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How to Install Fabtech 6 in. Basic Lift System w/ Shocks on your Sierra
Installation Time
4 hours
Tools Required
- Basic Hand Tools
- Floor Jack
- Jack Stands
- Assorted Metric and S.A.E sockets, and Allen wrenches
- Torque Wrench
- Die Grinder w/ Cutoff Wheel or Sawzall
Shop Parts in this Guide
INSTRUCTIONS
FRONT SUSPENSION
1. Disconnect the negative terminal on the battery. Jack up the front end of the truck and support the frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE! Remove the front tires.
2. Working from front of the truck, disconnect the tie rod ends from the steering knuckle by striking the knuckle to dislodge the tie rod end. Use care not to damage the tie rod end when removing. SEE FIGURE 1
3. Unplug the ABS brake connection from the frame and control arm. Remove the brake hose bracket from the steering knuckle. Remove the brake hose bracket from the coil bucket and save hardware. Remove the caliper from the rotor and secure the brake caliper to the frame out of the way. DO NOT ALLOW THE BRAKE CALIPER TO HANG FROM THE BRAKE LINE HOSE. SEE FIGURE 2
4. Remove the wheel stud clips and discard. Remove bearing cover, axle nut, washer, and rotor with hub bearing. (DO NOT REMOVE THE HUB BEARING FROM THE ROTOR). Retain parts and hardware for reinstallation. SEE FIGURES 3-4
5. Remove the upper and lower ball joint nuts. Disconnect the upper and lower ball joints from the steering knuckle by striking the knuckle with a large hammer next to each ball joint on the knuckle to dislodge the ball joints. Use care not to hit the ball joints when removing. Save nuts and discard knuckle. SEE FIGURE 5
6. Remove the shock assembly and save with the hardware. Remove and discard the factory brake line bracket from the brake hose that attached the hose to the upper control arm. SEE FIGURE 6
7. Disconnect and remove CV axles from differential housing and the sway bar endlinks and save. Discarding ONLY the CV axle hardware. SEE FIGURE 7
8. Remove the lower control arms from the frame and retain with the hardware for reinstallation. SEE FIGURE 8
9. Locate, remove, and save the sway bar, discard hardware. SEE FIGURE 9
10. Remove front factory differential skid plate and splash shield and discard.
11. Disconnect front driveshaft from differential housing and retain bolts and u joint clamps for reinstallation. Locate, remove, and discard the factory rear crossmember with hardware.
12. Disconnect the electrical connection including the two retaining clamps and the vacuum line from differential housing. Remove differential housing assembly from vehicle. Retain hardware for reinstallation.
13. Locate the rear driver lower control arm mount on the frame. Measure 3” from the inside edge of the mount toward the frame and mark with a paint pen. Use a sawzall and cut the mount from the frame. SEE FIGURE 10
14. Locate the rear passenger lower control arm mount on the frame. Measure 3 ½” from the inside edge of the mount toward the frame and mark with a paint pen. Use a sawzall and cut the mount from the frame. SEE FIGURE 11
15. Locate the factory front lower control arm pockets. Grind ¼” section from both Corners of the pockets. SEE FIGURES 12-13
DUE TO VARIANCES IN EACH TRUCK, ADDITIONAL GRINDING MAY BE REQUIRED FOR PROPER FITMENT OF THE CROSSMEMBERS. USE THESE MEASUREMENTS AS A STARTING POINT AND CLEARANCE THE FRAME POCKETS AS NEEDED FOR PROPER FITMENT OF THE CROSSMEMBERS
16. Locate the front differential. The diff will need to be trimmed / cut in three places. The first is the 90 degree tab on the bottom front of the diff. Measure in 1 ¼” from the outer edge and cut with a sawzall as shown in photos. The second cut is the bottom rear gusset on the passenger side of the diff. Measure down ¼” from the pinion side of the gusset and mark 1 ½” long and ½” deep. Using a barrel sander, sand down the gusset as shown in photos below. The third cut is second gusset from the rear on the driver side of the diff. Mark the gusset 2 ¼” from the top and a ¼” in. Using a barrel sander, sand down the gusset. SEE FIGURES 14-19
USE THESE MEASUREMENTS AS A STARTING POINT AND CLEARANCE THESE AREAS AS NEEDED FOR PROPER FITMENT OF THE DIFFERENTIAL
17. Locate the driver upper differential mount. The locating pin on this mount needs to be cut off. Using a die grinder with a cutoff wheel, cut the pin flush with the bracket. SEE FIGURES 20-21
18. Locate FT20347 (driver) & FT20633 (pass) Diff. brackets and the factory diff hardware. Install the brackets to the factory mounts with the taller part of the bracket to the front of the truck with the factory hardware. NOTE: Use the provided 1/2-13 X 2” Carriage bolt on the passenger side diff bracket.Torque to 127 ft-lbs.
