Many states and municipalities have laws restrictingbumper heights and vehicle lifts. Consult state andlocal laws to determine if the changes you intend tomake to the vehicle comply with the law.

WARNING

The installation of larger tires may reduce the effective-ness of the braking system.

WARNING

Always wear eye protection when operating powertools.

WARNING

Before you install this kit, block the vehicle tires to pre-vent the vehicle from rolling.

WARNING

Accidental deployment of the air bag can result in seri-ous personal injury or death. To avoid accidentaldeployment during installation of the kit, the Supple-mental Restraint System (SRS, or airbag) must remaindeactivated. Do not allow anyone near the airbag dur-ing installation. Refer to the factory service manual orowner's manual for the recommended procedure todisable the SRS. After you install the kit, reactivate theSRS before driving the vehicle.

NOTE

Performance Automotive Group recommends usingthe Loctite® supplied in the kit on the threads of all kitnuts and bolts unless specified otherwise in theseinstructions.

1 Frontier - Kit 40083


Before Starting Installation

1. Carefully read all warnings and instructions com-pletely before beginning.

2. Verify all parts have been received in this kit bychecking the parts list at the end of this document.

3. Only install this kit on the vehicle for which it isspecified. If anytime during the installation youencounter something different from what is outlinedin the instructions, call technical support at (928)636-7080.

4. Special tools needed:

a. Welder or access to a professional weldingshop.

b. Die grinder or similar tool capable of cuttingmetal.

c. Saws All or similar reciprocating cutting bladetool.

5. Park vehicle on a clean, dry, flat, level surface andblock tires so vehicle cannot roll in either direction.

NOTE

Kit parts are prefaced by the word kit and appear inbold print.

NOTE

If parts are missing from kit, please be prepared to pro-vide the following information:

1. Name of purchase location2. Bar Code on side of box3. Date above bar code4. Date inside box cover5. Inspector # from inside box cover

Engine Compartment

1. Disconnect both battery cables. Disconnect nega-tive cable first, then positive cable.

2. Remove battery tie-downs and battery from vehicleand place on floor or ground.

Inside Cab

1. Airbag Fuse

a. Remove fuse cover.

b. Remove airbag fuse.

NOTE

The location of the airbag fuse may vary; check theowner's manual.

PositiveCable

BatteryTie-Downs

NegativeCable

Glove Box

Cover


Prepare to Install KitMeasurements

1. Measure and record distance between front bumperand fenders.

Driver Side ________ Passenger Side ________

2. Measure and record distance between rear bumperand bed

Driver Side ________ Passenger Side _________

3. Measure and record distance between cab and bed.

Driver Side ________ Passenger Side _________

Front of Vehicle

1. Grill

a. Remove six pop-up clips from top of grill andcore support.

Pop-UpClips

Grill

b. Turn four turn clips 45°, depress four lower clips,and remove grill from core support.

2. Front Bumper

a. Remove four screws and two bolts and lowerfascia from fascia.

b. Remove four bolts from fascia and skid plate.

Grill

LowerClips

TurnClips

Fascia

LowerFascia

Screws& Bolts

Fascia

Bolts

SkidPlate


c. Remove four bolts and skid plate from frontbumper and crossmember.

d. Disconnect two fog light wiring harnesses, ifequipped.

e. Remove two bolts and two side supports fromdriver and passenger inside front bumper.

Cross-Member

Skid Plate

FrontBumper

SideSupport

Bolt

f. Remove six bolts (four upper and two lower) andfront bumper from core support and bumpersupport.

g. Remove four bolts and bumper support fromframe rails.

TopBolts

FrontBumper

BottomBolts

Bolts

BumperSupport

FrameRail


Engine Compartment

1. Airbox

a. Disconnect wiring harness from airbox cover.

b. Remove two bolts and engine cover fromengine.

c. Remove clamp and vent hose from intake cham-ber.

WiringHarness

Intake

AirboxCover

EngineCover

Bolts

VentHose

Clamp

IntakeChamber

d. Remove two bolts from intake chamber.

e. Loosen clamps on intake and throttle body andremove intake.

f. Remove two clips, airbox cover, and airbox filter.

2. Remove two nuts and metal heater core tube fromfirewall.

Bolts

IntakeChamber

ThrottleBody Clamp

Intake

AirboxClamp

Firewall

HeaterTube

Nuts


3. Remove two bolts, bracket, and AC line from driverside firewall.

4. Fan shroud & radiator

a. Remove two bolts and two brackets from radia-tor and top of core support.

b. Disconnect and remove two wiring harnessesfrom electric fan and AC condensor.

WARNING

If the engine cooling system is hot, the coolant will beHOT and UNDER PRESSURE. To prevent seriouspersonal injury, wait until the cooling system is com-pletely cool before removing the cap and/or hoses fromthe radiator.

Firewall

Bolts

AC Line& Bracket

Radiator

Brackets

Bolts

ACCondenser

WiringHarnesses

ElectricFan

c. Remove clamp and overflow hose from radiator.

d. Remove three bolts from fan shroud, electricfan, and top of radiator.

e. Depress two clips along bottom of fan shroudand remove lower fan shroud.

