Trail Master Suspension TM403N User Manual

400 W. Artesia Blvd. Fax: [phone]

Compton, CA 90220 Ph: [phone]

www.trailmastersuspension.com

FORD F-150 4WD SUSPENSION LIFT KIT

‘09- ’13 KIT# TM403N

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 com­pound on the threads of all kit nuts and bolts unless
specified otherwise in these instructions.

TM403N

Revised

12.5.13

2

Before Starting Installation

NOTE

TM403N

Revised

12.5.13

Wheel & Tire Requirements
Stock 17” & 18” wheels will not work in conjunc­tion with this kit.

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 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.

Fits 2011-UP w/ Electric steering rack.

Torque Specifications:

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

Tire & Wheel Information:

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.

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 Trail Master equipped vehicle.
For this application, 18” and larger wheel not to
exceed 9” in width with a maximum
backspacing of 5 1/2” is acceptable. A quality
tire of radial design, not exceeding 35” tall X

13.5” wide is recommended. Please note that
the use of a 35” X 13.5” tire may require fender
modification. Violation of these
recommendations will not be endorsed as
acceptable by Trail Master Suspension and will
void any and all warranties either written or
implied.

3

TM403N

Revised

12.5.13

Prepare to Install Front
Suspension

1. Place your floor jack under the front
cross member and raise vehicle. Place
jack stands under the frame rails behind
the front wheel wells and lower the
frame onto the stands. Remove the
jack and remove the front wheels.

2. Remove any skid plates if necessary.

3. Work on one side of the vehicle at a
time.

4. Unbolt the OE brake line and bracket
from the side of the knuckle. Save the
hardware for reinstallation.

5. 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.

7. Remove the front rotors from the front
hub.

8. Remove the dust cap and the nut from
the end of the CV in the hub.

14. Remove the upper ball joint nut from
the knuckle and separate using the ap­propriate tool.

15. Remove the lower ball joint nut, sepa­rate using the appropriate tool. Re­move the knuckle from the vehicle while
pulling it away from the CV and set the
knuckle aside.

16. Remove the three nuts from the top of
the coil over assembly and the one
large nut and bolt on the bottom. Re­move the coil from the vehicle. Save
hardware for reinstallation.

17. Remove the two bolts that retain the
lower a-arms and remove them from
the truck.

18. Repeat on the other side of the vehicle.

19. Mark the driveshaft orientation and
disconnect the front drive shaft from the
differential. Secure the driveshaft up
and out of the way of the work area.

20. Remove the rear cross member brace;
retain (2) of the bolts and nuts for rein­stallation.
NOTE: Careful heating of the OE

bolts may be necessary to loosen
the factory thread locker.

9. Remove the anti-lock wiring and sensor
from the hub if applicable.

10. Remove the vacuum line from the rear
of the hub.

11. Disconnect the sway bar end links from
the sway bar. Save hardware for rein­stallation.

12. Unbolt and remove the sway bar from
the vehicle. Save hardware for reinstal­lation.

13. Remove the tie rod end nut and sepa­rate from the knuckle using the appro­priate tool.

21. Make sure that the front differential is
well supported, remove the existing
hardware from both passenger and
driver side differential mounting areas.
Carefully lower differential out of vehicle
and set aside. Note the vent routing for
reinstall. Be careful the differential is
heavy.

22. In order to install the rear crossmem­ber, the driver side control arm mount­ing pocket needs to be removed.
Measure up 3 3/4” from the top of the
cam bolt hole and draw a horizontal line
across the entire pocket. See Illustra-

4

tion 1.
IMPORTANT!: For 2010-UP mod-

els ONLY, the front of the passenger
side rear A-arm pocket will need to
be trimmed approximately 1/4” in or­der to install the rear crossmember.
See ILLUSTRATION 1a.

23. Using a suitable cutting tool, (abrasive
cutoff wheel, Sawz-all, etc.) cut the
frame along the previously marked lines
as shown in Illustration 1 & 1a (For
2010 Models only). After cutting the
section out of the frame, clean the area
thoroughly and paint the exposed metal
with a good quality paint.

Illustration 1a

Pass Side Frame

Cut

Front of Passenger Side

Rear A-arm Pocket

TM403N

Revised

12.5.13

2010-UP Models ONLY!

