IMPORTANT NOTES:
A. WHEEL CHANGE REQUIRED: Trail Master's Nissan suspension system is designed to be used with wheels with a back space of 3 3/4 inches or less. Wheels with a back space greater than 3 3/4 inches, including factory wheels, will interfere with the steering knuckle adaptor used in this system. Serious tire damage will result if wheels with a back space of more than 3 3/4 inches are used. Prior to installation you must determine carefully that your choice of wheel/tire combination will not come in contact with steering knuckle adaptors.
B. EXHAUST MODIFICATION: Corss-over pipe alteration is necessary to accommodate this suspension system on 6 cylinder models only. Trail Master offers the NX30 accessory to perform this modification. Kit comes complete with all necessary hardware and instructions.
C. Front end alignment will be required after system installation.
D. PRODUCT SAFETY WARNING: Certain Trail Master products are intended to improve off road performance. Modifying your vehicle for off road use may result in the vehilce handling differently than a factory equipped vehicle. Use of oversized tires, suspension lifts, body lifts and other suspension modifications may raise your vehicles center of gravity resulting in an increased tendency for the vehicle to pitch and roll during sudden turns or abrupt maneuers. Extreme care must be used to prevent loss of control or vehicle roll-over. Failure to drive your modified vehicle safely may result in serious injury or death. Drive at reduced speeds to ensure your ability to maintain control of the vehicle under all driving conditions. always wear seat belts.
Trail Master does not recommend combined use of suspension lifts, body lifts, or other lifting devices. Combining lift devices may require altering your vehicles track width to ensure safe handling characteristics. consult a professional mechanic with off-road experience before combining any lifting devices.
FRONT INSTALLATION INSTRUCTIONS;
PATHFINDER AND PICKUP
1. Raise vehicle with hydraulic jack or equivalent and place jack stands under frame away from lower A-arm anchors. Remove wheels, front skid plates, and front anti-sway assembly by removing front mount bolts and end links at lower A-arms.
2. Measure exposed threads on torsion bar adjustment bolts and record for reassembly. Unload torsion bars. Note position of indexer and torsion bar A-arm mount plate. Label torsion bars to insure driver and passenger side do not get interchanged. Disconnect torsion bar to A-arm mount plate. Remove torsion bars from vehicle.
3. Remove brake clips securing lines to frame. Without kinking line, carefully pull line assemblies down approximately three inches.
4. Remove front drive shaft, (6 cylinder models only). Match mark flanges for proper reassembly.
5. Remove compression rod end nuts, washer, and bushing. Remove bolts attaching rod to lower A-arm, 2 per rod. Remove rod and bushing assemblies from vehicle.
6. Remove front lower A-arm pivot bolts. (splined on backside). Block A-arms from frame.
7. Safely support front differential. Remove bolts anchoring differential vent line to front corssmember. Remove bolts retaining differential to front crossmember mounts. Remove rear differential crossmember bolts from frame.
8. Raise differential. Remove four bolts retaining front crossmember to frame. Remove crossmember.
9. Remove A-arm pivot bushing from frame member using recommended service tool in the OEM service manual. NOTE: Use caution not to deform or score frame member when removing bushings.
10. Install "SL" sleeves into frame, where OEM bushings were removed in step 9.
11. Install front lower A-arm drop brackets "LA". Insert 9/16" x 3 1/2" bolts into "LA" and through "SL" from back side. Install 1/2 x 3 1/2" bolts, through "LA from backside. When installing 1/2" bolts in "LA"s, insert "LAS" spacers, one in front, one in rear, between frame and "LA". Maintain frame spacing by running 1/2" bolts through #2 sleeves. DO NOT tighten fasteners at this time.
12. Install OEM front crossmember into "LA" brackets. Insert OEM bolts through "LA" brackets and crossmember from back side. Torque all fasteners in steps 11 and 12 to specs.
13. Lower differential onto front crossmember. Reform differential vent line and reattachment to front cross member. Reinstall front differential to crossmember mount bolts. DO NOT tighten mount bolts at this time.
14. Install rear differential crossmember drop brackets. Mount bracket "7049" on rear side of front OEM tab using 1/2" x 1" bolt, waher and nut. Install bracket "7050" on rear side of rear OEM tab. Secure with 1/2" x 1" bolt, washers, and nuts provided. NOTE: Brackets angle rearward, radius end down. Repeat on opposite side.