RadiatorCap

Clamp

OverflowHose

Radiator

Bolts

FanShroud

FanShroud

Clips

LowerFan Shroud


f. Remove four nuts, fan clutch, and fan from pul-ley.

g. Position clean drain pan or bucket beneath radi-ator stopcock.

h. Remove radiator cap.

i. Open radiator stopcock and drain coolant intoclean drain bucket or pan.

NOTE

Pulley may shift due to belt tension. This will not harmany components.

WARNING

If the engine cooling system is hot, the coolant will beHOT and UNDER PRESSURE. To prevent seriouspersonal injury, wait until the cooling system is com-pletely cool before removing the cap and/or hoses fromthe radiator.

Pulley

Nuts

Fan &Fan Clutch

Radiator

Stopcock

j. Once all coolant has been drained, removeclamps, upper, and lower radiator hoses.

k. Remove two clamps and two transmission cool-ant lines, if equipped, from bottom of radiator.

l. Remove any hoses clipped onto fan shroud.

m. Pull fan shroud and electric fan up and out ofvehicle.

Clamp &Upper Hose

Clamp &Lower Hose

Trans. CoolerLines & Clamps

Radiator


n. Remove two bolts from AC condenser andupper radiator.

o. Using kit ties, hang AC condenser from uppercore support.

p. Pull radiator up and out of vehicle.

5. Power steering reservoir

a. Remove power steering reservoir from bracket.

ACCondenser

Bolt

Radiator

CoreSupport

Kit Ties

ACCondenser

Reservoir

Bracket

b. Remove three bolts and bracket from passengerside wheel well.

6. Engine wire harness

a. Remove or cut electrical tape covering wiringharness clip on passenger side wheel well.

b. Remove wiring harness from upper clip andlower clip located on passenger side enginebracket.

Bracket

Bolts

ElectricalTape

Clips

WiringHarness


7. Remove bolt, power steering cooler line, andbracket from driver side frame rail.

8. ABS sensors

a. Remove or cut two ABS sensor harness clipsfrom driver side wheel well.

b. Disconnect driver and passenger ABS sensorharnesses from two spring perches.

Driver SideFrame

Bolt

CoolerLine

Clips

ABSHarness

ABSHarness

SpringPerch

Frame

c. Remove two bolts, two brackets, and ABS har-nesses from two spring perch brackets.

9. Steering Shaft

a. Strap steering wheel to prevent accidentalmovement.

b. Mark lower steering shaft in relation to rack &pinion shaft as shown.

c. Remove bolt and slide lower steering shaft upand off of rack & pinion shaft.

WARNING

Accidental deployment of the air bag can result in seri-ous personal injury or death. To avoid accidentaldeployment during installation of the lift kit, the Supple-mental Restraint System (SRS, or airbag) must remaindeactivated. Do not allow anyone near the airbag dur-ing installation. Refer to the factory service manual orowner's manual for the recommended procedure todisable the SRS. After kit installation, the SRS must bereactivated before driving the vehicle.

CAUTION

If the following step is not performed, the airbag clock-spring could be damaged. Do not turn the steeringwheel while the steering shaft is disconnected.

ABSHarness

Bracket

Bolt

LowerSteeringShaft

Mark

Bolt

Rack &Pinion


10. Remove two nuts and brake line bracket from lowerdriver side firewall.

Inside of Vehicle

1. Manual transmission

a. Pull up and remove cup holder trim panel fromcenter console.

b. Pull up and remove shift boot trim panel fromcenter console.

c. Using pliers and rag (to protect shift knob)remove shift knob from shift lever.

d. Remove bolt and wiring harness bracket fromfloor.

Brake Lines

Bracket

Driver SideFirewall

Nuts

Shift BootPanel

Shift Knob

Cup HolderPanel

WiringHarness& Bracket

Bolt

Floor

e. Remove four bolts and boot ring from floor.

f. Remove two inner shift boots from shift leverand floor.

g. Remove two zip ties and shift tower boot fromshift tower.

h. Remove three bolts and shift lever assemblyfrom vehicle.

Bolts

Boot Ring

Inner ShiftBoot

Shift Lever

Inner ShiftBoot

Shift Tower

Zip Ties

Shift TowerBoot

Shift Tower

Bolts

Shift LeverAssembly


Underside of Vehicle

1. Wire harness

a. Remove plastic cover from passenger side wir-ing harness behind front wheel.

b. Remove bolt, bracket, and wiring harness fromframe rail.

2. Remove two nuts and two parking brake cables frombottom center of cab.

WiringHarness

Psgr. Side Frame

PlasticCover

WiringHarness

Bolt& Bracket

Psgr. SideFrame

Cab

Park BrakeCables

Nuts

Rear of Vehicle

1. Fuel filler

a. Open fuel door and remove fuel cap.

b. Remove bolt and fuel filler from bed bracket.

c. Remove vent clip and hose from fuel filler venttube.

d. Remove two clips, clamp, filler hose, and fuelfiller from fuel tank and vehicle.

