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400 W. Artesia Blvd. Fax: (310) 747-3912
Compton, CA 90220 Ph: (877) 695-7812
www.trailmastersuspension.com
2009– 2013 FORD F-150 2WD ONLY
2 1/2” FRONT SPACER KIT
KIT# TM402 & TM402N
TM402 &
TM402N
Revised
8.9.13
WARNING
Installation of a Trail Master suspension lift kit will
change the vehicle’s center of gravity and handling characteristics both on- and off-road. You must drive the vehicle safely! Extreme care must be taken to prevent vehicle rollover or loss of control, which could result in serious injury or death. Avoid sudden sharp turns or abrupt
maneuvers and always make sure all vehicle occupants
have their seat belts fastened.
WARNING
Before you install this kit, read and understand all instructions, warnings, cautions, and notes in this instruction sheet and in the vehicle owner’s manual.
CAUTION
Proper installation of this kit requires knowledge of the
factory recommended procedures for removal and installation of original equipment components. We recommend
that the factory shop manual and any special tools
needed to service your vehicle be on hand during the
installation. Installation of this kit without proper knowledge of the factory recommended procedures may affect
the performance of these components and the safety of
the vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components
install this kit.
WARNING
Many states and municipalities have laws restricting
bumper heights and vehicle lifts. Consult state and local
laws to determine if the changes you intend to make to
the vehicle comply with the law.
WARNING
The installation of larger tires may reduce the effectiveness of the braking system.
WARNING
Always wear eye protection when operating power tools.
WARNING
Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.
WARNING
DO NOT combine suspension, body, or other lift devices.
Use of vehicle with combined lifts may result in unsafe
and/or unexpected handling characteristics.
WARNING
This kit should only be installed on a vehicle that is in
good working condition. Before you install the kit, thoroughly inspect the vehicle for corrosion or deformation of
the sheet metal. If the vehicle is suspected to have been
in a collision or misused, do not install this kit. Off-road
use of your vehicle with this kit installed may increase
the stress applied to the factory components. Failure to
observe this warning may result in serious personal injury and/or severe damage to your vehicle.
NOTE
Lift height may vary depending on vehicle configuration,
engine size, additional accessories, the factory suspension package, and vehicle’s condition.
NOTE
Trail Master recommends using thread locking com-
1
pound on the threads of all kit nuts and bolts unless
specified otherwise in these instructions.
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TM402 &
TM402N
Revised
8.9.13
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Page 3
Before Starting Installation
NOTE
TM402 &
TM402N
Revised
8.9.13
Torque Specifications:
See factory service manual for torque values when
reusing OE fasteners.
Kit parts are prefaced by the word kit and appear in
bold print.
1. Carefully read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by
checking the parts list at the end of this document.
3. Only install this kit on the vehicle for which it is
specified. If anytime during the installation you encounter something different from what is outlined in
the instructions, call technical support at (877) 695-
7812.
4. Park vehicle on a clean, dry, flat, level surface and
block tires so vehicle cannot roll in either direction.
5. Measure ride height with the vehicle supporting its
own weight on level ground. To settle the suspension,
the vehicle should be driven forward at least 10 feet
immediately prior to taking these measurements. Ride
height is the measurement from the center of the axle
straight up (vertical) to the fender lip. Record this
measurement for all four wheels.
NOTE
See factory service manual for torque values when re-using
OE fasteners.
Bolt Size Grade 5 (ft.-lbs.) Grade 8 (ft.-lbs.)
1/4”-20 10 10
1/4”-28 10 12.5
5/16”-18 17 22.5
5/16”-24 20 25
3/8”-16 30 40
3/8”-24 35 45
7/16”-14 50 65
7/16”-20 55 70
1/2”-13 75 100
1/2”-20 80 115
9/16”-12 105 135
9/16”-18 115 150
5/8”-11 150 195
5/8”-18 160 210
3/4”-16 175 225
NOTE
This kit can be installed on 2009-2013 vehicles
equipped with an electric steering rack
Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the
factory service manual. When re-assembling the vehicle it is recommended by the vehicle manufacturer
that certain fasteners are replaced in order to maintain proper retention characteristics. This system
may not include all replacement hardware as recommended by the factory service manual. Additional
replacement hardware should be obtained prior to
installation of this system to meet the requirements
of the factory service manual.
Engine Compartment
1. Disconnect both battery cables. Disconnect nega-
tive cable first, then positive cable.
