Trail Master Suspension TM104N User Manual

400 W. Artesia Blvd. Fax: [phone]

Compton, CA 90220 Ph: [phone]

www.trailmastersuspension.com

CHEVEROLET/GMC 1/2 TON 4WD SUSPENSION LIFT KIT

‘99- ’06 KIT# TM104N

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 fas tened.

WARNING

Before you install this kit, read and understand all in­structions, warnings, cautions, and notes in this instruc­tion sheet and in the vehicl e owner’s manual.

CAUTION

Proper installation of this kit requires knowledge of the
factory recommended procedures for removal and instal­lation of original equipment compo nents. 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 det ermine if the ch anges you intend to make to
the vehicle comply w i th the law.

WARNING

The installation of larger tires may reduce the effective­ness of the braking system.

WARNING

Always wear eye protect i on when operating power tools.

WARNING

Before you install this kit, block the vehicle tires to pre­vent the vehicle from roll ing.

WARNING

DO NOT combine suspension, body, or other lift devices.
Use of vehicle with combined lifts may result in unsafe
and/or unexpected handling characterist ics.

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 th e veh icle is susp ected to ha ve 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 fac tory 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 com­pound on the threads of all kit nuts and bolts unless
specified otherwise in these instructio ns.

TM104N

Revised

1.27.14

2

TM104N

Revised

1.27.14

Before Starting Installation

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 [phone].

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 sus-

Wheel & Tire Requirements

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 T r a ilmaster
equipped vehicle. For this application, a wheel not
to exceed 9” in width with a maximum backspacing
of 5 1/4” must be used. Addit io nally, a quality tire
of radial design, not exceeding 35” tall X 12.5”
wide is recommended. Please note that the use of a
35” X 12.5” tire may require fender modification.
Violation of these recommendations will not be en­dorsed as acceptable by Trailmaster Suspension and
will void any and all warranties either written or
implied. 2005 trucks require a 17” wheels to clear
the calipers.
If your truck has a tire pressure sensors on the fac­tory wheels please contact the wheel manufactures
for proper installation and removal.
Factory rims can be used.

pension, 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.

Torque Specifications:

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

See factory serv ice manual for torque value s 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

3/4”-16 175 225

TM104N

Revised

1.27.14

Important Note

A replacement CV style front drive shaft is recommended for owners who use 4 x 4 Hi range for

extended periods of time.

Vehicles equipped with a 246 transfer case (Auto-trac) will require a replacement CV style front

drive shaft.

Part Number 51256, Standard duty shaft with the slip shaft installed on the drive shaft.

2004 models with traction control and Borg Warner transfer case 4482 may require

Trailmaster driveshaft 51257.

NOTE

Please note that while every effort is made to ensure tha t the installation of your Trailmas ter lift kit is a
positive experience, variations in construction and assembly in the vehicle manufacturing process will
virtually ensure that some parts may seem difficult to install. Add itionally, the current trend in manufac­turing of vehicles results in a frame that is highly flexible and may shift slightly on disas sembly prior to
installation. The use of pr y bars and tapered punches for alignment is considered normal and usually
does not indicate a faulty product. However, if you are uncertain about some aspect of the installation
process, please feel free to call our tech support department at the number listed on the cover page. We
do not recommend that you modify the Trailm aster parts in any way as this will void any war ranty ex­pressed or implied by the Trailmaster Suspension company.

Prepare to In st a ll Front Suspe n si on

1. If there are factory skid plates installed, remove them.

2. Measure torsion bar adjusting screw depth and record this dimension for later use when
replacing the torsion adjuster arm on reassembly. Remove the torsion bar adjusting
screw. Apply a small amount of lubrication grease to the puller threads and the puller
shaft-to-adjuster arm contact point. Lo ad puller and torsion adjuster arm until the
adjuster nut can be removed from the cross member. Release the pull er to unload the
torsion bar . With the bar unloaded, slide it forward into the lower control arm until the
adjuster arm falls free. If the bar seems stuck, use a hammer and punch through the
hole in the rear of the cross member to dislodge it. Repeat this procedure on the other
side of the vehicle.

3. Remove the torsion bar cross member by removing the through bolts on each side of
the vehicle. With the cross member out of the way, the torsion bars can be pulled from
the lower control arms and removed. Mark the torsion bars as to their orientation (left
side, right side, and front). They must

be reinstalled exactly as removed! Save these

nuts and bolts for reuse on reassembly.