15. Raise rear differential and crossmember into "7049" and "7050" brackets. Fasten crossmember to drop brackets using OEM bolts. Tighten all fasteners in steps 13, 14 and 15 to spec. Using top hole in "7050" bracket as template, drill 3/8 hole in OEM frame tab and secure with 3/8 x 1 bolts and nuts.
16. Remove cup washer from front side of compression rod frame mount using chisel or equivalent. Dress surface to remove any burrs after removal of washer. NOTE: Do not remove cup washer from back side of compression rod mount. Repeat on opposite side.
17. Install step washer "SW" in backside of compression rod frame mount.
18. Install bracket "RAD" on to front surface of driver's side compression rod frame mount. NOTE: "Tuning" or "Dressing" of frame member may be required for custom fit of "RAP" on to frame. Insert 3/'4" x 2" bolt and waher through "RAD" into "SW". Install nut, run up, but Do Not tighten. (Left image) Using small "C" clamp, draw rear surface of "RAD" tight to frame. Using the two rearmost holes in bracket as a template, drill two 5/16" holes into frame. Install 3/8" x 1 1/4" self-tapping bolts and tighten to specs. Using remaining hole as template, drill a 3/8" hole through frame flange. Install 3/8" x 1" bolt, washers, and nut. Torque to spec. Now torque 3/4" bolt and nut assembly to spec. Repeat step on passenger side using bracket "RAP". (Right image)
19. Install front bump stop extensions, "AB5" brackets. Position bracket in such a way that the 3/8" bolt/nut combination to be installed, does not interfere with gusset inside frame. Index and drill, 3/8" hole through frame. Mount "AB5"s using 3/8" x 1" bolts, washers and nuts. torque fasteners to spec. Repeat step on opposite side.(See image) NOTE: Operation of vehicle without stop extensions will result in damage and/or failure to OEM and related components.
20. Reinsert torsion bar clamp bolts in A-arms as they were stock, inside out. Install lower A-arms into "LA" brackets using OEM bolts, spline head rearward. DO NOT tighten privot bolt at this time. tighten pivot bolts after lowering vehicle to ground. Install compression rods and bushings through brackets "RAD" and "RAP" respectively. Reinstall OEM bolts retaining compression rods to A-arms. Reassemble compression rod rear bushing, washer, nut assembly. Torque OEM compression rod fasteners to specs.
21. Install brake line extension brackets "FBB"s onto OEM frame brackets. Slitting frame may be required to remove line from OEM hanger. Do not cut or score line when slitting bracket. Fasten "FBB"s with 3/8 x 1 bolts, washers, and nuts. Tighten to spec. Refasten brake line assemblies into "FBB" brackets with OEM clips.
22. Support lower A-arms. Remove stock shocks. Remove cotter pins and nuts from upper ball joints and outer tie rod ends. Separate ti-rod end and upper ball joint from knuckle using recommended tool. Thoroughly clean surfaces that will be in contact with "AKL", AKR", and "KP" components. Check engagement surfaces for burrs. If burrs are present, remove by lightly dressing with file.
23. SAFETY NOTE: It is imperative that the assembly and torque sequences in this step be followed to assure a complete and proper installation. ASSEMBLY NOTE: Apply loctite to all threaded surfaces in this step. Install tapered sleeves, "TTS", into OEM steering knuckle tie-rod taper. Place Trail Master adaptor, "AKL", on driver side OEM steering knuckle. Install 1/2 x 2 1/2 bolt from the top down and install nut, DO NOT tighten. Insert tapered stud, "7048", through base of knuckle adaptor and into OEM knuckle. Place plate "KP" over lower end of stud and install 7/16 x 1 1/4 fine thread bolts finger tight. Install 5/8" slotted nut on lower end of tapered stud. Torque 5/8" slotted nut to 95 LBS. Torque 7/16 bolts to 55'LBS. Install 5/8" slotted nut onto upper end of stud and torque to 75 LBS. Insert cotter pins supplied. In the event that slot does not line up with hole in stud, tighten nut to gain access. DANGER: To insure tapered stud is properly seated, torque on upper slotted nut Must Not exceed torque of lower slotted nut. Torque 1/2 x 2 1/2 fastener assembly to 75' LBS. Engage upper ball joint into "AKL" and torque to OEM spec. (See image) Repeat procedure on passenger side using "AKR".
24. Remove tie-rod adjustment sleeve and outer tie-rod end. NOTE: Adjustment sleeves must have 3/8" of material removed from each end. Inner and outer tie-rod ends must have 1/4" removed from threaded ends for proper alignment to be achieved. NOTE: Thread engagement of inner and outer tie-rod ends to sleeve Must Be Identical. Repeat ste on opposite side.
