Trail Master TM409E User Manual

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400 W. Artesia Blvd. Fax: (310) 747-3912
Compton, CA 90220 Ph: (877) 695-7812
www.trailmastersuspension.com
2005– 2012 FORD F-250/F-350 4WD
2 1/2” SPACER KIT
KIT# TM409E
TM409E 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-
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pound on the threads of all kit nuts and bolts unless specified otherwise in these instructions.
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TM409E Revised
8.9.13
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Before Starting Installation
NOTE
TM409E 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
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.
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Install Front
TM409E Revised
8.9.13
Suspension
1. Measure and record the distance from the center of each wheel to the top of its fender opening. Record below.
2. Place the vehicle in neutral. Place your floor jack under the front axle and raise the vehicle. Place jack stands under the frame rails and lower the frame onto the stands. Remove the jack and place the vehicle back in gear, set the emergency brake, and place blocks both in front and behind the rear wheels.
Brake Line Bracket
6. Lower the front axle as far as possible. Remove only one spring (mark or note spring orientation before removal).
Remove OE spring isolator.
3. Remove the front wheels.
4. Raise the axle using the floor jacks to remove the tension from the shocks.
Lower Shock Mount
5. Disconnect the end links to the sway
bar, frame brake line bracket and OE
shocks. (both sides).
7. Compress spring down, install new
coil spacer (94-2859), poly ring (90-
4198), OE spring isolator and reinstall
spring. Be sure to line up the previ­ously applied coil spring reference
90-4198 Poly Ring
Coil Spring
94-2859 Coil Spacer
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mark.
8. Lift axle back up and reinstall the brake line bracket and reconnect sway bar end links.
NOTE: For 2008 models, unbolt
the brake line bracket from the frame. Measure down 2” from the original frame mounting hole and drill another 3/8” hole. Secure the brake line bracket to the new hole in the frame using the previously re­moved OE hardware.
9. Now would also be a good time to in­spect the rear shocks for damage or fluid leakage. Replace if necessary.
TM409E Revised
8.9.13
10. Install the shock relocation brackets
(94-5273 drvr and 94-5276 pass) into
the lower shock mounts using the pre-
viously removed OE bolts and hard­ware. Secure the OE shock lower
mount into the shock relocation brack-
ets using the supplied 14mm-2.0 X
80mm bolts and hardware.
Shock
Shock Relocation bracket 94-5273 drvr and 94-5276 pass
14mm X 80mm Bolt
OE Bolts
11. Put wheels back on Torque to manu­facturer’s specifications and lower the vehicle to the ground.
12. Recheck all hardware for tightness af-
ter off road use.
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TM409E 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.
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Kit Parts List:
Box TM409E
94-2859 COIL SPACER 2
90-4198 POLY RING 2
94-5273 SHOCK RELOCATION MOUNTS:
94-5276 SHOCK RELOCATION MOUNTS:
90-6430 HARDWARE KIT: 1
71-140801751000 14mm-2.0 X 80 HEX BOLT Gr. 10.9 2 72-14200816 14mm-2.0 STOVER NUT Gr. C 2 73-01400030 14mm HARDENED FLAT WASHER 4
Drvr 1
Pass 1
TM409E Revised
8.9.13
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Notice to Owner Operator, Dealer and Installer:
TM409E 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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