2. Remove nut and ground strap from exhaust.

FuelDoor

Cap

FuelFiller

Bolt

BedBracket

Vent Clip& Hose

Fuel FillerHose& Clamp

Fuel Tank

Clips


3. Rear bumper

a. Remove wiring harness clip from bed rail.

b. Disconnect two license plate wiring harnessesfrom rear bumper.

c. Remove six bolts and bumper from frame rails.

d. Depress clips and remove upper plastic stepfrom bumper.

Bed Rail

Clip

WiringHarness

LicensePlate Wiring Harness

RearBumper

Frame

Bolts

BumperBracket

RearBumper

Clips

UpperPlasticStep

e. Depress clips and remove lower plastic stepfrom bumper.

f. Remove six nuts, six studs, and bumper frombracket and crossmember.

Install KitCab

1. Prepare to lift cab from frame

a. Loosen, but DO NOT REMOVE, cab mountingbolts on driver side.

NOTE

The number of cab mounting bolts may vary with thelength of the cab.

RearBumper

LowerPlasticStep

RearBumper

Studs& Nuts

BumperBracket

Cab Mount

Loosen BoltsAt These Mounts

Bolt Lower Hardware


b. Remove bolt and lower hardware from each cabmount on passenger side.

2. Cab passenger side

a. Position a hydraulic floor jack and a wood blockunder passenger side of cab (under the bodyseam). Slowly lift cab just enough to install a kitblock on top of factory upper bushing.

NOTE

Retain lower hardware from each cab mount. Lowerhardware will be re-used.

WARNING

Use extreme caution when lifting body from frame. Toprevent serious personal injury, ensure the liftingdevice is securely placed. Keep your hands out frombetween the body and frame.

CAUTION

Continually check hoses, wires, lines, etc. to be surethat everything is flexing properly and not binding, ordamage to the vehicle could result. Be especially care-ful of the a/c hoses at the fire wall, the belt pulley, andat the core support. Ensure brake lines stretch whilelifting. Bending the lines to gain ample slack may benecessary. Be extremely careful not to kink the lines.

WARNING

The kit blocks must be installed in addition to the fac-tory upper and lower bushings. Installing the kit blockswithout the factory upper and lower bushings couldresult in damage to the vehicle or serious personalinjury.

Remove BoltFrom These Mounts

Bolt Lower Hardware

Cab Mount

b. Install kit blocks onto upper bushings on eachcab mount as shown below.

c. Lower cab onto kit blocks.

d. Install lower hardware and kit bolt (12mm x180mm) on each cab mount. DO NOTTIGHTEN.

Kit Block(3” x 2”)


Crew CabONLY



Kit Bolt(12mm x 180mm),Kit Washer(1/2” USS) Lower Hardware

Crew CabONLY


3. Cab driver side

a. Repeat previous steps on driver side of cab.

b. Set cab-to-bed spacing according to previousmeasurement.

c. Remove each kit bolt, one at a time, and apply asmall amount of kit Loctite® onto threads.Install kit bolt, kit washer (1/2” USS), and lowerhardware. TIGHTEN kit bolt to 55 ft. lbs.

Bed

1. Prepare to lift bed from frame

a. Loosen, but DO NOT REMOVE, bed mountingbolts on driver side.

NOTE

Lower hardware varies between each body mount andcan include rubber bushings and/or washers.

NOTE

The number of bed mounting bolts may vary with thelength of the bed.

Kit Bolt(12 x 180mm),Kit Washer(1/2” USS)

LowerHardware

Kit Block

Loosen BoltAt These Mounts

Bolt Bed Mount

2. Remove bolt and washer from each bed mount onpassenger side.

3. Bed passenger side

a. Using a hydraulic floor jack and a wood block,slowly lift passenger side of bed a little morethan 3”.

b. Install a kit block (3” x 2”) on each bed mount.

NOTE

Retain washer from each bed mount. Washers will bere-used.

WARNING

Use extreme caution when lifting the bed from theframe. To prevent serious personal injury, ensure thelifting device is securely placed. Keep your hands outfrom between the bed and frame.

CAUTION

To prevent damage to the vehicle while lifting the bed,continually check hoses, wires, brake lines, etc. toensure everything is flexing properly and not binding.Ensure clearance between bed and cab is maintained.

Remove BoltFrom These Mounts

Bolt Bed Mount

Kit Block(3" x 2")


c. Lower bed onto kit blocks.

d. Install kit bolts (10mm x 120mm) and factorywashers onto each bed mount. DO NOTTIGHTEN.

**2011 Models will use 6 bed blocks and bolts**

e. Repeat previous steps on driver side of bed.

f. Set bed-to-cab spacing according to previousmeasurement.

g. Remove each kit bolt, one at a time, and apply asmall amount of kit Loctite® onto threads.Install kit bolt and washer. TIGHTEN kit bolt to55 ft. lbs.

Rear of Vehicle

1. Spare tire

a. Lower and remove spare tire according to vehi-cle owner’s manual.

b. Remove two clips and winch tunnel from bed.

c. Remove two clips and winch horn from cross-member.