Wheel & Tire Requirements
The factory wheel and tire combination will fit once this
kit is installed.
NOTE
In order to maintain proper alignment for the
life of the vehicle, the installation of a cam
alignment kit may be necessary. This kit is
now available for purchase from Specialty
Products Company PN# S/P86230.
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TM402 &
TM402N
Revised
8.9.13
Install Front
Suspension
1. Be sure you are working on a level surface. Block the rear tires and raise the
front of the vehicle. Support the frame
with jack stands under the front crossmember.
2. Remove the front wheels.
3. Work on one side of the vehicle at a time.
4. Remove the tie rod end nut and separate
from the knuckle using the appropriate
tool.
6. Save for reinstallation.
7. Unbolt the upper ball joint nut, but do not
remove it from the knuckle. Separate using the appropriate tool.
Upper Ball
Joint
8. Remove upper ball joint nut and carefully
lower the A-arm assembly. Save hardware for reinstallation.
9. Remove the lower strut bolt from the
lower control arm. Save the hardware for
reinstallation. Be sure to note the direction of the bolt for reinstallation.
Tie Rod end
5. Unbolt the sway bar from the sway bar
end links. Save hardware for reinstallation.
Sway Bar
End Link
Lower Strut
Mount Bolt
10. Remove (3) upper strut tower nuts hold-
ing the strut assembly to the strut tower.
Save the hardware for reinstallation.
Upper Strut
Mount Nuts
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TM402 &
TM402N
Revised
8.9.13
11. Remove the strut assembly from the vehicle.
12. Now would also be a good time to inspect
the struts for damage or fluid leakage.
Replace if necessary.
13. Install the strut spacer (94-2834m) onto
the OE strut mounting studs. Secure with
the previously removed OE nuts. Torque
the nuts to factory specifications.
NOTE: Be sure to use thread locker
on the OE nuts.
Strut Spacer
(94-2834m)
NOTE: Be sure to use thread locker
on the OE bolt.
16. Reinstall the knuckle to the upper ball
joint and secure using the OE nut.
Torque the upper ball joint nut to factory
specifications.
NOTE: It may help to use (2)
wrenches to tighten the upper ball joint
nut. One to tighten the nut and one to
keep the ball joint stud from spinning.
Upper Ball
Joint Nut
14. Install the strut assembly into the strut
tower and start the (3) upper 10mm
flange nuts. (Make sure that the bottom of
the strut is aligned as well) Torque the
upper strut tower 10mm nuts to 60 ft./lbs.
NOTE: Be sure to use thread locker on
the OE nuts.
Strut
Assembly
15. Install the lower strut bolt in the original
position and torque to manufacturers
specifications.
17. Reconnect the sway bar to the end links
using the previously removed OE hardware.
18. Reinstall the tie rod end to the knuckle.
Torque to factory specifications.
19. Unbolt the ground cable bolt from the
front upper A-arm pocket. Save hardware
for reinstallation.
20. Install the bump stop (15-11018) to the
bump stop bracket (94-5456 drvr and 94-
5459 pass) using the supplied 3/8” hardware.
21. Install the bump stop bracket (94-5456
drvr and 94-5459 pass) into the front upper A-arm pocket. Secure in place using
the 1/2” X 1 1/4” bolt in the existing front
inner hole. Tighten the bolt.
NOTE: Be sure the bracket is sitting
flat on the frame
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15-11018
Bump Stop
TM402 &
TM402N
Revised
8.9.13
Front Upper
A-Arm
Mounting
Pocket
Ground
Cable
Bolt
1/2” X
1 1/4”
Bolt
Drill 3/8” Hole
Secure Using
3/8” x 1” Bolt
Bump Stop
94-5456
drvr and
94-5459
pass
Front of Vehicle
22. Using the rear outer hole in the bracket as
a guide, drill through the A-Arm pocket
using a 3/8” drill bit. Secure using the
3/8” X 1” bolt and hardware. Torque the
3/8” and 1/2” hardware according to the
torque chart on page 3.
23. Reinstall the ground cable and bolt using
the previously removed OE hardware.
24. Repeat steps 5 through 24 on the remaining side of the vehicle.
25. Reinstall the front wheels.
26. Now would also be a good time to inspect
the rear shocks for damage or fluid leakage. Replace if necessary.
