Trail Master TM412N, TM414N, TM411N, TM413N User Manual

TM411N, TM412N,

TM413N, TM414N

Revised

7.11.13

400 W. Artesia Blvd. Fax: [phone]

Compton, CA 90220 Ph: [phone]

www.trailmastersuspension.com

FORD SUPER DUTY F-250 4WD GAS SUSPENSION LIFT KIT

2011– 2013 KIT# TM412N

FORD SUPER DUTY F-350 4WD GAS SUSPENSION LIFT KIT

2011– 2013 KIT# TM414N

FORD SUPER DUTY F-250 4WD DIESEL SUSPENSION LIFT KIT

2011– 2013 KIT# TM411N

FORD SUPER DUTY F-350 4WD DIESEL SUSPENSION LIFT KIT

2011– 2013 KIT# TM413N

WARNING

Installation of a Trail Master suspension lift kit will change the
vehicle’s center of gravity and handling characteristics both on­and 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 shar p 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

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.

WARNING

Many states and municipalities have laws restricting bumper
heights and vehicle lifts. Consult state and local la ws 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 une xpected
handling characteristics.

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 compound on the

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threads of all kit nuts and bolts unless specified otherwise in thes e
instructions.

TM411N, TM412N,

TM413N, TM414N

Revised

7.11.13

2

Before Starting Installation

TM411N, TM412N,

TM413N, TM414N

Revised

7.11.13

Torque Specifications:

NOTE

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

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
negative cable first, then positive cable.

Wheel & Tire Requirements

The factory wheel and tire combination will fit
once this kit is installed.

Tire & Wheel Information:

Due to differences in manufacturing, dimensions and
inflated measurements, tire and wheel combinations
should be test fit prior to installation. Tire and wheel
choice is crucial in assuring proper fit, performance,
and the safety of your Trailmaster equipped vehicle.
For this application, we recommend a wheel not to
exceed 10” in width with a maximum backspacing of
5 3/4” must be used. Additionally, a quality tire of
radial design, not exceeding 37” tall X 12.50” wide is
also recommended. Violation of these recommenda­tions will not be endorsed as acceptable by Trailmas­ter Suspension and will void any and all warranties
either written or implied.

See factory service manual for torque values
when reusing OE fasteners.

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

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Front Installation:

1. Position your vehicle on a smooth, flat, hard
surface (i.e. concrete or asphalt). Block the
rear tires and set the emergency brake.

2. Measure and record the distance from the
center of each wheel to the top of its fender
opening. Record below.

3. Place the vehicle in neutral. Place your floor

RF: LF:

TM411N, TM412N,

TM413N, TM414N

Revised

7.11.13

IMPORTANT!: THE ENTIRE INSTALLA-

TION PROCESS MUST BE DONE WITH

HAND TOOLS TO ENSURE PROPER IN-

STALLATION. DO NOT USE IMPACT

TOOLS.

11. Install new pitman arm on sector shaft. Oil
the sector shaft threads to ensure a proper
torque reading. Install Pitman arm retaining
nut and tighten until snug. See Illustration

1.

LR: RR:

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.

4. Remove the track bar bolt from the driver
side frame mount. Save this hardware for
re-use.

5. Remove the cast track bar mount on driver
side of frame. Save the bolts and pal nuts.
Hardware will be reused.

6. Unbolt the sway bar from the sway bar end
links on both sides of the vehicle. Save the
hardware for reuse.

7. Mark the orientation of the sway bar and
unbolt it from the frame of the vehicle. Save
the hardware for reuse.

8. If the vehicle is equipped with a factory
steering stabilizer unbolt it and remove it
from the vehicle.

9. Remove the cotter pin and nut from drag
link, at the pitman arm. Save the nut for
reinstallation. Use a tie rod separator to
separate drag link from Pitman arm.

12. Insert the key and unlock the steering wheel.

13. Install the Pitman arm torque tool (96-5002)

to the Pitman arm using one of the previ­ously removed OE 14mm track bar bracket
outer retaining bolt and nut plate. See Illus-
tration 2.

14. Secure the torque tool (96-5002) to the exist-

ing hole in the frame crossmember using the
supplied 7/16” X 1 1/4” bolt and hardware.
See Illustration 2.
NOTE: The steering wheel may need to

be turned in order for the hole in the torque
tool and the frame crossmember to line up.
Once the bolts are tightened the torque tool
will align it’s self properly.

