ULTRA RIDE FRONT STEER IFS INSTALLATION INSTRUCTIONS
1) Remove front
sheet metal, radiator and engine.
2) Locate and mark
the front axle centerline on the tops of the frame rails. (Note: On some
vehicles the centerline may need to be moved to better center the wheels in the
wheel opening. 1953-56 Ford Pickups are one example. On them we move the
centerline forward 1.)
3) Remove all front
suspension and any crossmembers that will be in the way of the new suspension.
(Note: If you need to remove the crossmember that supports the radiator and the
front sheet metal you must measure and record where the core support mounts so
that you can build a new support and get it in the proper position. this is VERY
IMPORTANT!)
4) Put frame on jack stands,
leveling it side to side. If you are going to have any rake in the chassis,
front to rear then set the frame at the anticipated rake front to rear.
If youre not going to have any rake then set the chassis level front to rear.
5) Check frame for
squareness by cross measuring diagonally from like points on each frame rail. if
frame is out of square you must get it square before proceeding.
6) If your frame is
of the open C channel type then you must box it in at least 6 ahead and
6 behind the axle centerline. We recommend that you box it from the firewall
forward if possible. Make your boxing plates from at least 3/16 steel plate.
(Note: When boxing any frame, tack weld the boxing plates in place on both sides
then weld in place very slowly, skipping from side to side, only welding 1to
2 at a time. If you weld more than that you will warp your frame rails.)
7) With the frame
boxed, leveled and raked, use a
level to draw vertical centerline marks down the inside and outside of the frame
rails.
8) Set lower
crossmember in place with the rack mounts forward, centering it front to rear on
your centerline marks. Level it side to side and front to rear. With the
crossmember level front to rear you may find that you have a slight gap between
the top of the crossmember and the bottom of the frame. If this happens then
fill the gap with weldable shim material.
Measure from each
lower a-arm hole in the crossmember to the opposite frame rail to make sure you
have the crossmember centered side to side. With the crossmember located, tack
weld it in place in several places on each frame rail. Now recheck all
measurements.
9) Next locate the upper towers,
they also center front to rear on the axle centerline. The side with the tapped
holes goes to the outside of the frame and the inside drops down to meet the top
of the lower crossmember upright. It may be necessary to grind a
little of the bottom of the inside of the tower to get it to set all the
way down on the frame. Mark and drill 1/2 holes in frame rail sides where the
bolts go through the coilover mounts.
10) Set chassis up
on jack stands, leveling it side to side. Set it at anticipated rake front to
rear.
11) Locate and mark
axle centerline on tops of frame rails. Then using a level mark outsides of both
frame rails.
12) Remove stock
front suspension completely. In some applications it may be necessary to remove
engine to install crossmember, if so then do that before proceeding.
13) Put crossmember
up underneath frame centering it front to rear on the axle centerline. Raise it
up against the bottom of the frame rails, leveling it front to rear. (Note:
There may be a gap either in front or in rear between the bottom of the frame
and the top of the crossmember, depending on how much rake you set in the frame
front to rear. The crossmember must be level front to rear as well as side to
side. If this leaves you with a gap then fill it with weldable material if it is
more than you can fill with weld.)
14) With
crossmember located tack weld it in place on both frame rails, skipping from
side to side when welding. After tacking in place double check all measurements.
If everything is right then weld completely in place, again skip from side to
side to prevent overheating and warpage.
15) Install a-arms
on crossmember. Install coilover shocks on lower a-arms and on upper mounts on
crossmember.
16) Install
spindles on a-arms.
17) Install rack
and pinion on crossmember, install tie rod ends on rack. Bolt tie rod ends to
spindles from underneath.
18) Pack wheel
bearings with grease, then install caliper mounting brackets and rotors on
spindles. Next, install calipers on brackets. There is a right and left caliper,
just remember that when mounted the bleeder screw on the calipers must be up.
Refer to enclosed brake kit instruction sheet.
19) Grease ball
joints.
20) With all
suspension components installed set vehicle on the ground to check ride height,
if necessary adjust coilover shocks as needed.
21) Plumb brake
hoses and build steering shaft from column to rack and pinion. If you need brake
hoses or steering shaft components give us a call, we can provide both.
22) Tighten all
bolts and fittings to the proper torque for their size. Retighten after 100 and
500 mile