IMPORTANT! BE SURE TO BRING
THE VEHICLE IMMEDIATELY TO A
REPUTABLE ALIGNMENT SHOP TO
BE ALIGNED!
27. Torque all bolts to factory specifications.
Re-torque all bolts after 500 miles.
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Install Rear
Suspension
1. Block the front tires and raise the rear
of the vehicle. Support the frame with
jack stands forward of the rear springs.
2. Remove the rear wheels.
3. Unbolt the lower shock mount bolts or
unbolt and remove the rear shocks on
both sides of the vehicle. It may be
necessary that you slightly raise the
axle to unload the shocks for removal.
4. Work on one side of the vehicle at a
time.
TM402 &
TM402N
Revised
8.9.13
5. Reinstall the lower shock mounts using the previously removed OE lower
bolts or install the provided Trailmaster rear shock (TM75801W) using the
previously removed OE hardware.
Torque per OE specifications.
6. Check all hardware at this time to ensure that everything is tight. Check for
adequate clearance on all repositioned
brake lines and emergency brake cables. Make sure you check with the
suspension fully extended, and compressed.
7. Reinstall the wheels and lower the vehicle to the ground. Torque the lug
nuts according to the wheel manufacturers recommendations.
8. Torque all bolts to factory specifications. Re-torque all bolts after 500
miles.
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Engine Compartment
TM402 &
TM402N
Revised
8.9.13
Troubleshooting
1.Connect both battery cables. Connect positive
cable first, then negative cable.
Miscellaneous
1.Apply kit label (warning) onto dashboard in plain
sight of all vehicle occupants.
2.Adjust headlights.
3.Check all fasteners to ensure they are tight.
4.Ensure all wires, hoses, cables, etc. are properly connected and there is ample slack.
WARNING
If the engine cooling system is hot, the coolant will be
HOT and UNDER PRESSURE. To prevent serious personal injury, wait until the cooling system is completely
cool before removing the cap from the radiator.
5.Start engine and top off cooling system. Purge
air from cooling system according to manufacturer’s instructions. Install radiator cap.
6.Align vehicle
1. Once the vehicle has been lifted, some vehicle
vibration may become more apparent to the
driver. The reason for the vibration may be due to
the angle at which the driveline operates. A suspension lift increases the operating angle of the
driveline and normal vehicle vibration is amplified.
Some vibration characteristics are as follows:
a. Acceleration vibration: vibration felt during
acceleration of the vehicle and caused by the
rear axle pinion angle being too high.
b. Deceleration vibration: vibration felt during
deceleration of the vehicle and caused by the
rear axle pinion angle being too low.
c. General vibration: vibration caused by rear pinion angle in relation to the transfer case output
shaft.
Dynamic Vehicle Check
1. Check steering and suspension in all positions
to ensure that there is no bind and adequate
clearance between all moving, fixed, and
heated members. Check operation of clutch,
brake system, and parking brake. Check operation of transmission and transfer case. Ensure there is full engagement in all gears and
4WD ranges. Check battery connections and
electrical component operations. Test-drive
vehicle.
WARNING
Retorque all fasteners after 500 miles and after off road
use. All suspension lift components should be visually
inspected and fasteners retorqued during routine vehicle
servicing.
WARNING
Re-torque all fasteners after 500 miles and after
off road use. All suspension lift components
should be visually inspected and fasteners retorqued during routine vehicle servicing.
Caution:
Larger wheel and tire combinations increase
stress and wear on steering and suspension
components, which leads to increased maintenance and higher risk for component failure. Larger wheel and tire combinations also alter speedometer calibration, braking effectiveness, center
of gravity, and handling characteristics. Consult
an experienced local off road shop to find what
wheel and tire combinations work best with your
vehicle.