4. Disconnect the ABS sensor wire and position it out of the way to prevent damage to the
wiring or connector ends. Rem ove brake caliper assembly and securely fasten it awa y
from the wor k area.

4

TM104N

Revised

1.27.14

Steps 5 through 12 are performed one side at a time:

5. Remove the 6 bolts that attach the CV axle to the differential. Save these for reuse.

6. Detach the outer end of the tie rod from the spindl e ass em bl y . Special to ols are
available to safely remove these without damage to the joint or the protective boot.
Your GM servic e manual has de ta ils on this proc edure

7. Remove the anti-sway bar links that connect the sway bar to the lower A-arm. Save this
hardware for reuse on reassembly.

8. Remove the shock absorber mounting bolts from the lower A-arm. Save this hardware
for reuse.

9. Remove the upper and lower A-arm pivot nuts. Save this hardware for reuse on
reassembly.

10. Support the A-arm assembly and carefully remove the pivot bolts. Lower the assembly
to the floor and set aside. This assembly is relatively heavy and not a rigid assembly.
Be very careful when removing. Save the pivot bolts for reuse.

11. Remove the upper shock nuts and remove the stock shock absorbers. Discard these
parts.

12. Detach the front driv e shaf t from the diff eren tial yolk and secu re it out of the way.
Disconnect the electro nic sensor and vent line from the differential and secure them out
of the way.

13. Remove the factory bump stops by using a large channel lock type of pliers and discard
the stops.

14. Remove drag link from the pitman arm and idler arm. It may be easier to remove the
Idler arm from the frame with the drag link. Set this assembly aside. Save the nuts for
reuse.

15. Remove the front differential lower mounting bolt. Save this nut and bolt for reuse.

16. Remove the passenger side differential mounting bolts. Save this hardware for reuse.

17. Remove the differential cross member and discard this hardware.

18. While suppor ti ng the diffe re ntial , re mov e th e upper mo un t bolt an d carefully lower the
differential to the ground. Retain this nut and bolt for reuse on reassembly.

19. Using a 2” hole saw without

the pilot drill, r emove the bump s top mount from the frame
on each side of the vehicle. It is important that you do NOT remove any more material
than you have to. Do NOT drill through this pad with the hole saw!

20. Using an angle grinder or equivalent, remove any remaining weld from this area to
achieve a smooth surface.

21. Using a re c ip rocating saw or other sui table saw, on the driver side A-arm pocket /
differential mount, cut the rear section out as shown in Illustration A and to the
dimensions shown in Illustration 1.

5

A1

TM104N

Revised

1.27.14

Illustration A

A1+A2

Drivers Side

OEM

PN 96-1505

Front of vehicle

Illustration 1

Drivers side.

Front of vehicle

A2

Illustration 2

Passenger side.

Front of vehicle

6

Remove to

clear

TM104N

Revised

1.27.14

22. On the passenger side mount, cut a 45º section from the pocket as per Illustration 2.

23. On the OEM bump stop flanges on both sides of the truck, cut the front corners to allow
for shock clearance. See Illustration 3.

24. On the front upper A-arm mount pockets, knock the existing alignment cam pins off with
a hammer and grind the surface smooth.

Install Front Suspension

1. Install the provided replacement bump stops (PN 15-11018) to the main cross member
as indicated in Illustration 4. It is important that this is done now as it is not possible to
install these stops after installation of the cross member.

2. With the differential out of the vehicle, temporarily mount the main cross member (PN
82-1459) to the frame using the existing lower A-arm pockets and OEM bolts. Make
sure that the cross member is located with the inside face of the rear flange even with
the rear edge of the OEM bump stop flange as indicated in Illustration 3 (the driver side
should look the same as the passenger side when properly
located). When
the location is
set, clamp the
cross member
to the flanges
to prevent
movement and
drill the 2 upper
mount holes
throug h the
OEM flange on
both sides of
the truck. The
bottom hole is
not accessible
with a drill at
this time, it
must be
marked for later
drilling. Install
provided 3/8” X
1 1/4” NC bolts,
washers and
Stover nuts and
tighten to
prevent
movement.
Repeat this
step on the

Front of vehicle

Important!

See note 3.

3/8” X 1 1/4”

3 places per side

PN 82-1459

Illustration 3

Passenger side.

See note 24.

This hole must be

drilled with the cross

member removed.

See note 4

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