1/4”

Cut Piece

82-5504 Rear

Crossmember

Install Front Suspension

Illustration 1

Drvr Side Frame

Cut

Rear
Crossmember
Mounting
Pocket

Cut
Mark

Cut Piece

1. Install the driver side and passenger
side front differential drop brackets 82-
5526 drvr and pass) to the frame with
the previously removed OE bolts and
hardware. Leave the bolts loose. See
Illustration 2.
NOTE: The jog in the brackets will
face towards the front of the truck.

OE Bolt

Front
Diff Drop
Brackets

82-5526

3 3/4”

Front View

Side View

9/16” X

4” Bolt

Differential

Illustration 2

Front Diff Brackets

5

Illustration 3

Rear Crossmember

Install

TM403N

Revised

12.5.13

Pass Side

OE Bolt

Pass Side

82-5518

Sway Bar

Drop

Drvr Side

82-5539

Rear

Differential

Bracket

OE Bolt

7/16” X 1

1/4” Bolt

82-TM241150 Front

Crossmember

Illustration 4

Rear Differential

Mount Install

82-5504 Rear

Crossmember

82-5504 Rear

Crossmember

18mm X

150mm Bolt

7/16” X

1 1/4”

Bolt

9/16” X

4” Bolt

Frame

Mounting

Pocket

Differential

Differential

6

TM403N

Revised

12.5.13

Illustration 5

Front Crossmember

Install

TM241150 Front

OE Bolt

Crossmember

2. Carefully hang the differential into the
front differential drop brackets with the
supplied 9/16” X 4” bolts and hardware
from pack (90-6302). Leave the bolts
loose. See Illustration 2.

3. Using the differential drop extension
pack (90-6189) fit the new hose to the
differential. Place the supplied plug in
the end of the tube and connect the fac­tory tube to it. Route the vent hose as
previously noted. Use the supplied zip
ties to secure the hose.

4. Raise the rear crossmember (82-5504)
into place and install the supplied pas­senger side 18mm X 150mm cross­member bolt. Install the bolt with the
head to the front. Do not install the nut
at this time. See Illustration 3.

5. Install the passenger side sway bar
drop bracket (82-5518) onto the previ­ously installed 18mm crossmember
bolt. Install the nut onto the crossmem­ber bolt. Leave the bolts loose. See
Illustration 3.

6. Secure the passenger side sway bar
drop bracket (82-5518) to the OE sway
bar mounting holes in the frame using
the supplied 7/16” X 1 1/4” bolts and
hardware. Leave the bolts loose. See
Illustration 3.

7. Install the (2) OE crossmember support
brace bolts into the (2) remaining holes
on the pass side of the rear crossmem­ber. Leave the bolts loose. See Illus-
tration 3.

8. Secure the rear crossmember (82-

5504) to the driver side OE sway bar
mounting holes in the frame using the
supplied 7/16” X 1 1/4” bolts. Leave

the bolts loose. See Illustration 3.

82-5516 Rear

Crossmember

Brace

82-5504 Rear

Crossmember

1/2” Drill

Bit

Illustration 6

Rear Crossmember

1/2” X

1 1/2”

Bolt

Brace Install

7

90-5692

Nut

Plate

1/2” X

1 1/2”

Bolt

TM403N

Revised

12.5.13

Illustration 7

A-Arm Install

90-5535
Cam Bolt

90-5533

Cam Bolt
Lower
A-Arm

9. Install the rear differential drop bracket
(82-5539) to the differential using the
supplied 9/16” X 4” bolt, through the
mounting hole in the rear crossmember,
with the head facing the rear of the ve­hicle. Leave the bolts loose. See Illus-
tration 4.

10. Install the front cross member (82-

Illustration 8

Crossmember

Skid Plate Install

Rear
Crossmember

TM241150) into original front A-arm
mounting locations, using the factory
bolts with the heads to the front, leave
loose. See Illustration 5. IMPOR-

TANT!: 2012 –Up models, the bottom
of the A-arm pocket may need to be
trimmed approximately 1/4” in order
to fully install the front crossmem­ber.

11. To ensure proper rear crossmember
placement, test fit the driver side A-arm
in the crossmember mounting pockets.
Secure using the supplied cam bolts
(90-5533 rear and 90-5535 front), cam
eccentric (90-5532), 18mm washers
and nuts.

12. Once the A-Arm is securely in place,
tighten the previously installed 7/16”
hardware and the OE pass side cross­member bolts and hardware. Remove
the A-Arm and cam bolts from the vehi­cle.

