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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TM409E
Revised
8.9.13
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Page 3
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
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
4
Page 5
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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Page 8
Notice to Owner Operator, Dealer and Installer:
TM409ERevised
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.
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.