Note on Sport Model Trucks – This light bar will not mount correctly on sport model trucks without realigning the bumper. TRUCKS WITH FACTORY TOW HOOKS
1. Temporarily remove the factory tow hooks and set them aside along with the bolts.
2. Position your KC light bar so the brackets will sandwich between the tow hooks and the frame. ( NOTE – The light bar must be rolled into Bumper place by inserting the lower end of the brackets into the opening first Bolts and then rolling it up into place.)
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REMOVAL OF EXISTING MIRRORS
1. Have both windows in the down position. To remove the trim panel on both doors, first remove the panel around the door handle, using 10 mm socket remove the screw holding the door handle. Next remove the four screws that hold the door trim panels in place (See diagram A on page 5). Remove the door trim panel by lifting up and then out.
2. Unplug the electric cord that comes from the mirrors located at the rear of each mirror at the mirror mount area.
3. Support the stock mirror while removing the 3 mirror mount lug nuts using a 10 mm socket. Save the stock nuts for later in the install.
4. Remove the stock mirror (save the stock gaskets as they will be re-used).
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REMOVAL OF EXISTING MIRROR:
1. Have both windows in the down position. Remove the trim panel on both doors, start by removing two philips screws. One is located in the hand hold and the other is in the corner in front of the window. (note – there are two trim panel clips below the window).
2. Remove the foam insulation covering the stock mirror mounting nuts.
3. Support the stock mirror while removing the 3 mirror mount nuts and then remove the stock mirrors.
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Monster Exhaust System Installation:
1. Disconnect the negative (ground) cable from the battery (if there is more than one battery, disconnect both negative cables). Secure the cable so it cannot accidentally come in contact with the post.
2. Raise the vehicle and support it securely with properly weight-rated safety stands, ramps or a commercial hoist. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the wheels are centered squarely on the topsides. Place the transmission in park (automatic), set the parking brake and securely block the wheels that are on the ground.
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As a general rule, the taller a vehicle is, the easier it will roll. Offset, as much as possible, what is lost in rollover resistance by increasing tire track width. In other words, go “wide” as you go “tall”. Many sportsmen remove their mud tires after hunting season and install ones more appropriate for street driving; always use as wide a tire and wheel combination as possible to enhance vehicle stability. Braking performance and capability are decreased when significantly larger/heavier tires and wheels are used. Take this into consideration while driving.
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FRONT INSTALLTION INSTRUCTIONS
1. Block the rear wheels of the vehicle. Raise the front of the vehicle and support the vehicle with jack stands under the frame rails. Remove the front wheels and tires and set aside. Position a hydraulic jack under the front axle and raise the jack until the front suspension begins to compress.
2. On both sides of the vehicle, scribe alignment marks on the adjustment cam and axle bracket at the lower link to axle attachment point for later reference. See Photo 1
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This installation sheet is for brackets with tube & rail system. Drop steps purchased separately.
BRACKET INSTALLATION
1) Remove contents from box and check for damaged parts. Verify all parts are present, making sure to read and understand instructions before install.
2) Locate (8) factory holes on inside body panel. Remove black tape covering holes 3, 5, 6, & 7 on Quad Cabs and holes 2, 3 & 4 on Reg Cabs. Install frame lock bolts into factory locations.
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The net amount of ride height increase depends upon the age and use of the vehicle, wheel offset, and numerous other factors. Stated torsion bar ride height increases are based upon factory specifications. If the torsion bars were “cranked up” at some point in the past, expect a corresponding reduction in overall height increase with the new torsion keys. Note that torsion bars, like any other spring, are subject to fatigue and sagging over time. Also, torsion bars have different ratings depending on how the vehicle was equipped from the factory. In some cases, installing heavier rated bars (which can be purchased from a dealer) may be the only solution to regaining ride height lost from adding heavy aftermarket accessories, such as a winch bumper or snow plow.
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All hardware should be tightened only enough to ensure safety during assembly. Fully tighten all hardware after entire assembly is completed.
1. Insert pairs of 5/8 inch x 7 1/2 inch and 5/8 inch x 8 inch hex bolts through holes in four 1/2 inch thick top bars from the kit. Place the 7 1/2 inch bolt/bar assemblies over the side rails of the vehicle ahead of the cab mount structure. Place the 8 inch bolt/bar assemblies over the side rails behind the cab mount structure.
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Please read instructions thoroughly and completely before beginning installation. Installation by a trained mechanic is recommended
Step 1: Position truck on a flat surface and lift vehicle by the frame so that the front wheels are off the ground using a floor jack and jack stands or a (2) two post lift if available and remove the front wheels and tires
Locate the front sway bar and unbolt the lower end link. (Do this on both sides of vehicle).
Next locate the lower track bar mount on the passenger side of the vehicle and unbolt from axel.
Step 2: Place an index mark on the stock coil and a matching one on the lower coil pocket . This will allow you to replace the coils in the stock location Next locate the upper shock mounts (they are located in the engine compartment) and remove the upper shock hardware. Next remove the 3 nuts from the upper shock mounts (Do this on both sides of truck). Now remove the lower shock mounting bolts and remove the shocks by pulling them up through the engine compartment. (Do this on both sides of truck)
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