1. Disconnect the negative terminal on the
battery. With the vehicle on level ground
and the emergency brake set, block the
front tires.
2. Jack up the rear of the vehicle and
support the frame rails with jack stands.
Never work under an unsupported
vehicle!
3. Remove the rear tires.
4. Remove the spare tire.
5. You do not need to remove the bed for
this installation, but it will make the
installation much easier.
6. You will need the following tools:
a. 90’ drill
b. ½” drill bit
c. ¾” wrench
d. ¾” – ½” drive socket and ratchet or impact gun
e. 13MM socket and ratchet
f. 1-1/4 wrench (for the top bolt on the bump stop)
7. Hardware Included:
a. 6 – 4 ½” x ½” Grade 8 Bolts
b. 4 – 4” x ½” grade 8 Bolts
c. 6 – 1 ½” x ½” Grade 8 Bolts
d. 32 - ½” Grade 8 Washers
e. 16 – ½” Locknuts
f. 4 – 3/16” x 2” x 2” x ½” OD Square Washers
1. Remove factory stock bump stop and mount from the frame.
2. Locate the Bump Stop Assemblies, determine which
are the driver and passenger sides. Use the hole
from the factory bump stop and install bolt to hold
the side frame gusset bracket to the frame. Make
sure to tighten the factory 13mm bolt to ensure that
the plate is mounted securely before moving to the
next step. Do this on both sides of the truck
3. Using the Bump Stop Assemblies as a template, drill a ½”
hole through the frame gusset and into the inside portion
of the stock frame. Pay attention to drill as straight as
possible.
**** Caution: Be careful not to drill into the factory hard
brake lines on the inside of the framerail on the driver’s
side of the truck.
4. Use the 4½” x ½” Grade 8 Bolts to go through the bump
stop bracket assembly, the side frame gusset plate, and through the stock frame. Place one ½”
washer on the bolt and insert from the outside inward.
5. Locate the 3/16” thick square 2” x 2” plates. Place
these plates on the bolt on the inside of the frame rail.
Then place a standard ½” washer over the threaded
end and start the nut on the bolt. ***Do not tighten
these bolts yet. It will be tightened later.
6. Locate the 1-1/2” tube cross member. Slide the tube up
over the exhaust and on top of the frame rail. Line
these plates up with the bump stop can assembly.
***The cross member mount in the center is tapered
with the longer (bigger) side toward the Rear of the
truck. This will line up with the under frame support.
7. Install 4 of the 1½” x ½” Grade 8 Bolts with washers through
the cross member outer mounting plate to attach it to the
bump stop mount assembly. Use washers and start the
nuts. ****Do not tighten bolts yet.
8. Locate the large triangular frame support assembly. Place
the assembly under the truck with the wide end facing the
rear. From under the frame place the assembly against the
top plate of the cross member from step 7.
9. Locate the 1½” x ½” Grade 8 Bolts with washers to secure the
triangular frame support to the cross member through the 2
holes. Make sure you put washers on the bolts on both sides
and install the nut on the threaded end. Tighten these bolts
now.
10. Next, locate the 2 holes in the front smaller side of the
triangular frame support. Take the 90’ drill and ½” drill
bit and drill through the frame assembly through both
sides of the cross member. Install 4½” x ½” Grade 8 Bolts
to secure the triangular frame support to the factory
cross member. Make sure you use washers and put the
nuts on the threaded end of the bolt. ****Do not
tighten the bolts yet.
11. Locate the 4 holes in the rear larger side of the triangular
frame support. Again, take the 90’ drill and ½” drill bit and drill through the stock cross member.
Install 4½” x ½” Grade 8 Bolts to secure the triangular frame support to the stock cross member.
Make sure you use washers and put the nuts on the threaded end of the bolt.
12. Now tighten all of the bolts mounting the triangular frame support to the cross members. You
should have all 8 bolts mounting this assembly tight.
13. Locate the bump stop and remove the Schrader valve cap
and mounting nut. Insert the bump stop into the outer
bump stop mount assembly. Align the bump stop
locating pin in the top cap of the mounting can. This will
slide in and must be located before tightening the nut on
the top mount.
****Make sure you align the pin before tightening the
nut.
14. Tighten the top nut on both bump stops to ensure they
are secure. Replace the Schrader valve cap.
15. Locate the bump stop mount pad assembly and u-bolts.
Set the bump stop pad on the top of the axle tube near
the spring perch. Slide the u-bolt up from the bottom of
the axle assembly through the mounting holes in the
bump stop pad assembly. This will fit just between the
shock mount and the spring perch on the axle. Make sure
the bump stop pad is aligned on the axle to meet the
bump stop when the suspension collapses. Follow step
18 for the correct alignment.
16. To ensure they are aligned correctly you must re-install the rear wheels and let the truck down off
the jack stands to check for the alignment of the pads with the bump stops. The bump stop shaft
should be 90 degrees to the pad when looking at the contact area where the bump stop will touch
the bump stop pad on the rear axle. You should rotate the bump stop pad and u-bolts until they line
up with the bump stop before tightening the nuts on the u-bolts. Once aligned, tighten the nuts on
the u-bolts evenly by tightening them a little at a time and going in a clock wise rotation as you
tighten.
17. Re-install spare tire.
18. Check all of the mounting bolts that you have installed
19. Test drive truck over bumpy terrain.
20. You will hear contact from the bump stop and the mounting plate. This is normal and is expected.
21. . Check, and re-tighten if needed, all mounting bolts after 100 miles and periodically thereafter.
For additional support or technical questions,
please call 480.671.0820 or
email info@addictivedesertdesigns.com
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