NOTE: The use of the torque tool is to
keep the Pitman arm from moving right or

Illustration 1

Pitman Arm Assembly

Sector
Shaft
Nut

Cotter
Pin

10. Remove the sector Pitman arm retaining nut

and save for reinstallation. Use a Pitman
arm puller to remove the OE pitman arm.
The threads of the sector shaft and the Pit­man arm retaining nut must be cleaned of all
factory dry adhesive.

FD-800

Pitman
Drag
Link

4

Arm

Frame Crossmember

OE 14mm Track
Bar Retaining Bolt

Existing
Hole

Illustration 2

Pitman Arm Torque Tool

Pitman
Arm

TM411N, TM412N,

TM413N, TM414N

Revised

7.11.13

96-5002
Torque Tool

Pitman
Arm

Frame
Crossmember

96-5002 Torque Tool

left, but allow for movement up the sector
shaft. If you do not have this tool, a length
of chain or a flat bar with two holes is a
suitable replacement.

15. Torque the Pitman arm retaining nut to 375
ft./lbs.

16. With the torque tool (96-5002) still in place
remove the pitman arm retaining nut. The
threads of the sector shaft and the Pitman
arm retaining nut MUST

be cleaned using
brake cleaner or another suitable method to
remove the previously applied oil.

Illustration 3

Track Bar Bracket Assembly

OE 14mm
Nut Plate

7/16” X 1
1/4” Bolt

17. Use the entire supplied thread locking com­pound to thoroughly cover the entire surface
of the threads on the Pitman arm retaining
nut.

18. Reinstall the Pitman arm retaining nut to the
sector shaft and torque to 350 ft./lbs.
NOTE: Whether re-using the existing

pitman arm retaining nut or replacing with
a new nut, the supplied locking compound
must be used.

19. Unbolt and remove the Pitman arm torque
tool (96-5002) from the vehicle.

OE Pal
Nut

(1) 9/16” X
1 1/2” Gr. 8
Bolts

9/16”
Hardware

OE Track Bar Hardware

82-9290 Track
Bar Drop
Bracket

OE Bolt

Track Bar

(2) 9/16”
X 3” Gr. 8
Bolts

OE Bolt

5

OE Track
Bar Bolt

90-9295
Cam Plates

TM411N, TM412N,

TM413N, TM414N

Revised

7.11.13

Illustration 4

Front Radius Arm Drop

Bracket Assembly

3/4” X 1 1/2”
Gr. 8 Bolt

82-3166
Radius
Arm Drop
Bracket

Frame Pocket

3/4” Stover
Nut and
Washers

90-2507
Spacer
Tube

3/4” X 1 1/2”
Gr. 8 Bolt

3/4” X 5”
Gr. 8 Bolt

The Notched
Bracket Goes
on the Bottom

82-3167
Radius
Arm Drop
Bracket

NOTE: Save this Pitman arm torque
tool to add to your toolbox for any future Pit­man arm installations.

20. Install track bar drop bracket (82-9290) us-
ing (2) 9/16” X 3”, (1) 9/16” X 1 1/2” and
(2) OE bolts. Use thread locker on the bolts.
Torque OE the bolts to 129 ft. lbs. and the
9/16” bolts to 110 ft. lbs. See ILLUSTRA­TION 3.

21. Unbolt the front brake line bracket from the
lower spring perch. Save hardware for re­use.

22. Unbolt and unclip the ABS wiring con­nected to the radius arm. Save hardware for
reuse.

23. On the driver side, unclip the axle vent line
from inside the frame.

24. On the passenger side unclip the axle hub

vacuum line from inside of the axle bump
stop plate.

25. Remove the transfer case skid plate. Also
remove the rubber grommets, sleeves and
clips from the frame.
NOTE: Trimming of the transfer case

skid plate is necessary for reinstallation.
On the passenger side

, use the supplied
transfer case skid plate cut template
(52802B-Supplement) as a guide. Line up
the holes and trace the template onto the
skid plate. carefully trim the skid plate.
This modification is needed to clear the
catalytic converter .
On the driver side

, carefully trim off
the rounded kick out in the side of the skid
plate. These modification is needed to
clear the transfer case. These are only
starting points and additional trimming
may be necessary.

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