- Locate rear bumper attachment point on driver side.
- Remove bumper fasteners.
- Install mounting bracket onto linkage as shown. Torque to 33 ft-lbs / 44 Nm.
NOTE: 2500, 3500 HD trucks do not use spacer ( 5 ). Use fastener ( 2 ) on HD trucks.
- Slide upper mount over factory studs, install fasteners and torque to 70 ft-lbs / 95 Nm.
- Install step pad assembly onto linkage assembly with two socket cap screws.
- Adjust step pad position side to side. Allow for foot access. Torque allen head bolts to 10 ft-lbs / 13.5 Nm.
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Brake system work should always be carried out by qualified individuals. If you are not completely confident of your skill in this area, have someone who is do the installation or assist you with the installation. Revolution Brake LLC accepts no responsibility for the consequences of improperly installed brake components. Your life depends on your brakes, be careful.
Installation: Jack up the front of the vehicle and secure with jack stands. Refer to the shop manual and remove front wheels, calipers, rotors and flex hoses. These brake parts will not be reused. After disconnection of the flex hoses from the chassis hard lines, it is a good idea to plug the hard lines to prevent excessive brake fluid loss and entry of air into the system. Small (3/16″ diameter) rubber or soft plastic plugs are usually available from your local automotive parts store and work well.
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For bolts into aluminum, use light oil, or anti-seize, not Loctite! For bolts into the steel bracket, use Loctite.
Check for free movement of the lever and pulley after bolting to the bracket! If the lever sticks at any point in it’s travel, check the bracket for any weld spatter, or plating material, and use a Dremel to smooth the area. If the pulley pin is rubbing, it may be pressed in too far. Support the back side of the pulley, and press or tap it in with a hammer, until it has clearance.
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INSTALLATION OF HOTCHKIS FRONT STABILIZER BAR
1) Please look at the original front antiroll bar and note the orientation of the front bar. You will want to install the new Hotchkis bar in the same manner.
2) Securely block the rear wheels of the vehicle. Use a jack to raise the vehicle and support with jack stands.
3) Remove the factory plastic undertrays from the car with a 10mm socket on the bolts, and a small screwdriver to pry open the plastic trim plugs.
4) Disconnect the endlink from the stabilizer bar using a 14mm wrench.
5) Using a 14mm socket and extension, remove the factory frame brackets. Then remove the stock bar from the vehicle.
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Removal & Installation WARNING Do not loosen the axle wheel hub retainer until the wheel and tire are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. NOTE Have an assistant press the brake pedal to keep the axle from turning. 1. Before servicing the vehicle, please familiarize yourself with safety procedures.€ 2. Remove the axle-to-wheel hub retainer nut and washer.€ 3. Remove the parking brake shoes. WARNING Do not use a hammer to separate the outboard CV-joint from the hub. Damage to the threads and internal CV-joint components can result.€ 4. Press the outboard CV-joint until it is loose from the hub.€ 5. Remove and discard the toe link-to-wheel knuckle nut. WARNING Do not damage the boot while separating the toe link from (more…)

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REMOVAL NOTE: Perform the work with the engine installed to body when replacing a single part. 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the actuator cover of the intake cam sprocket. 6) Fasten the cam sprocket and remove from the cam shaft using ST. ST 499207400 CAM SPROCKET WRENCH
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1. Before servicing the vehicle, refer to the Precautions section. 2. Remove or disconnect the following: • Negative battery cable • Transfer case, if equipped • Transmission 1 • Pressure plate. Loosen the bolts evenly in /2 turn steps. • Clutch disc To install: 1. Install or connect the following: • Clutch disc and pressure plate. Tighten the pressure plate bolts evenly in /2 turns to 23 ft. lbs. (31 Nm) for 2.4L and 2.5L engines; 37 ft. lbs. (50 Nm) for 4.0L engines. • Transmission • Transfer case, if equipped • Negative battery cable
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The following procedures for removing the fan clutch gives the factory recommended loosening and tightening directions for the fan hub nut. However, it has been our experience that certain aftermarket parts manufacturers have changed this to enable use of universal fit parts. We recommend trying the factory direction first, then, if the nut doesn’t seem to be moving, reverse the direction. Placing too much load on the water pump snout will break it.
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1) Remove the (3) screws holding the plastic bumper fascia to the bottom of the trunk pan.
2) Remove the spare tire and jack from inside the trunk.
3) Remove the (2) rearmost plastic drain plugs from the bottom of the trunk pan.
4) Using the rotary cutting tool, remove material from the lower part of the plastic fascia as shown in the Fascia Trim Detail above.
5) While gently pulling the fascia down and rearward, install the bolt plates and 1/2-13 x 4 1/2 long carriage bolts on top of the bumper support tubes.
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Borla Performance Cat-Back ™ Exhaust System Installation
1. Place a clamp over the expanded end of the front muffler assembly and set it into position as shown in figure 4 making sure to install the hangers into the rubber isolators. Do Not tighten the clamp.
2. Place a clamp over the expanded end of the rear muffler assembly and set it into position as shown in figure 5. Do Not tighten the clamps.
3. Check your exhaust system for proper clearance under the vehicle and also for tip alignment.
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