Kit Bolt(10 x 120mm),Washer

Kit Block

WinchTunnel

Clips

WinchHorn

Cross-Member

2. Rear bumper

a. Mark and cut two bumper brackets from bumpercrossmember as shown below.

b. Install cut bumper crossmember into two kitbrackets (rear bumper).

WARNING

The following procedure is intended only to enhancethe appearance of the vehicle. The rear bumper will nolonger be rated for towing of any kind. Towing with therear bumper after it has been lifted can result in death,serious personal injury, or damage to the vehicle. Tow-ing after the bumper has been lifted should be accom-plished using a rated Class III receiver type hitch.

Mark &Cut OffBumperBracket

BumperCross-Member

Saws-All

Mark & Cut


c. Install two kit brackets (rear bumper) onto framerails with six bolts. Align bumper crossmemberin two kit brackets (rear bumper). Snug bolts,but DO NOT TIGHTEN.

d. Install two kit brackets (rear bumper, support)onto two kit brackets (rear bumper) with four kitbolts (1/2” x 1-1/2”), eight kit washers (1/2”USS), and four kit nuts (1/2” Nylock). Snug, butDO NOT TIGHTEN.

e. Through center of four holes in two kit brackets(rear bumper, support), mark bumper cross-member.

f. Drill four 1/2” holes into bumper crossmembercorresponding to previously made marks.

Bolts

Kit Bracket(R. Bumper,Driver)

Cross-Member

MarkCrossmember

Kit Bracket(R. Bumper,Support)


g. Install two kit brackets (rear bumper, support)onto bumper crossmember with four kit bolts (1/2” x 1-1/2”), eight kit washers (1/2” USS), andfour kit nuts (1/2” Nylock). DO NOT TIGHTEN.

h. Install bumper onto two kit brackets (rearbumper) with six studs and six nuts.

i. Align bumper to bed according to previouslyrecorded bumper to bed measurements.


Cross-Member

Kit Bolts(1/2” x 1-1/2”),Kit Washers(1/2” USS),Kit Nuts(1/2” Nylock)

Kit Bracket(R. Bumper,Support)

Six Studs& Six Nuts

RearBumper



j. Install lower plastic step onto bumper andbumper crossmember.

k. TIGHTEN six studs and six nuts.

l. TIGHTEN six bolts and two kit brackets (rearbumper).

m. TIGHTEN eight kit bolts (1/2” x 1-1/2”) and twokit brackets (rear bumper, support).

n. Install upper plastic step onto bumper.

o. Connect two license plate wiring harnesses ontorear bumper.

p. Install spare tire onto vehicle.

RearBumper

LowerPlastic Step

UpperPlastic Step

RearBumper

LicensePlate Wiring Harness

RearBumper

3. Fuel filler

a. Loosen clamp and remove fuel filler hose fromfuel filler.

b. Install kit hose (1” x 3”) onto fuel filler with kitclamp (#20 hose). DO NOT TIGHTEN.

c. Install kit extension (fuel filler) into kit hose (1” x3”) with kit clamp (#20 hose). DO NOTTIGHTEN.

WARNING

Use extreme caution when working near the fuel linesand the fuel tank. Clean up spilled fuel immediately. Aspark could cause an explosion or fire resulting in seri-ous personal injury and property damage.

Clamp

FuelFiller

Fuel FillerHose

Kit Hose(1” x 3”)

FuelFiller

Kit Clamp(#20 Hose)

Kit Extension(Fuel Filler)

Kit Clamp(#20 Hose)

Kit Hose(1” x 3”)


d. Install fuel filler hose onto kit extension (fuelfiller) with clamp. DO NOT TIGHTEN.

e. Align top of fuel filler with bed side and installfuel filler hose onto fuel tank with clamp.

f. Install vent hose and clip onto fuel filler venttube.

g. Adjust fuel filler hose and kit hose (1” x 3”) andinstall fuel filler onto bed with bolt.

h. TIGHTEN kit clamps (#20 hose) and clamps.

i. Install fuel cap.

Fuel Filler

Clamp

Fuel FillerHose

Bed

FuelFiller

Bolt

Underside of Vehicle

1. Parking brake cables

a. Install two kit brackets (2-1/2” c-shaped) ontobottom center of cab with two nuts.

b. Install two parking brake cables onto two kitbrackets (2-1/2” c-shaped) with two kit bolts (1/4” x 1”), four kit washers (1/4” SAE), and two kitnuts (1/4” Nylock).

2. Crush blocks

a. Remove four rubber pads from two frame rails.

b. Install rubber pad on top of each kit spacer (2” x3” x 2”).

WARNING

Welding should be performed by a certified welder orwelding shop. Improper welding can damage vehicleand/or kit parts and cause serious personal injury.

Nuts

Park Brake Cables

Kit Bolts(1/4” x 1”),Kit Washers(1/4” SAE),Kit Nuts(1/4” Nylock)

Cab

Kit Brackets(2-1/2”C-Shaped)

Bed Rail

Pad

Frame Rail


c. Install four kit spacers (2” x 3” x 2”) betweenframe rail and bed rail and weld kit spacers (2” x3” x 2”) onto frame.