13. Install the rear crossmember brace
(82-5516) to the rear crossmember us­ing the 1/2” X 1 1/2” bolts and hard­ware. Tighten the bolts. See Illustra-
tion 6.

14. Use the upper holes in the crossmem­ber brace as a guide for drilling through
the frame. See Illustration 6.

15. Center punch and drill the holes using
a 1/2” drill bit. See Illustration 6.

Front
Crossmember

3/8” X 1

1/4” Bolt

3/8” X 1

1/4” Bolt

82-5517
Crossmember
Skid Plate

16. Secure the upper holes in the rear
crossmember brace (82-5516) to the
frame using the 1/2” X 1 1/2” bolts and
nut plate (90-5692). See Illustration 6.

17. Secure the rear upper differential
mount to the frame using the previously
removed OE bolt. See Illustration 4.

18. Install the lower a-arms into the new
cross members with the supplied cam

8

TM403N

Revised

12.5.13

Illustration 9

Front Driveshaft Spacer

Front Diff
Flange

Driveshaft
Spacer
90-4248

Front
Driveshaft
Flange

(6) 10mm
X 90mm

12.9 Bolts

bolts (90-5533 front and 90-5535 rear),
cam eccentric (90-5532), 18mm wash-
ers and nuts. The cams should fit be­tween the cam guides on the cross
members. Center the cams in the
guides. You will torque the bolts at the
end of the install when the vehicle is on
the ground. See Illustration 7.

19. Install the crossmember skid plate (82-

5517) to the front and rear crossmem­bers using the supplied 3/8” X 1 1/4”
bolts and hardware. See Illustration 8.

driveshaft must be clearanced by a
qualified driveline shop.
NOTE: The use of this driveshaft

spacer is intended for light usage
only. If the intended usage is for
high speed off road, this spacer
should not be installed. The factory
front driveshaft should be length­ened by a qualified driveline shop.

Trail Master takes NO

responsibil-

ity for damage caused as a result of
the installation of this spacer.

22. Install the sway bar frame mounts to
the sway bar drop brackets using the
previously removed OE bolt plates,
spacer plates (90-9434), OE and hard­ware. See Illustration 10.

23. Secure the sway bar end links to the
sway bar using the previously removed
OE hardware.

24. Torque the sway bar mount hardware
to 60 ft./lbs.

20. Torque all differential, sway bar and
crossmember hardware according to
the torque chart on page 18 or to manu­facturers specifications.
NOTE: The rear cross member is slot-

ted, the rear cross member needs to be
pushed as far to the Passenger side as pos­sible before it is tightened.

21. Reinstall the front driveshaft to the dif-

ferential by slipping in the new alumi­num front driveshaft spacer (90-4248)
and fasten with (6) supplied 10mm– 1.5
X 90mm 12.9 bolts. Be sure to use red
thread locker on these bolts. See Illus-
tration 9. Torque the bolts according to
the chart on page 3. Rotate driveshaft
to check for binding. If it binds the

OE Bolt
Plate

Sway Bar

Illustration 10

Pass Side Sway

Bar Drop

82-5518
Sway Bar
Drop
Bracket

90-9434
Sway Bar
Spacer
Plate

9

TM403N

Revised

12.5.13

90-6317

7/16”

Hardware

OE Hardware

82-2977

Coil

Spacer

OE Coil

Over

Shock

Illustration 11

With coil spacer

Notch

to

outside

28. Install the OE bolt through the lower
shock mount and a-arm. Torque to fac­tory specifications.

29. Support the lower A-arms. Position
the new front knuckles. Attach the
knuckle to the lower ball joint.

NOTE: Correctly position and

slide the vacuum actuator over the
CV before the next step.

30. While raising the knuckle and lower
control arm slide the CV through the
vacuum actuator and the knuckle. At­tach the nut to the end of the CV
shaft. Torque to 17 ft/lbs. and attach
the dust cap. Torque the small alumi­num vacuum cover bolts to 11 ft/lbs.

31. Attach the knuckle to the upper ball
joint. Torque to 85 ft/lbs. Torque the
lower A-arms nut to 111 ft/lbs.

OE Bolt

25. Transfer all the parts from the factory
knuckles to the supplied Trail Master
knuckles (90-4253 drvr and 90-4254
pass) except the vacuum actuator.
NOTE: Tighten all the factory

hardware carefully. Be sure to follow
the factory assembly procedures and
torque specifications.