SEE FIGURES 22-23
19. Locate the supplied ½” x 1 ¾” and 9/16” x 1 ¾” hardware and the front diff. Install the diff onto the new drop brackets using the ½” hardware on the driver’s side and the 9/16” on the passenger side. Torque the ½” hardware to 127 ft-lbs. and the 9/16” to 184 ft-lbs. Re-connect the electrical and vacuum connections back onto the diff. (CHECK THE CLEARANCE OF THE DIFF TO THE FRAME IN SANDED AND CUT SPOTS ON THE DIFF. FOR ADAQUATE CLEARANCE TO THE FRAME AND CROSSMEMBER). SEE FIGURE 24
20. Locate and install FT20611BK rear crossmember into the factory lower control arm pockets using the stock hardware and leave loose at this time. (CHECK THE CLEARANCE OF THE DIFF TO CROSSMEMBER WHERE IT WAS SANDED DOWN IN STEP #17 FOR ADAQUATE CLEARANCE TO THE FRAME AND CROSSMEMBER). SEE FIGURE 25
21. Locate and install FT20610BK front crossmember into the factory lower control arm pockets using the stock hardware. Leave loose. (CHECK THE CLEARANCE OF THE DIFF TO CROSSMEMBER WHERE IT WAS SANDED DOWN IN STEP #18 FOR ADAQUATE CLEARANCE TO THE FRAME AND CROSSMEMBER). SEE FIGURES 26-27
22. Install FT90085 bushing kit into FT20365 diff bracket.
23. Remove the 3 factory diff housing bolts.
24. Install diff bracket using the factory bolts and the 1/2-13x4-1/2” bolt, nut, and washers. Torque 1/2” hardware to 127 ft-lbs and factory hardware to 58 ft-lbs SEE FIGURE 28
25. Locate FT20284 Crossmember Support Tubes. Install the lower control arms into the new crossmembers using the 5/8” x 5” hardware in the front pocket. Position the control arms into the crossmember and insert only the front 5/8” bolt just so that it is through the arm. Position the Support tube between the crossmembers and rotate them up to the locating tabs on the crossmember. Install 5/8” x 5 ¾” hardware in the rear pocket and the front bolt with hardware. Leave loose. SEE FIGURE 29
26. Locate FT20304 Skid Plate and the supplied ½” x 1-1/4” hardware and attach the rear of the skid plate to the bottom of the rear crossmember. Use the supplied 7/16” x 1 ¼” hardware and attach the front of the skid plate to the front crossmember (MAKE SURE THAT THE DIFF IS CLEARANCED ENOUGH TO CLEAR THE SKID PLATE). SEE FIGURE 30
27. Torque the crossmember frame pocket bolts to 125 ft-lbs., the lower control arm bolts to 254 ft-lbs. the ½” skid plate hardware to 127 ft-lbs., and the 7/16” to 83 ft-lbs.