3. Exhaust ground strap

a. Install kit bracket (3” w/ stud) onto exhaust withnut.

b. Install ground strap onto kit bracket (3” w/ stud)with kit washer (1/4” SAE) and kit nut (1/4”Nylock).

Bed Rail& Pad

Kit Spacer(2” x 3” x 2”)

Frame Rail

ExhaustGround Strap

Kit Washer(1/4” SAE),Kit Nut(1/4” Nylock)

Exhaust Nut

Kit Bracket(3” W/ Stud)

4. Wire harness

a. Install kit bracket (3” w/ stud) onto passengerframe rail with bolt.

b. Install bracket and wiring harness onto kitbracket (3” w/ stud) with kit washer (1/4” SAE)and kit nut (1/4” Nylock).

c. Install plastic cover onto bracket.

Bracket &WiringHarness


Psgr. Side Frame


Bolt

PlasticCover

WiringHarness


Inside of Vehicle

1. Manual transmission

a. Mark cut and alignment marks along shift leverjust below bend.

b. Cut shift lever along cut mark.

CAUTIONUse wet rags to insulate plastic shift assembly compo-nents from welding heat. Damage may occur to shiftlever assembly and/or components if care is not takento protect components from heat while welding.

WARNING

Welding should be performed by a certified welder orwelding shop. Improper welding can damage vehicleand/or kit parts and cause serious personal injury.

ShiftAssembly

Cut Mark

AlignmentMark

c. Position kit extension (shift, 5/8” x 3”) betweentwo cut halves of shift lever and align previouslymade alignment marks. Weld kit extension intoplace.

d. Grind welds smooth and install shift leverassembly onto shift tower with three bolts.

e. Install shift tower boot onto shift tower using kitties (zip).

Kit Extension(Shift,5/8” x 3”)

ShiftAssembly

AlignmentMarks

Shift Tower

Bolts

Shift LeverAssembly

Shift Tower

Zip Ties

Shift TowerBoot


f. Install two inner shift boots onto shift lever andfloor with boot ring and four bolts.

g. Install wiring harness and bracket onto floor withbolt.

h. Install shift boot trim panel onto center console.

i. Install cup holder trim panel onto center console.

j. Install shift knob onto shift lever.

Bolts

Boot Ring

WiringHarness& Bracket

Bolt

Floor

Shift BootPanel

Shift Knob

Cup HolderPanel

Engine Compartment

1. Install heater core tube onto firewall with two nuts.

2. Install AC line and bracket onto driver side firewallwith two bolts.

3. Brake line bracket

a. Install kit bracket (2” w/ stud) onto lower hole oflower driver side firewall with bolt.

b. Install kit bracket (2” step w/ stud) onto upperhole of lower driver side firewall with bolt.

Firewall

HeaterTube

Nuts

Firewall

Bolts

AC Line& Bracket

Driver SideFirewall

Nut


Brake Line Bracket



c. Install brake line bracket onto two kit bracketswith two kit washers (1/4” SAE) and two kit nuts(1/4” Nylock).

4. ABS sensors

a. Install kit bracket (2” w/ stud) onto driver sidespring perch with bolt.

b. Install ABS harness and bracket onto kitbracket (2” w/ stud) with kit washer (1/4” SAE)and kit nut (1/4” Nylock).

c. Repeat above steps for passenger side ABSharness and bracket.

Dvr. Side Firewall

Kit Bracket(2” StepW/ Stud)

Nut

Brake LineBracket


FRONT

ABS Harness& Bracket


Bolt

SpringPerch


5. Steering shaft

a. Install kit extension (steering) into lower steer-ing shaft. Ensure marks on lower steering shaftand rack & pinion are aligned.

b. Install rack & pinion into kit extension (steer-ing), ensuring marks on lower steering shaft andrack & pinion are aligned.

c. Apply a small amount of kit Loctite® onto fac-tory bolt and kit bolt (3/8” x 1-1/4”).

d. Install and TIGHTEN bolts to 33 lb.-ft.

6. Install engine wiring harness onto engine and wheelwell with two clips.

WARNING

Verify the steering extension is securely installed asspecified in the instructions. Failure to do so maycause steering malfunction, resulting in property dam-age or serious personal injury.

Kit Extension(Steering)

Kit Bolt(3/8” x 1-1/4”)

Rack & Pinion

Lower Steering ShaftAlignmentMarks

Bolt

ElectricalTape

Clips

WiringHarness


7. Power steering reservoir

a. Remove cap and drain contents of reservoir intoclean drain pan or bucket.

b. Position drain pan or bucket beneath largediameter hose on passenger side of engine.

c. Remove clamp and large diameter hose fromengine and drain contents into drain pan orbucket.

d. Remove clamp and large diameter hose fromreservoir.