26. Attach the spacer (82-2977) to the top
of the shock using the previously re­moved OE hardware. See Illustration

11.
NOTE: The notch in the bottom

ring face toward the outside of the
truck.

27. Install the strut assembly into the strut
mounting locations. Secure using the
7/16” supplied hardware on the top
from hardware pack (90-6317). Torque
to 45-50 ft./lbs. See Illustration 11.

NOTE: Check lower control arm

to CV boot clearance at full droop.
The lower control arm may need to
be trimmed and sanded to prevent
contact.

32. Connect the anti-lock wiring harness
and sensor to the hub if applicable.

33. Install the supplied brake line bracket
(82-7210) to the trailing edge of the
knuckle using the previously removed
OE bolt.

34. Secure the OE brake line bracket on
the front brake line to the new bracket

(82-7210) using the

5/16” X 1” bolt and

hardware.

35. Attach the vacuum lines to the rear of
the hub.

36. Install the front rotors on to the front
hub.

37. Install the front calipers on to the front
rotors by reinstalling the retaining bolts.
Torque to factory specifications.

10

TM403N

Revised

12.5.13

NOTE: On 2010-Up models, the

installation of the caliper bolt spac­ers (90-6736 2 per side) will be nec­essary to keep the end of the bolts
from contacting the brake rotor.
NOTE: For 2012-Up models, the
brake caliper mounting bracket holes
will need to be drilled out to 5/8”.
Also the casting nubs on the caliper
mounting brackets (the bottom flat
surface near the mounting holes)
may need to be sanded smooth for
brake caliper installation.

38. Install the tie rod end to the knuckle.
Torque to 111 ft/lbs.

39. Repeat the installation on the other
side of the vehicle.

40. Remove stock brake line bracket from
frame. Carefully remount the brackets
with the supplied brake line drops (90-
3202 drvr and pass) in between
bracket and frame. Use factory hard­ware to fasten the shorter end of the
bracket to the frame. Position the
drops, best for your application. Use
the supplied hardware from pack (90-

6299) to fasten OE bracket to the new
brake line drop.

WARNING!: Make sure the brake
lines that you just modified are not rest­ing against any moving parts.

41. Reinstall the wheels and tires and
lower the vehicle to the ground. Torque
the factory wheels to 150 ft/lbs. If you
are using aftermarket wheels follow the
manufacturers recommended specifica­tions.

component. Use zip ties to secure
these items. At full droop, cycle the
steering from lock to lock while
observing the reaction of these
components. Reposition them if
needed.

45. Reconnect the previously removed
positive and negative battery cables.

IMPORTANT! BE SURE TO BRING
THE VEHICLE IMMEDIATELY TO A
REPUTABLE ALIGNMENT SHOP TO BE
ALIGNED!

IMPORTANT!: AFTER INSTALLA­TION OF KIT AND BEFORE THE VEHI­CLE IS FIRST STARTED, BE SURE TO
CENTER THE FRONT WHEELS AND
THE STEERING WHEEL. IF THE FRONT
WHEELS AND THE STEERING WHEEL
ARE NOT CENTERED BEFORE START­ING THE VEHICLE, IT MAY TRIGGER A
DIAGNOSTIC TROUBLE CODE THAT
WILL HAVE TO BE RESET BY THE
MANUFACTURERS SERVICE FACILITY.

NOTE: SEE PAGE 16 FOR STEER­ING STOP ADJUSTMENT INSTRUC­TIONS.

42. Recheck all hardware for proper instal­lation and torque at this time.

43. Torque the 18MM cam bolts to 180-

200 ft/lbs.

44. On both sides of the vehicle, check the
routing of the brake lines and the ABS
wire harnesses. There must be no
pinching, rubbing, or stretching of either

11

TM403N

Revised

12.5.13

Prepare to 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. Remove the shocks on both sides of

the vehicle. It may be necessary that you
slightly raise the axle to unload the
shocks for removal.

4. Unbolt the rear driveshaft from the rear

differential. Secure out of the work area.

5. On drivers side, unbolt the existing

brake line bracket from the frame.

6. Install the supplied brake line exten-

sion bracket (82-5502) to the frame using
the previously removed OE hardware.
Then bolt the factory bracket to the new
bracket using the supplied 5/16” X 1”
hardware from hardware pack (90-6314).

