Rough Country 5040 User Manual

90504000

INSTRUCTION SHEET

’73 - ’91 CHEVY/GMC FRAME REINFORCEMENT

FOR SOLID AXLE ½ AND ¾ TON TRUCKS

5040

Please read instructions before beginning installation. Check the kit hardware against the parts list. Be sure you have all needed parts and
know where they go.

5040 PARTS LIST

GM Frame Section Bottom

GM Frame Section Side

NOTES:

1. This bracket system is not intended as a frame rail section replacement. It is intended use is a frame section support for use on frames
where minor fatigue and/or cracks have started to develop about the steering gear box area.

2. Before starting verify that the frame rail is straight and in alignment. If you can not determine this yourself check with your local frame
shop.

3. This bracket system requires welding. The welding should be done by a certified welder (welder needs complete understanding of
MIG welding). Welding wire to be used is ER-70-S, using 100% CO2sheilding gas in a controlled environment.

INSTALLATION INSTRUCTIONS

Step 1. Lift front of vehicle and place safety stands under front of axle

Step 2. Remove steering gear box. This is done by removing steering

Step 3. Place side section on frame and determine if brake line will have

Step 4. On vehicles equipped with power steering you must remove

Step 5. Check frame for cracks. At the end of any cracks drill a small

Step 6. Fully weld the length of all cracks and then grind flush so that the

Step 7. Install new side support plate (included in kit) using bolts, nuts

Step 8. With plate installed and frame free of any dirt, grease, oil or

Step 9. Now the skip weld of the side plate is complete, you must go

Step 10. Install the bottom cover plate so that the two holes in it line up

Step 11. Once again c-clamp the unit for as plat and flush fit as possible

Step 12. Do not make a solid continuous weld. Skip weld only in areas shown.
Step 13. Install steering gear box onto frame. Wire brush the threads on the four retaining bolts and clean out the threaded holes in the

housing. Remove drivers side tire.

drag link assembly, steering shaft (you will probably need a
pitman arm separation tool)and gear box to frame bolts.

to be relocated for installation. After installation reinstall brake
line by drilling a whole in frame support.

hydraulic lines from gear box prior to removing gear box from
frame. Keep lines in upright position and seal ends so
contamination can not enter system.

stop hole (1/8 “ diameter). Grind a small v-grove along the
length of the crack. Be careful to only grind a minimum of
material away. Try not to enlarge the crack.

new support plate lays as flat as possible against the frame rail.

and washers on frame rail through gear box mounting holes.
Tighten the four bolts. (It may be necessary to use a c-clamp to
obtain a flat, flush fit on the support plate.)

scale, you can begin to skip weld unit into place. Do not make a
solid continuous weld. Skip weld only in areas shown in the
diagrams . Plug weld the elongated holes for added coverage.

back and fully weld the bottom edge of this plate to the frame.

with the existing rivets on the bottom of the frame rail.

for welding.

gear box. Torque the four bolts in a criss-cross pattern to 70 ft. lbs.

Plug Weld

Steering Gear Box

Locate with rivets

Page 1

Brake Line

INSTRUCTION SHEET

Step 14. Install steering shaft to gear box and torque fastners to 25 ft. lbs.

Diagram #1

Frame

Frame Support lower plate

If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products.

MAINTENANCE INFORMATION
It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 100 miles and then every 1000 miles. Wheel
alignment steering system, suspension and driveline systems must be inspected by a qualified professional mechanic at least every 3000
miles.

Diagram #2

Frame Support side plate

Steering Box

Technical Assistance - [phone]

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