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TM402 &
TM402N
Revised
8.9.13
Kit Parts List:
Box TM402
94-2834m STRUT SPACER 2
90-6317m HARDWARE PACK: SPACER MOUNT 1
.100FNFLZ 10mm-1.25 SERRATED FLANGE NUT 6
94-5456 BUMP STOP BRACKET: Drvr 1
94-5459 BUMP STOP BRACKET: Pass 1
90-6264 HARDWARE PACK: Bump Stop 1
15-11018 BUMP STOP 2
STOVER NUT 2
WASHER 2
90-6693 HARDWARE PACK:
Bump Stop 1
70-0371001800 3/8” X 1" Gr. 8 HEX BOLT 2
72-037100816 3/8" USS STOVER NUT 2
73-03700042 3/8" HARDENED FLAT WASHER 4
70-0501251800 1/2" X 1 1/4" Gr. 8 HEXBOLT 2
73-03700042 1/2" HARDENED FLAT WASHER 2
Box TM402N
Box TM402
94-2834m STRUT SPACER 2
90-6317m HARDWARE PACK: SPACER MOUNT 1
10mm FLANGE NUT 6
94-5456 BUMP STOP BRACKET: Drvr 1
94-5459 BUMP STOP BRACKET: Pass 1
90-6264 HARDWARE PACK: Bump Stop 1
15-11018 2
BUMP STOP 2
STOVER NUT 2
WASHER 2
90-6693 HARDWARE PACK:
Bump Stop 1
70-0371001800 3/8” X 1" Gr. 8 HEX BOLT 2
72-037100816 3/8" USS STOVER NUT 2
73-03700042 3/8" HARDENED FLAT WASHER 4
70-0501251800 1/2" X 1 1/4" Gr. 8 HEXBOLT 2
73-03700042 1/2" HARDENED FLAT WASHER 2
TM75801W REAR SHOCK 2
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TM402 &
TM402N
Notice to Owner Operator, Dealer and Installer:
Vehicles that have been enhanced for off-road performance often have unique handling characteristics
Revised
8.9.13
due to the higher center of gravity and larger tires. This vehicle may handle, react and stop differently than
many passenger cars or unmodified vehicles, both on and off–road. You must drive your vehicle safely!
Extreme care should always be taken to prevent vehicle rollover or loss of control, which can result in serious injury or even death. Always avoid sudden sharp turns or abrupt maneuvers and allow more time and
distance for braking! Trail Master Suspension
reminds you to fasten your seat belts at all times and reduce speed! We will gladly answer any questions concerning the design, function, maintenance and correct use of our products.
Please make sure your Dealer/Installer explains and delivers all warning notices, warranty forms
and instruction sheets included with Trail Master Suspension
product.
Application listings in this catalog have been carefully fit checked for each model and year denoted. However, Trail Master Suspension
reserves the right to update as necessary, without notice, and will not be
held responsible for misprints, changes or variations made by vehicle manufacturers. Please call when in
question regarding new model year, vehicles not listed by specific body or chassis styles or vehicles not
originally distributed in the USA.
Please note that certain mechanical aspects of any suspension lift product may accelerate ordinary wear of original equipment components. Further, installation of certain Trail Master Suspension
products may void the vehicle’s factory warranty as it pertains to certain covered parts; it is the consumer’s responsibility to check with their local dealer for warranty coverage before installation of the lift.
Warranty and Return policy:
Trail Master Suspension
materials. Trail Master Suspension’s
Trail Master Suspension’s
warranties its full line of products to be free from defects in workmanship and
obligation under this warranty is limited to repair or replacement, at
option, of the defective product. Any and all costs of removal, installation,
freight or incidental or consequential damages are expressly excluded from this warranty. Trail Master
Suspension is not responsible for damages and / or warranty of other vehicle parts related or non-related
to the installation of Trail Master Suspension
product. A consumer who makes the decision to modify his
vehicle with aftermarket components of any kind will assume all risk and responsibility for potential damages incurred as a result of their chosen modifications. Warranty coverage does not include consumer
opinions regarding ride comfort, fitment and design. Warranty claims can be made directly with Trail Mas-
ter Suspension or at any factory authorized Trail Master Suspension dealer.
IMPORTANT! To validate the warranty on this purchase please be sure to mail in the warranty card.
Claims not covered under warranty-
• Parts subject to normal wear; this includes bushings, bump stops, ball joints, tie rod ends and heim joints
• Discontinued products at Trail Master Suspension’s
discretion
• Bent or dented product
• Finish after 90 days
• Leaf or coil springs used without proper bump stops
• Products with evident damage caused by abrasion or contact with other items
• Damage caused as a result of not following recommendations or requirements called out in the installation manuals
• Products used in applications other than listed in Trail Master Suspension’s
catalog
• Components or accessories used in conjunction with other manufacturer’s systems
• Warranty claims without “Proof of Purchase”
• Trail Master Suspension
accepts no responsibility for any altered product, improper installation, lack of
or improper maintenance, or improper use of our products.
E-Mail: info@trailmastersuspension.com
Website: www.trailmastersuspension.com
Ph: (877) 695-7812
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