28. Locate the factory coilovers. Remove the nut clips from the cross-shaft and discard. Using a press, press out the cross-shaft and the bushing from the bottom of the coilover and discard. SEE FIGURES 31-33
29. Locate Box 3 FTS21042BK which has FT20339 Shock Mount to Arm, FT20323 Shock Extensions, FT20568 Shock Brackets, FT20342 or FT20351 Aluminum Bushings ( Due to vehicle Variences), Hardware Kit FT20295, FT1036 Bushings, and FT148 Sleeves. Using a press, press the bushings and sleeves (IMPORTANT: Use the provided lube to prevent squeeking) into the shock extension. Insert the Aluminum Bushings into the bottom of the factory shock. SEE FIGURE 34-36
30. Place the Shock Brackets around the bottom of the shock and align with the aluminum sleeves. Position the shock extension over the brackets and also align with the aluminum sleeves. Locate the supplied ½” x 4” bolts and hardware and install through the aluminum bushing and the shock mount. Leave loose. Locate the 5/16” x 1 ½” bolts and hardware and install into the shock brackets. Tighten the 5/16” hardware so the brackets are evenly spaced on the shock. Torque to 20 ft-lbs. Torque the ½” hardware to 127 ft-lbs. SEE FIGURE 37-40
31. Locate the factory upper shock hardware. Install the shock into the factory shock bucket and leave loose. SEE FIGURES 41-42
32. Locate FT20339 Lower Shock Mount, FT20352 Lower Mount Shim, and the supplied 7/16” x 2 ½” hardware. Position the mount onto the lower control arm so the flat side of the bracket will be flush with the stop on the arm. Position the shim (ONLY USE THE SHIMS ON THE FORGED STEEL CONTROL ARMS) in between the new mount and the control arm. Attach with the 7/16” hardware and torque to 50 ft-lbs. Rotate the lower control arm up and attach the strut to the new mount with the provided ½” x 3 ¾” hardware and torque to 127 ft-lbs. (it may be necessary to rotate the shock and extension to attach). Torque the top shock bolts to 83 ft-lbs. SEE FIGURES 43-46
33. If you have the factory aluminum knuckle locate FTS20612D and FTS20612P you need to install the FT20613 and FT20614 ball joint spacer under the nut when installing the knuckle. Attach the lower control arm to the knuckle using the stock hardware and torque to 70 ft-lbs. Attach the upper control arm to the new knuckle using the factory hardware and torque to 75 ft-lbs. SEE FIGURE 47
34. Reinstall axle shaft through new knuckle and torque axle nut to 150 ft-lbs. and install bearing cover.
35. Locate and install the FT20289 CV spacers between the CV axle and the differential housing using 10mm x 50mm bolt and washer with the provided thread lock compound and torque to 58 ft-lbs. in a cross pattern. SEE FIGURES 48-49
36. Reinstall the dust shield and hub bearing assembly using the stock hardware and torque flange bolts to 125 ft-lbs.
37. Trim the dust shield to clear the caliper. SEE FIGURES 50-51
38. Reinstall brake rotor and caliper. Torque caliper bolts to 100 ft-lbs.
39. Locate FT20277 outer tie rods. Loosen the jam nut and remove the factory outer tie rods and discard, leaving the factory jam nut on the inner tie rod. Install the new outer tie rod onto the inner tie rod until it makes contact with the jam nut. Attach new tie rod end to the knuckle with the supplied nut and torque to 40 ft-lbs. (THIS IS JUST A STARTING POINT; A FINAL ALIGNMENT MUST BE PERFORMED UPON COMPLETION OF SUSPENSION SYSTEM). SEE FIGURES 52-53
40. Locate FT20312 (Drv), FT20318 (Pass) Sway Bar Frame Bracket, and the supplied 7/16”x2 ¼” and 10mm x 30mm hardware. Position the frame bracket on the frame so that sway bar will be farther back from the suspension and attach with the 10mm hardware. Locate the factory sway bar with the factory mounts and attach to the new brackets with the 7/16” hardware and torque to 83 ft-lbs. and the 10mm hardware to 58 ft-lbs. SEE FIGURE 54
41. Locate FT20602 Sway Bar Mounts and the supplied 18mm x 50mm hardware. Position the Sway Bar Mount so that it is on the bottom of the sway bar with the SHORTER side of the mount against the stop plate end of the mount. Attach with the 18mm hardware and torque to 300 ft-lbs. Locate the factory sway bar end links and attach to the new mount and the lower control arm. (NOTE - SOME PICK UP TRUCKS MAY BE EQUIPPED WITH SUV STYLE SWAY BAR). SEE FIGURE 55
42. Locate FT20313 (drv.) FT20314 (pass) Brake Line Bracket and ¼” x ¾” hardware. Position the new bracket into the factory brake line bracket location and attach with the factory hardware and the ¼” hardware. Attach the factory brake line bracket to the new Fabtech bracket. Carefully bend the hard brake line and attach with the supplied ¼” hardware. Torque to 10 ft-lbs. SEE FIGURES 56-60
43. Re-route the brake hose and the ABS Line to the steering knuckle using the adel clamp to the back of the steering knuckle and attach with ¼” x 3/4” bolt and washer. Torque to 10 ft-lbs. Route the ABS line next to the brake hose. Re-connect the ABS line to the harness in the wheel well. Using provided plastic tyraps secure line to the hose and away from the tire and wheel. SEE FIGURE 61