7. Reroute rear ABS as necessary use

the supplies zip ties to secure lines.

8. Unhook the emergency brake cable

and remove from OE metal wire clip by
pinching the tangs on the line.

Install Rear Suspension

1.Bolt the supplied emergency brake
bracket (82-7826) to the OE emergency
brake frame bracket using the supplied
1/2” X 1 1/2” Bolt. See Illustration 12.

2. Use the inside hole in the emergency
brake bracket as a guide for drilling
through the frame. See Illustration 12.

3. Center punch and drill the holes using
a 3/8” drill bit. See Illustration 12.

4. Secure the emergency brake bracket

(82-7826) to the frame using the 3/8” X 1
1/2” bolt. See Illustration 12.

5. Slip the cable through new bracket
(82-7826) and re-connect the emergency
brake cable.

Illustration 12

Emergency brake line

drop Bracket

OE

Frame

Bracket

2009-2011 Model Install Shown

E-Brake

Bracket
82-7826

1/2” X 1

1/2” Bolt

9. Support the rear axle with a floor jack

and remove the U-bolts on the driver
side. Loosen the U-bolts on the passen­ger side.

10. Remove the factory lift block from the

spring assembly. This will not be rein­stalled.

12

3/8” Drill

Bit

3/8” X 1

1/2” Bolt

TM403N

Revised

12.5.13

NOTE: 2012-Up models will reuse

the previously removed OE metal wire
clip and OE bolt to secure the emer­gency brake cables to the new
bracket.

6. Install the lift block (95-405F) onto the

axle pad, making sure the pins are fitted
into the holes on the spring perch. Use
your floor jack to raise the axle to the
spring making sure the tabs on the spring
block fit into the holes on the lift block.
See Illustration 13.

7. Secure the assembly with the U-bolts

(13-90390) supplied in hardware pack
and new high-nuts and washers from
hardware pack (20-65302). Do not
tighten the U-bolts at this time. See Il-

lustration 13.

NOTE: Make sure the block sits

flush on the axle perch.

8. Repeat the installation on the other
side of the vehicle.

9. When the installation of the remaining
side is complete, torque the U-bolts to

105 ft. lbs.

10. Insert the supplied sleeves (60859) in
both end of the shocks.

11. Install your new Trail Master shocks
(TM75790W w/ shaft end up ) and
torque this hardware to 66 ft./lbs.

12. Slip in new aluminum rear driveshaft
spacer (90-4338) and fasten with sup­plied 12mm X 60mm bolts and washers
from hardware pack (90-6493). Be sure
to use thread locker on these bolts. See

Illustration 13

Block install

95-405F

Lift

Block

U BOLT
13-90390

13

20-65302
Hi-Nuts

TM403N

Revised

12.5.13

Illustration 14

Rear Driveshaft Spacer

Rear
Differential

(4) 12mm X
60mm Bolts
and Washers

Illustration 14. Rotate the driveshaft to
check for binding. If it binds the drive­shaft must be clearanced by a qualified
driveline shop.

Rear
Driveshaft

Driveshaft
Spacer 90-4338

NOTE: The use of this driveshaft
spacer is intended for light usage
only. If the intended usage is for high
speed off road, this spacer should not
be installed. The factory rear drive­shaft should be lengthened by a quali­fied driveline shop.

IMPORTANT!

: Fully cycle the
rear suspension and check for drive­shaft plunge. If the driveshaft is too
long it will destroy the transfer case.
Trail Master takes NO

responsibility
for damage caused as a result of the
installation of this kit.

13. Reinstall the wheels and tires and
lower the vehicle to the ground.

14. Reinstall the wheels and tires and
lower the vehicle to the ground. Torque
the factory wheels to 150 ft/lbs. If you
are using aftermarket wheels follow the
manufacturers recommended specifica­tions.

15. Recheck all hardware for proper in­stallation and torque at this time.

14

Dynamic Vehicle Check

TM403N

Revised

12.5.13

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

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.

NOTES:

 On completion of the installation, have the

suspension and headlights re-aligned.

 After 100 miles recheck for proper torque on

all newly installed hardware.

 Recheck all hardware for tightness after off

road use.

IMPORTANT!: 18” OR LARGER WHEELS

MUST BE USED IN

CONJUNCTION WITH THIS LIFT KIT!