Reservoir

LargeHose

Drain Pan

Large Dia.Hose

Clamp

Reservoir

Clamp

Large Dia.Hose

e. Remove two factory hose clamps and heatshield from hose.

f. Install heat shield and two factory clamps ontokit hose (5/8” x 14”).

g. Install kit hose (5/8” x 14”) onto engine and res-ervoir with two factory clamps.

NOTE

This kit is supplied with two kit clamps (#10 hose) if thetwo factory clamps (above) do not fit over kit hose (5/8”x 14”).

HeatShield

Clamp

Hose

HeatShield

Clamps

Kit Hose(5/8” x 14”)


h. Install bracket onto passenger side wheel wellwith three bolts.

i. Install reservoir onto bracket.

j. Refill reservoir using power steering fluid fromdrain pan or bucket.

CAUTION

Reuse power steering fluid ONLY if fluid is not contam-inated. Follow vehicle owner’s manual instructions forrefilling power steering fluid. Contaminated orimproper fluid may cause damage and/or failure.

Bracket

Bolts

Reservoir

Bracket

8. Radiator brackets

a. Remove bolt and driver side bracket from radia-tor.

Brackets

Radiator

Bolt


b. Mark and cut bracket as shown.

Driver SideBracket

Mark & CutHere

AFTER CUT

c. Position kit bracket (radiator, driver) ontobracket and mark bracket through two holes inkit bracket. Ensure kit bracket is set to 3”.

d. Drill two 1/4” holes into bracket corresponding toholes in kit bracket (radiator, driver).

e. Install kit bracket (radiator, driver) onto bracketwith two kit bolts (1/4” x 1”), four kit washers (1/4” SAE), and two kit nuts (1/4” Nylock). Ensurekit bolt heads are facing out.

Driver SideBracket

Mark & DrillHere

Psgr. Side(Before Cut)

3”

Kit Bracket(Radiator,

Driver)

Set KitBracket Onto Dvr. SideRadiator Bracket To 3” Hole-To-Hole

Driver SideBracket

Kit Bracket(Radiator, Driver)

Kit Bolts(1/4” x 1”),Kit Washers(1/4” SAE),Kit Nuts(1/4” Nylock)


f. Remove rubber isolator from bracket and installonto large hole of kit spacer (2” x 3” x 1”).

g. Install kit spacer (2” x 3” x 1”) onto driver sideradiator pin.

h. Install kit u-nut (5/16”) onto kit spacer (2” x 3” x1”).

i. Mark and cut driver side bracket to clear radia-tor.

Driver SideBracket

Isolator


Isolator

Kit U-Nut(5/16”)


Driver SideBracket

Mark & Cut


j. Install bracket onto lower driver side radiatorwith bolt. DO NOT TIGHTEN.

k. Install bracket onto kit spacer (2” x 3” x 1”) withkit washer (5/16” USS) and kit bolt (5/16” x 1”).

l. TIGHTEN lower bolt and kit bolt (5/16” x 1”).

m. Repeat above steps for passenger side bracket.

Driver SideBracket

Kit Bracket(Radiator, Driver)

Bolt

Radiator

Kit Bolt(5/16” x 1”),Kit Washer(5/16” USS)



9. Power steering cooler line

a. Install kit bracket (2” Z-shaped) onto passengerside frame with bolt.

b. Install power steering cooler line onto kitbracket (2” Z-shaped) with kit bolt (1/4” x 1”),two kit washers (1/4” SAE), and kit nut (1/4”Nylock).

10. Fan shroud & radiator

a. Install radiator onto core support brackets.

b. Remove kit ties from core support and AC con-densor.

CAUTION

CAREFULLY bend AC line. Over bending AC line maycause the line to crack and/or leak.

Power Steering Cooler Line

Kit Bracket(2”Z-Shaped)

Bolt Psgr. Side Frame

Kit Bolt(1/4” x 1”),Kit Washers(1/4” SAE),Kit Nut(1/4” Nylock)

CoreSupport

Kit Ties

ACCondenser

c. Slightly bend AC line down on AC condenserand install AC condenser onto radiator with twobolts.

d. Remove two rubber isolators from two radiatorbrackets and install onto large hole two kit spac-ers (2” x 3” x 1”).

e. Install two radiator brackets onto core supportwith two bolts.

ACCondenser

Radiator

Bolts

AC Line

RadiatorBracket

Isolator


f. Install two kit u-nuts (5/16”) onto two kit spac-ers (2” x 3” x 1”).

g. Install radiator onto radiator brackets with two kitwashers (5/16” USS) and two kit bolts (5/16” x1”).

h. Install fan and fan clutch onto pulley with fournuts.

Kit U-Nut(5/16”)

RadiatorBracket

Bolt


CoreSupport

Kit Washers(5/16” USS),Kit Bolts(5/16” x 1”)

RadiatorBrackets

Pulley

Nuts

Fan &Fan Clutch

i. Install fan shroud and electric fan onto radiatorwith three bolts.

j. Connect AC condenser and electric fan wiringharnesses.

k. Install two transmission cooler lines onto radia-tor with two clamps, if equipped.

l. Install lower fan shroud onto fan shroud with twoclips.

