Trail Master systems do not incorporate components to accommodate extended cab and\or two piece driveshafts unless otherwise stated.
Driveline Note: Post installation vehicles may experience driveline vibrations. Driveline angles may require tuning, slider on shaft may require replacement, shafts may need to be lengthened, shafts may need to be trued, and U-joints may require frequent replacement. TM systems are not recommended for vehicles with 13 inch or shorter driveshafts.
All replacement spring or add-a-leaf systems require compression stop installation or spring failure may occur. Not all TM systems include compressions stop extensions to maintain this criteria. Compression stop to axle dimension must be maintained or your Trail Master warranty may be voided!
1. Check all fasteners for proper torque. Check to insure there is adequate clearance between ALL rotating, mobile, and fixed members. Insure there is adequate clearance between exhaust and brake lines, fuel lines, fuel tank, floor board, etc Check steering gear for interference and proper working order. Inspect brake lines for damage and adequate clearance. Test brake system for proper working order.
2. After installation of system it may be necessary to replace brake hoses front and rear to ensure adequate slack in hoses when suspension is at full extension. On front of vehicle a steering sweep should be performed to ensure brake hoses have sufficient slack and will not come in contact with any rotating, mobile or fixed members. Failure to perform check \ replacement may result in OE and\ or related component failure! Longer replacement hoses may be located through your local parts supplier.
3. Perform headlight adjustment.
4. Retain this land all information regarding your altered vehicle for future reference.
5. Bronco II’s with CV type rear driveshaft require replacement driveshaft. Vehicles with automatic Trans Part No. CVDSB2, with manual transmission. Part No. CVDSB1.
- Passenger Side Strut Arm Bracket——————— 1
- 7/16 x 1-1/4 Bolts——————————————— 8
- 7/16 NI Locknuts———————————————- 8
- 7/16 Flat Washers——————————————- 16
- Drivers Side Strut Arm Bracket————————– 1
- 7/16 x 1-1/4 Bolts——————————————— 8
- 7/16 x NI Locknuts——————————————– 8
- 7/16 Flat Washers——————————————- 16
- Aluminum Body Extension Blocks———————– 2
- 1/2 x 4 Bolts—————————————————- 2
- 1/2 NI Locknuts———————————————— 2
- 1/2 Lock Washers——————————————– 2
- Drivers Side Axle Bracket———————————-1
- Passenger Side Axle Bracket—————————- 1
- 7/16 x 1-1/4 Bolts ———————————————4
- 7/16 NI Locknuts ———————————————-4
- 7/16 Flat Washers ——————————————–4
- Coil Springs —————————————————-2
- U-Bolts, Round 1/2 x 2-3/4 x 11(Ranger) —————4
- U-Bolts, Round 1/2 x 2-3/4 x 8(Bronco II) ————– 4
- 1/2 Nuts ———————————————————- 8
- Bronco-Sway Bar Brackets ——————————– 2
- 7/16 x 1-1/2 Bolts ——————————————— 4
- 7/16 NI Locknuts ———————————————- 4
- 7/16 Flat Washers ——————————————– 8
- 7/16 Flat Washers (FB116 Kit Only) ——————– 4
- Cast Iron Blocks ———————————————– 2
- 1/2 Centering Sleeve —————————————– 2
- Rear Single Leaf Springs ———————————– 2
- 3/8 x 4-/2 Center Pins —————————————- 2
- 3/8 Center Pin Hex Nut ————————————— 2
- PA10 Pitman Arm P/S ————————————— 1
- PA15 Pitman Arm (FB116 Kit Only) ——————— 1
- Brake Bracket Extension (FB116 Kit Only) ———— 2
- Brake Bracket Extension (FB117 Kit Only) ———— 2
- F89FBB ———————————————————- 2
- 3/8 x 1 Bolts —————————————————– 2
- 3/8 Locknuts —————————————————– 2
- 3/8 Flat Washers ———————————————– 2
1. To begin installation, safely raise vehicle.
2. Remove tires and wheels.
3. Starting at front, remove stock shock absorbers. Place floojack under each axle for safety.
4. Remove bottom bolt with 18mm wrench. Remove top nut with 18mm wrench.
5. Remove stock radius arm brackets from frame rail only. Each bracket is attached at two points with rivets.
6. Using 15mm wrench remove remaining nuts/bolts from frame rail.
7. Install new radius arm brackets. On drivers side remove bolts that hold pressurized fuel system box allowing space for installation of new bracket bolts. Put bracket in place, loosely install 8 – 7/16 x 1 – 1/4 locknuts, bolts, and washers. When both brackets are in place, tighten hardware.