NOTE

All warranty information, instruction sheets, and
other documents regarding the installation of this
product must be retained by the vehicle owner
Information contained in the instructions and on
the warranty card will be required for any war­ranty claims. The vehicle owner needs to under­stand the modifications made to the vehicle and
how they affect vehicle handling and perform­ance. Failure to provide the customer with this
information can result in damage to the vehicle
and severe personal injury.

.

15

TM403N

Revised

12.5.13

Steering Stop Shim Adjustment Instructions:

1. After having the vehicle properly aligned by a qualified alignment shop, ensure that

your work space is of adequate size and the work surface is level. Place the vehicle
in park and set parking brake. Place blocks both in front of and behind the rear
wheels.

2. With the vehicle on the ground make sure the steering wheel and the tires are

straight.

3. Turn the steering wheel to full lock left and remove the appropriate shims from the

passenger side front stop and the driver side rear stop until the steering wheel at full
lock is in the same position as Illustration A.

4. Turn the steering wheel to full lock right and remove the appropriate shims from the

driver side front stop and the passenger side rear stop until the steering wheel at full
lock is in the same position as Illustration B.

5. Be sure to use thread locking compound on the 5/16” X 1” shim retaining bolts. See

Illustration C.

Illustration A

Full Lock Left

20 deg.

Full Lock Left

Full Lock Right

Illustration B

Full Lock Right

20 deg.

IMPORTANT!: Any more steering angle than shown in the illustrations may result in CV failure.

16

Illustration C

Shim Installation

T

h

C

r

o

e

m

a

d

p

L

o

u

o

n

c

k

d

i

TM403N

Revised

12.5.13

n

g

Steering Knuckle

Steering Stop
Shims

5/16” X 1”
Bolts

Steering Stop Shims

NOTE: This Illustration is just a representation and every application will be different

17

TM403N

Box 1 of 4-PN 52209B/52209BMX-1

Revised

12.5.13

Kit Parts List:

Box TM403N-1
82-5504 REAR CROSSMEMBER 1

82-5516 REAR CROSSMEMBER BRACE 1
90-6705 HARDWARE PACK:

70-0501501800 1/2” X 1 1/2” HEX BOLT Gr. 8 2
72-050100816 1/2” STOVER NUT Gr. C
73-05000834 1/2” SAE HARDENED FLAT WASHER - 2 Not Used 4

91-5517 CROSSMEMBER SKID PLATE 1
90-6223 HARDWARE PACK:

70-0371251800 3/8” X 1 1/4” HEX BOLT Gr. 8 4
72-037100816 3/8” STOVER NUT Gr. C 4
73-03700034 3/8” HARDENED FLAT WASHER 8

82-5526 DIFFERENTIAL DROP:
90-6189 HARDWARE PACK:

90-2217 HOSE:

5/16" ID X 3 1/2" 1

90-2216 HOSE MENDER: BRASS (5/16") 1

90-6302 HARDWARE PACK:

70-0561251800 9/16” X 4” HEX BOLT Gr. 8– 1 Not Used 4
73-05600034 9/16” HARDENED FLAT WASHER
72-056100816 9/16” STOVER NUT Gr. C– 1Not Used 4

82-5539 DIFFERENTIAL DROP:
90-6701 HARDWARE PACK:

71-181502501000 18mm-2.5 X 150mm HEX BOLT 10.9 1
72-01810932 18mm-2.5 STOVER NUT Gr. C 1
73-01810934 18mm USS FLAT WASHER 2

90-4248 FRONT DRIVESHAFT SPACER 1
90-6716 HARDWARE PACK:

71-181502501000 10mm- 1.5 X 90mm HEX BOLT 12.9 6

90-6493 HARDWARE PACK:

.120C600HCS1Y 12mm- 1.75 X 60mm 10.9 HEX BOLT 4
73-01200830 12mm SAE FLAT WASHER 4

90-4338 REAR DRIVESHAFT SPACER 1

90-5692 NUT PL ATE: Brace 1

Box TM403N-2
90-4253 KNUCKLE:

Drvr 1

82-2977 COIL SPACER 2
90-6317 HARDWARE PACK:

72-043200810 7/16” GR. 8 HEX NUT 6
73-04300830 7/16” SAE FLAT WASHER 6

Brace 2

- Not Used 2

Skid Plate 1

Front Drvr and Pass 2

Differential 1

Differential 1

– 2 Not Used 8

Rear Drvr 1

Rear Crossmember 1

Front Driveshaft Spacer 1

Rear Driveshaft Spacer 1

Spacer Mount 1

18

73-04300836 7/16” SPLIT LOCK WASHER 6

90-6299 HARDWARE PACK:

Front Brake Lines 1

70-0311001500 5/16" X 1" Gr. 5 HEX BOLT 2
72-03100100512 5/16" NYLOCK NUT 2
73-03100030 5/16" SAE FLAT WASHER 4

82-7210 BRAKE LINE BRACKET:

Front Knuckle 2

90-6736 HARDWARE PACK:

62NWHDY/SAEXT

 5/8” (thick) Hardened Flat Washer 4

Caliper Bolt Spacers 1

Box TM403N-3
90-4254 KNUCKLE:

Pass 1

95-405F 4" LIFT BLOCK 2
Box TM403N-4

82-TM241150 FRONT CROSSMEMBER 1
82-5502 REAR BRAKE LINE DROP 1
82-7826 EMERGENCY BRAKE BRACKET 1
90-6422 HARDWARE PACK:

E-Brake Bracket 1

70-0501501800 1/2” X 1 1/2 HEX BOLT Gr. 8 1
73-05000034 1/2” HARDENED FLAT WASHER 2
72-0501100816 1/2” NYLOCK NUT Gr. 8 1

90-6314 HARDWARE PACK:

70-0311001800 5/16” X 1” HEX BOLT Gr. 8
72-031100816 5/16” STOVER NUT Gr. C -

Brake Line Drop/ Bump Kit 1

-Not Used 1

Not Used 1

73-03100832 5/16” USS FLAT WASHER -Not Used 2
70-0371501800 3/8” X 1 1/2” HEX BOLT Gr. 8 2
72-037100816 3/8” STOVER NUT Gr. C 2
73-03700034 3/8” HARDENED FLAT WASHER 4

90-6393 HARDWARE PACK:

Front Brake Line Drops 1

90-3202 F150 BRAKELINE DROP 2

90-6299 HARDWARE PACK:

Front Brake Lines 1

70-0311001500 5/16" X 1" Gr. 5 HEX BOLT 2
72-03100100512 5/16" NYLOCK NUT 2
73-03100030 5/16" SAE FLAT WASHER 4

82-5518 SWAY BAR DROP:

Pass 1

90-6340 HARDWARE PACK:

Sway Bar Drop 1

70-0431751800 7/16” X 1 1/4" HEX BOLT Gr. 8 4
72-043100816 7/16” STOVER NUT Gr. C 4
73-04300830 7/16” SAE FLAT WASHER 8

90-6319 HARDWARE PACK:

Zip Ties 1

10999 ZIP TIE, 11", BLACK 12

90-6700 HARDWARE PACK:
90-5532 CAM ECCENTRIC:
90-5533 CAM BOLT– Rear:
90-5535 CAM BOLT– Front:
90-6313 HARDWARE PACK:

Cam Bolts 1

F-150 Slotted 4
18mm-2.5 X 150MM 10.9 2

18mm-2.5 X 160MM 10.9 2

Crossmember 1

TM403N

Revised

12.5.13

19

72-01810932 18mm STOVER NUT 4
73-01810934 18mm FLAT WASHER 4

13-90390 U-BOLT:

9/16"-18 x 3.36" x 12.50" 4

20-65302 HARDWARE PACK:

9/16” HI-NUTS 1

90-9434 SWAY BAR MOUNT WASHER PLATE 2
Box TM403N-5

TM75790W 9000 SERIES SHOCK 2

TM403N

Revised

12.5.13

20

TM403N

Revised

12.5.13

Revision Page:

21

Notice to Owner Operator, Dealer and Installer:

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
duce 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

Application listings in this catalog have been carefully fit checked for each model and year denoted. How­ever, Trail Master Suspension
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
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
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

• 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

• Components or accessories used in conjunction with other manufacturer’s systems

• Warranty claims without “Proof of Purchase”

• Trail Master Suspension
or improper maintenance, or improper use of our products.

E-Mail: [e-mail]
Website: www.trailmastersuspension.com
Ph: [phone]

reserves the right to update as necessary, without notice, and will not be

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,

accepts no responsibility for any altered product, improper installation, lack of

reminds you to fasten your seat belts at all times and re-

product.

product. A consumer who makes the decision to modify his

discretion

catalog