25. Reinstall anti-sway bar and end links. NOTE: Front bump stop extension brackets my require slight rotation to eliminate interference with anti-sway bar.
26. Install Trail Master shock absorbers. Torque fasteners to spec.
27 Reinstall torsion bars, driver and passenger side respectively, properly index bars and clamps using notes from step 2. Adjust torsion bars to the pre-recorded settings. Insure adjustment is within OEM specifications.
28. Perform exhaust modification using Trail Master exhaust kit part #NX30, if required.
29. Reinstall driveshaft.
30. Install RECOMMENDED wheel and tire combination. (3 3/4" backspace wheel)
31 Lower vehicle to ground. Torque OEM front pivot bolts to spec. Check ALL fasteners for proper torque. Check ALL brake lines and moving members for adequate clearance.
32. Complete REAR INSTALLATION, align front end. MAINTENANCE NOTE: Recheck all fasteners for torque after 500 miles of modearte use. There after, include a system inspection\check with regular service of the vehicle. Retain this instruction pamphlet and information regarding maintenance of your vehicle for future reference.
REAR INSTALLATION INSTRUCTION - PATHFINDER
1. Place vehicle in park and block front wheels. Remove rear shock absorbers. Remove bolt retaining pan hard rod to frame.
2. Remove clip attaching rear brake line to frame bracket. Carefully extend brake line rearward. Slit frame bracket. Do not cut or score brake line when slitting bracket. Remove brake line from bracket. Attach "RBB" bracket to OEM frame bracket with 3/8 x 1 bolt, washers, and nut. Attach brake line to lower end with OEM clip.
3. Raise rear of vehicle and place jack stands on each side of frame. Remove wheels and tires. Remove fasteners attaching differential vent tube to frame cross member. Replace vent line with 24" rubber hose supplied and secure with OEM fasteners.
4. Install pan hard rod bracket "TBL". Insert 9/16" x 3" bolt through bracket and #11 sleeve, run up, but do not tighten nut. Install 7/16 x 1" bolt, washer, and nut into upper hole in back side of bracket and frame. Tighten both fasteners to spec.
5. Using coil spring compressor, remove coils from vehicle. Remove upper coil insulators.
6. Using holes in "CBL"s as template, mark and center punch accessible holes, minimum of three per bracket. Drill 1/2' holes in OEM Spring seat.
7. Install "CBL"s with 7/16" x 1" bolts, washers and nuts. (Four per bracket supplied).
8. Remove OEM bumpstops. Install brackets "AB4" to frame using OEM bolts and nuts. Install OEM bumpstops using 3/8" x 1" bolts, washers, and nuts. Tighten all bolts to spec. (See image) NOTE: Operation of vehicle with outstop extensions will result in damage and/or failure to OEM and related components.
9. Install OEM coil insulators on to "CBL"s. Reinstall coil taking care that coil properly seats on axle and insulators.
0. Install RECOMMENDED wheels and tires. Lower vehicle to ground. Install Trail Master shock absorbers.
11. Reinstall pan hard rod into new bracket using OEM fasteners. Torque fastener to spec.
12. Again lift vehicle and safely support. Check clearance between drive shaft and cross member. In the event that clearance is less than 1/2", it will be necessary to concave crossmember to gain clearance. failure to do so may result in driveline component failure.
13. Lower vehicle to ground. Recheck all fasteners for proper torque. Check all brake lines and mobile members for adequate clearance.
REAR INSATALLATION INSTRUCTION-PICKUP
1. Place vehicle in park and block front wheels. Raise rear of vehicle. Place jack stands under each side of frame. Remove wheels and tires.
2. Remove rear shocks and differential vent line. Install replacement vent hose provided.
3. Remove pins in parking brake levers at wheel backing plates. Relocate cables from over spring to under spring. Align tab on axle holding brake line junction upward 15 degrees to gain length on brake line.
4. Support rear differential and remove U-bolt plates. Lower differential and place 3" blocks supplied "KB" between spring and spring perch. Narrow end of block forward.
5. Install replacement U-bolts supplied over spring. Install OEM U-bolt plate. Align blocks and torque U-bolts to spec.
6. Reinstall parking brake cables into levers with OEM pins and secure with cotter pins provided.
7. Install Trail Master shocks and RECOMMENDED wheels and tires.
8. Lower vehicle. Retorque All fasteners. Check all brake lines and mobile members for adequate clearance.
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This page last updated on 11/10/00.