BMR Suspension RK002 User Manual

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BMR MANUAL RACK CONVERSION KIT

PART# RK002

Before proceeding it should be noted that this kit is designed for use on the OE K-member or any K-

member designed for use with the OE rack. If you have a BMR K-member with a -1 part number extension,

it is designed .for a manual rack and requires Part #RK001.

Installation Procedure:

NOTE: Center the steering before proceeding.

1. Lift vehicle and support with stands under the
frame rails.

2. Remove both front wheels/tires. Open hood.

3. Locate the steering shaft on the drivers' side.
Using an 11mm socket and long extension, remove
the cross-bolt located on the upper portion of the
steering shaft as shown in Image 1.

Steps 4-10 involve power steering pump removal. If you
have already removed your power steering
pump, skip these steps and proceed to step 11.

4. Using a 15mm wrench or socket, loosen the belt tensioner and remove the serpentine belt.

5. Using an 18mm line wrench, loosen and remove both power steering lines. Plug the lines
to prevent fluid loss.

6. Drain the engine coolant and remove the upper radiator hose. NOTE: this step is necessary

to gain access for removal of the power steering pump pulley.

7. Using a power steeling pulley removal tool, remove the pulley from the front of the pump
to gain access to the mounting bolts behind it.

8. Using a 13mm socket, remove the three bolts securing the pump. Remove pump.

9. Using a 15mm socket, remove the two
bolts securing the power steering pump
bracket and remove the bracket.

10. Without the power steering pump it
is necessary to use a shorter drive belt.
Using a 51.5-52.5" long belt, re-route
the belt to match the image to the left.

11. Remove the cotter pins from both
outer tie rod ends.

12. Using an 18mm wrench, loosen the
castle nuts and remove. Strike the
knuckle with a brass hammer where the
tie rod end is inserted to free the tie rod
end from the knuckle.

13. Using a 15mm wrench and an 18mm
socket with a short extension, loosen the
two rack mounting bolts. The passenger side bolt can be removed however the drivers' side
bolts cannot be removed due to oil pan interference.

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BMR MANUAL RACK CONVERSION KIT (Cont.)

PART# RK002

NOTE: At this point there are two options for removing and re-installing the drivers' side
bolt. The preferred method requires raising the motor to remove the bolt however this is a
labor intensive process and can be skipped by using the second option. The second option
involves cutting the bolt to remove it and installing a new one from the bottom. Both options
are illustrated below.

OPTION 1:

1) Remove negative battery cable.

2) Using a 13mm wrench, remove the power wire from the back of the alternator.

3) Remove the rear mounting bolt on the alternator using the same 13mm wrench.

4) Using a 15mm socket, remove the front two mounting bolts from the alternator.

5) Remove alternator.

6) Using two 18mm wrenches, loosen and remove the nuts from both motor mount
bolts.

7) Place a block of wood and a hydraulic jack under the oil pan and lift the motor to
Remove the load off the motor mount bolts. Remove both bolts.

8) Jack the motor up until it is high enough to remove the drivers' side rack bolt.

OPTION 2:

1) Using a Sawzall, body saw or similar cutting tool, cut off the head of the drivers'

side rack bolt. NOTE: Depending on the saw, it may be necessary to remove the

sway bar to gain access to the bolt.

2) Remove the bolt from the bottom.

14. Remove the rack and pinion and steering shaft assembly. It may be necessary to use a
pry-bar to slide it out of the mounts. It may also require a few taps on the upper steering joint
to knock it loose from the steering column.

15. Verify that the new manual rack is centered by using the following procedure: turn the
input shaft all the way in one direction then measure the distance from the end of the tie rod
end to the rack mounting flange as shown in IMAGE 3. Now turn the shaft all the way in the
opposite direction and record this measurement as well. Subtract the smaller number from
the larger and this will be your centering measurement.

16. Thread the BMR outer tie rod ends onto the manual rack approximately half-way.
Position the two racks next to each other and adjust the tie rods until the overall width is as
close as possible.

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