44. Reattach the driveshaft to the differential yoke using the stock hardware and torque to 19 ft-lbs.
REAR SUSPENSION
45. Jack up the rear end of the vehicle and support the frame rails with jack stands. Supporting the rear differential, remove and discard the rear shocks, u bolts and blocks. Disconnect the brake line bracket at the differential and save the hardware. Remove the ABS line clip from the top of the frame and at the axle. Remove the e-brake cable bracket on the driver’s side of the frame and save the hardware. Lower axle down slowly. Use care not to over extend the brake hose. SEE FIGURE 62
46. Clamp the leaf spring at both ends of the spring and remove the center bolt.
47. Separate the overload spring from the pack.
48. Install the provided add a leaf with the new center bolt in a pyramid pattern smallest on the bottom graduating to the longest on top. Align by using the secondary factory pin installed in the spring. The factory flat overload leaf should remain on the bottom of the pack. Clamp the spring and tighten the center bolt as not to leave a gap between the springs. Cut the thread of the bolt smooth with the nut. The nut should be on the top of the leaf spring pack. SEE FIGURE 63
49. Locate and install the rear lift blocks with the provided short center pin on the bottom of the block, to the axle. The short end of the block should face to the front of the vehicle. Using the provided U bolts, nuts and washers, align the axle, lift blocks, and springs. Torque the U-Bolts to 184 ft-lbs.
50. Remove the rear bump stops from the frame. Take the factory bolts and use a die grinder with a cut off wheel and cut a ½” from the bottom. Locate FT20025 bump stop spacers and install to the factory bumpstops using the trimmed factory bolt. Use a drill with a 7/16 bit and drill out the weld nut in the frame that originally held the bumpstops in place. Install the 10mm x 25mm bolt in from the inside of the frame and attach the new bumpstop spacer. Torque the bolts to 58 ft-lbs. SEE FIGURES 64-67
51. Locate FT20349 Brake Line Bracket and the supplied 5/16” hardware. Attach the new bracket to the differential and attach the brake line to the new bracket. Torque to 29 ft-lbs.
52. Install new Fabtech shocks (not included with this kit) with the factory hardware and torque 100 ft-lbs.
53. Working from the driver’s side, insert the previously removed upper ABS line clamp into the existing hole on the inside of the frame. Re-insert the lower ABS line clamp back into the stock location. Use two of the supplied zip ties and attach the ABS line to the U-Bolt. Keep the line taught at the block and ensure that there is enough slack in the line for full travel of the rear axle. SEE FIGURES 68-70
54. Working from the passenger side, locate the original line clamp hole in the top of the frame and measure 2” down the inside of the frame and drill a ¼”. Insert the previously removed upper ABS line clamp into the new hole on the inside of the frame. Re-insert the lower ABS line clamp back into the stock location. Use two of the supplied zip ties and attach the ABS line to the U-Bolt. Keep the line taught at the block and ensure that there is enough slack in the line for full travel of the rear axle. SEE FIGURES 71-74
55. Remove the driver’s side E-brake cable from the previously removed bracket. Position the passenger side cable into the bottom position of the bracket where the driver’s side was originally. Re-install the bracket back into the factory location with the factory hardware. SEE FIGURE 75
56. Install tires and wheels and torque lug nuts to wheel manufacturer’s specifications. Turn front tires left to right and check for appropriate tire clearance. Note - Some oversized tires may require trimming of the front bumper & valance.
57. Check front end alignment and set to factory specifications. Readjust headlights.
58. Recheck all bolts for proper torque.
59. Recheck brake hoses, ABS wires and suspension parts for proper tire clearance while turning tires fully left to right.
60. Check the fluid in the front and rear differential and fill if needed with factory specification differential oil. Note - some differentials may expel fluid after filling and driving. This can be normal in resetting the fluid level with the new position of the differential/s.
61. Install Driver Warning Decal. Complete product registration card and mail to Fabtech in order to receive future safety and technical bulletins on this suspension.
62. Have vehicle properly aligned to factory specs.
Vehicles that will receive oversized tires should check ball joints, uniballs and all steering components every 2500-5000 miles for wear and replace as required.
RETORQUE ALL NUTS, BOLTS AND LUGS AFTER 50 MILES AND PERIODICALLY THEREAFTER.
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