TM405 &
TM405N
Revised
8.9.13
400 W. Artesia Blvd. Fax: (310) 747-3912
Compton, CA 90220 Ph: (877) 695-7812
www.trailmastersuspension.com
2004– 2008 FORD F-150 2WD/4WD (2004 HERITAGE EXCLUDED)
2009– 2012 FORD F-150 2WD ONLY
3.0” FRONT SPACER KIT
KIT# TM405 & TM405N
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.
TM405 &
TM405N
Revised
8.9.13
2
Before Starting Installation
NOTE
TM405 &
TM405N
Revised
Torque Specifications:
8.9.13
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
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.
3
TM405 &
TM405N
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.
Tie Rod end
6. Remove the dust cap from the hub.
7. Unbolt the OE brake line, ABS line and
brackets from the side of the knuckle. Save
the hardware for reinstallation.
Brake Line
Bracket
8. Remove the vacuum line from the back of the
hub.
9. Remove the front caliper and bracket assembly from the front knuckle by removing the
(2) retaining bolts.
NOTE: Make sure you do not let the
calipers hang on the brake lines or damage
will occur.
5. Unbolt the sway bar from the sway bar end
links. Save hardware for reinstallation.
Sway Bar
End Link
Complete steps 6 Through 13 On 4WD models
ONLY!:
Brake
Caliper
10. Remove the front rotors from the front hub.
11. Remove the backing plate bolt from the
knuckle to access the ABS sensor.
OE Backing
Plate Bolt
4
TM405 &
TM405N
Revised
8.9.13
12. Unbolt the ABS sensor from the hub. Remove the CV axle end nut. Save for reinstallation.
ABS
Sensor
13. Unbolt the upper ball joint nut, but do not
remove it from the knuckle. Separate using
the appropriate tool.
16. 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.
Lower Strut
Mount Bolt
17. Remove (3) upper strut tower nuts holding
the strut assembly to the strut tower. Save the
hardware for reinstallation.
Upper Strut
Mount Nuts
Upper Ball
Joint
Remove upper ball joint nut and carefully
14.
lower the A-arm assembly. Save hardware for reinstallation.
15. 4WD ONLY!
from the hub.
: Carefully remove the CV axles
18. Remove the strut assembly from the vehicle.
19. 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.
CV Axle Nut
Strut Spacer
(94-2834m)
5
TM405 &
TM405N
Revised
8.9.13
20. 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
21. Install the lower strut bolt in the original position and torque to manufacturers specifications.
NOTE: Be sure to use thread locker on
the OE bolt.
2WD ONLY!: Reinstall the knuckle to the
22.
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.
the upper ball joint nut to factory specifications.
NOTE: It may help to turn the wheel to
aid in reinstallation of the CV axle into the
hub.
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.
24. Reinstall the ABS sensor to the hub using the
previously removed hardware.
25. Reinstall the backing plate bolt to the knuckle
using the previously removed OE bolt.
26. Install the front rotors on to the front hub.
27. Install the front calipers on to the front rotors
by reinstalling the retaining bolts. Torque to
factory specifications.
NOTE: Use thread locker on the OE
caliper mounting bolts.
28. Reconnect the ABS lines and brake lines to
the knuckle using the previously removed
hardware.
29. Reconnect the hub vacuum line to the back of
the hub.
30. Reinstall the CV end nut and dust cap.
Torque the nut to factory specifications.
NOTE: Be sure to use thread locker on
the OE bolt.
31. Reconnect the sway bar to the end links using
the previously removed OE hardware.
Upper Ball
Joint Nut
Complete steps 24 Through 31 On 4WD models
ONLY!:
23. Carefully guide the CV axle through the hub
and reinstall the upper ball joint nut. Torque
32. Reinstall the tie rod end to the knuckle.
Torque to factory specifications.
33. Repeat steps 5 through 32 on the remaining
side of the vehicle.
34. Reinstall the front wheels.
35. 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!
36. Torque all bolts to factory specifications. Retorque all bolts after 500 miles.
6
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.
TM405 &
TM405N
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.
7
TM405 &
TM405N
Revised
8.9.13
Engine Compartment
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
Troubleshooting
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.
8
TM405 &
TM405N
Revised
8.9.13
Kit Parts List:
Box TM405
94-2834m STRUT SPACER 2
90-6317m HARDWARE PACK: SPACER MOUNT 1
10mm FLANGE NUT 6
Box TM405N
Box TM401
94-2834m STRUT SPACER 2
90-6317m HARDWARE PACK: SPACER MOUNT 1
10mm FLANGE NUT 6
TM75801W REAR SHOCK 2
9
TM405 &
TM405N
Notice to Owner Operator, Dealer and Installer:
Revised
8.9.13
Vehicles that have been enhanced for off-road performance often have unique handling characteristics
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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