Radiator

Bolts

FanShroud

ACCondenser

WiringHarnesses

ElectricFan

Trans. CoolerLines & Clamps

Radiator

FanShroud

Clips

LowerFan Shroud


m. Install upper and lower radiator hoses with twoclamps.

n. Install overflow hose onto radiator with clamp.

o. Clip hoses onto fan shroud, if necessary.

p. Refill radiator using coolant from drain pan orbucket.

q. Install radiator cap.

CAUTION

Reuse coolant ONLY if coolant is not contaminated.Follow vehicle owner’s manual instructions for refillingcoolant. Contaminated or improper coolant may causedamage and/or failure.

Clamp &Upper Hose

Clamp &Lower Hose

RadiatorCap

Clamp

OverflowHose

11. Airbox

a. Install air filter into airbox.

b. Install airbox cover onto airbox with two clips.

c. Connect wiring harness onto airbox cover.

d. Install intake onto throttle body and airbox coverwith two clamps. DO NOT TIGHTEN clamps.

e. Install intake chamber onto passenger sidebracket with bolt. DO NOT TIGHTEN.

f. Install kit spacer (.250”) between intake cham-ber mount and driver side bracket.

WiringHarness

Intake

AirboxCover

ThrottleBody Clamp

Intake

AirboxClamp

Psgr. SideBolt

IntakeChamber


g. Install intake chamber onto driver side bracketwith kit washer (1/4” SAE) and kit bolt (6mm x30mm).

h. TIGHTEN two clamps and intake chamber bolt.

i. Install vent hose onto intake chamber withclamp.

12. Install engine cover onto engine with two bolts.

Kit Bolt(6 x 30mm),Kit Washer(1/4” SAE)

Kit Spacer(.250”)

Driver SideBracket

VentHose

Clamp

IntakeChamber

EngineCover

Bolts

Front of Vehicle

1. Front bumper

a. Apply a small amount of kit Loctite® (6ml bottle)onto threads of two bolts and install kit bracket(front bumper, driver) onto driver side frame railwith two bolts. DO NOT TIGHTEN.

b. Repeat above step for kit bracket (front bumper,passenger).

c. Apply a small amount of kit Loctite® (6ml bottle)onto threads of two kit bolts (12mm x 30mm)and install kit bracket (front bumper, driver) ontobottom of frame rail with two kit bolts (12mm x30mm) and two kit washers (12mm).

d. Apply a small amount of kit Loctite® (6ml bottle)onto threads of two bolts and install tow hookand kit bracket (front bumper, passenger) ontobottom of frame rail with two bolts.

Kit Bracket(F. Bumper,Driver)

Bolts

FrameRail

Kit Bolts(12 x 30mm),Kit Washers(12mm)

Kit Bracket(F. Bumper,Driver)

FrameRail

Bolts

Tow Hook


e. TIGHTEN six factory bolts and two kit bolts(12mm x 30mm).

f. Position lower mount holes of bumper supportonto kit bracket (front bumper) studs and markinterference between top bolts and backside ofbumper support.3

g. Cut or drill two holes into bumper support corre-sponding to upper two bolts.

Mark BumperSupport

Top Bolt

Bottom Bolt

Top Bolt

BumperSupport

Mark Or DrillHole

AFTER CUT

h. Install bumper support onto two kit bracket(front bumper) studs with two kit washers (1/2”SAE) and two kit nuts (1/2” Nylock). DO NOTTIGHTEN.

i. Install bumper support onto two kit brackets(front bumper) with two kit bolts (1/2” x 1-1/2”),four kit washers (1/2” SAE), and two kit nuts (1/2” Nylock).

j. TIGHTEN two kit bolts (1/2” x 1-1/2”) and two kitnuts (1/2” Nylock) on two kit bracket (frontbumper) studs.

k. Install bumper onto upper bumper support withfour bolts. DO NOT TIGHTEN.

l. Connect two fog light wiring harnesses, ifequipped.

BumperSupport

Kit Nuts(1/2” Nylock),Kit Washers(1/2” SAE)

Kit Bracket(F. Bumper)

Kit Bolts(1/2” x 1-1/2”),Kit Washers(1/2” SAE),Kit Nuts(1/2” SAE)

Top OfBumperSupport

Bolts

FrontBumper

Upper BumperSupport


m. Bend lower bumper brackets to meet lowerbumper support brackets.

n. Install bumper onto lower bumper support brack-ets with two bolts.

o. TIGHTEN six bumper bolts.

p. Install two bumper side supports onto driver andpassenger side of bumper with two bolts.

BEFOREBEND

LowerBumperBracket

LowerBumperSupportBrackets

AFTERBEND

FrontBumper

Bolts

FrontBumper

SideSupport

Bolt

2. Grill

a. Install grill onto core support with four turn clipsand four lower clips.

b. Install top of grill onto core support with six pop-up clips.

3. Skid plate

a. Mark and cut skid plate as shown.