8. Remove stock coil springs. Remove retaining nut with a wrench. With nut removed simply turn coil spring out of upper spring tower pocket. (Note how stock spring fits in pocket)
9. Remove bump stops, then replace with new aluminum spacer.
10. After bump stops have been removed, you will need ‘to enlarge hole in each bump stop using 27/64 drill bit, then tap with 1/2 coarse thread tap.
11. Drill out stock hole in frame where bump stops were on both sides with 1/2 bit.
12. lnstall 1/2 lock washer on 1/2’x 4 bolt thru-frame and 3″ aluminum spacer on both sides and tighten.
13. Axle pivot bracket (Note: bracket is located on passenger side). Remove retaining. bolt at pivot point with 7/8 wrench., Remove five upper bolts with 13/16 wrench.
14. Install new bracket using stock bolts.
15. Align pivot arm hole with drift pin, insert stock bolts and tighten.
16. Axle pivot bracket – passenger side. Stock pivot bracket is located beneath and in front of oil pan; Bracket is held in place by four rivets which can be removed with drill, cold chisel, grinder, or cutting torch.
17. Remove pivot bolt with wrench.
18. New bracket plate mounts on front side of motors frame support. Use 4 – 7/16 x 1-1/4 bolts, locknuts, and ‘flat washers.
19. Attach stock support bracket to lower part of new bracket, using 4 – 7/16 x 1/2 bolts, locknuts, and-flat washers.
20. When all brackets are in place and hardware is hand tightened you are ready to tighten all hardware. This procedure will allow axles to maintain proper positioning.
21. Coil spring installation. Place smaller end of new spring on coil seat. Larger end fits in upper coil spring tower pocket. Note: Clench keeper tap back into stock position. Tighten coil retaining nut.
F89FBB Brake Bracket Assembly:
22. Remove brake line from frame clip. (Line off of master cylinder.)
23. Remove master cylinder brake line from rear of brake hose connection at coil spring tower.
24. Remove clip from hose connection.
25. lnstall new bracket into existing spring hole of spring tower using 3/8 x 1 bolt, 3/8 locknut, 3/8 flat washer.
26. Install brake hose into lower hole of bracket, reinstall clip, reinstall brake line from master cylinder. (Note: Brake line may need to be reformed for proper clearance).
27. Disconnect brake line from brake hose at coil spring tower.
28. Install new bracket into existing hole of spring tower using 3/8 x 1, 3/8 locknut, 3/8 flatwasher (washer to be mounted on backside with nut.)
29. lnstall brake hose and brake line with clip into lower hole of bracket. (Note: Brake line may need to be reformed for proper clearance). After complete installation of brake brackets, brakes will need to be bled. Turn wheels fully to both left and right to insure no interference of brake lines and brake hoses.
30. Shock absorber replacement. When installing your new Trailmaster shocks note: Stock bushing in upper tower can be left in stock position omitting one of the new bushings.
31. Removal of pitman arm. Remove tie rod and sector shaft nut. Using pitman arm puller remove arm.
32. Reinstall new arm in same location as old arm Tighten sector shaft nut 170-230 ft. lbs. Tie rod 52 74 ft. lbs. Turn wheel fully to ensure proper clearance.
Rear Lift Application
1. Place jack stands under rear axle.
2. Remove stock shock absorbers.
3. Remove U-bolts.
4. Lower jack stands allowing room for new blocks an new leaf springs.
5. Place new block-on axle pad (Note: face smaller tapered end of block toward front). Next place stock block on top of new block.
6. Install add-a-leaf on top of flat over load on bottom of arched leaf spring Longer gold -anodized U-bolts can then be installed and tightened.
7. lnstall your new Trailmaster shock absorbers.
8. Final touches. Check all hardware.
9. After wheels and tires are in place loosen front tie rod adjustment sleeves. Turning sleeves until wheels run straight.
10. Lower vehicle.
11. Retighten adjustment sleeves.
12. Align Front End.