Grill

TurnClips

Pop-UpClips

Grill

Mark & Cut

Skid Plate

AFTER CUT


b. Install kit u-nut (5/16”) onto two kit spacers (2” x3” x 1”).

c. Install two kit spacers (2” x 3” x 1”) onto bumpersupport with two front skid plate bolts.

d. Install skid plate onto crossmember with tworear skid plate bolts.

e. Install skid plate onto two kit spacers (2” x 3” x1”) with two kit washers (5/16” USS) and two kitbolts (5/16” x 1”).

Kit U-Nut(5/16”)


Front SkidPlate Bolts

Kit Bolts(5/16” x 1”),Kit Washers(5/16” USS)

Kit Spacers(2” x 3” x 1”)

Bumper Support

FrontBumper

Skid Plate

Rear SkidPlate Bolts

4. Lower fascia

a. Mark and cut lower fascia as shown.

b. Install lower fascia onto bumper with four screwsand two bolts.

Mark & CutBEFORECUT

AFTERCUT

FrontBumper

Screws& Bolts

LowerFascia


After Completing InstallationInside Cab

1. Install airbag fuse and fuse cover.

Engine Compartment

1. Install battery into vehicle with battery tie downs.

2. Connect both battery cables. Connect positive cablefirst, then negative cable.

Glove Box

Cover

PositiveCable

BatteryTie-Downs

NegativeCable

Miscellaneous

1. Apply kit label (warning) onto dashboard in plainsight of all vehicle occupants.

2. Check all fasteners to ensure they are tight.

3. Ensure all wires, hoses, cables, etc. are properlyconnected and there is ample slack.

4. Adjust headlights.

5. Remove radiator cap. Start engine and top off cool-ing system. Purge air from cooling system accordingto vehicle owner’s manual instructions. Install radia-tor cap.

Dynamic Vehicle Check

1. Check steering in both directions to ensure thatthere is no bind. Check operation of clutch, brakesystem, and parking brake. Check operation oftransmission and transfer case. Ensure there is fullengagement in all gears and 4WD ranges. Checkbattery connections and electrical component oper-ations. Test-drive vehicle.

WARNING

If the engine cooling system is hot, the coolant will beHOT and UNDER PRESSURE. To prevent seriouspersonal injury, wait until the cooling system is com-pletely cool before removing the cap from the radiator.

WARNING

Retorque all fasteners after 500 miles and after off roaduse. All body lift components should be visuallyinspected and fasteners retorqued during routine vehi-cle servicing.

CAUTION

Performance Automotive Group does not recommendany particular wheel and tire combinations for use withits body lifts and cannot assume responsibility for thecustomer’s choice of wheels and tires. Refer to yourowner's manual for recommended tire sizes and warn-ings related to the use of oversized tires. Larger wheeland tire combinations increase stress and wear onsteering and suspension components, which leads toincreased maintenance and higher risk for componentfailure. Larger wheel and tire combinations also alterspeedometer calibration, braking effectiveness, centerof gravity, and handling characteristics. Consult anexperienced local off road shop to find what wheel andtire combinations work best with your vehicle.


AccessoriesKit# 6423: Front & Rear Gap Guards

NOTE

All warranty information, instruction sheets, and otherdocuments regarding the installation of this productmust be retained by the vehicle owner. Informationcontained in the instructions and on the warranty cardwill be required for any warranty claims. The vehicleowner needs to understand the modifications made tothe vehicle and how they affect vehicle handling andperformance. Failure to provide the customer with thisinformation can result in damage to the vehicle andsevere personal injury.

Kit Parts ListQty. Description

NOTE

Depending on the vehicle configuration (automatic ormanual transmission, 2WD or 4WD, cab length, bedlength, etc.), some parts may not be used.

10 Block (3" x 2")4 Block (3" x 3")10 Bolt (1/2" x 1-1/2")7 Bolt (1/4" x 1")6 Bolt (10mm x 120mm)8 Bolt (12mm x 180mm)2 Bolt (12mm x 30mm)1 Bolt (3/8" x 1-1/4")6 Bolt (5/16" x 1")1 Bolt (6mm x 30mm)1 Bracket (2" step w/ stud)3 Bracket (2" w/ stud)1 Bracket (2" Z-shaped)2 Bracket (2-1/2" C-shaped)2 Bracket (3" w/ stud)1 Bracket (front bumper, driver)1 Bracket (front bumper, passenger)1 Bracket (radiator, driver)1 Bracket (radiator, passenger)1 Bracket (rear bumper, driver)1 Bracket (rear bumper, passenger)2 Bracket (rear bumper, support)2 Clamp (#10 hose)2 Clamp (#20 hose)1 Decal (bumper warning)1 Decal (logo)1 Decal (warning)1 Extension (fuel filler)1 Extension (shift, 5/8" x 3")1 Extension (steering)1 Hose (1" x 3")1 Hose (5/8" x 14")1 Loctite® (6ml bottle)14 Nut (1/2" Nylock)12 Nut (1/4" Nylock)1 Spacer (.250")6 Spacer (2" x 3" x 1")4 Spacer (2" x 3" x 2")6 Tie6 U-nut (5/16")6 Washer (1/2" SAE)24 Washer (1/2" USS)17 Washer (1/4" SAE)

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