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We recommend the use of loctite or a similar adhesive on all
steering hardware.
26. Using the new lower radiator support as a template, Mark the
lower core support for alignment of the new support. Align the
holes in the new bracket with the stock mounting holes. Mark the
core support for proper alignment of the new support after the
stock mount has been removed. Using a die grinder or hacksaw
cut away the bottom radiator mount from the core support. Be
especially careful of the a/c condenser when cutting the sheet
metal. Cut to the outside of each mounting hole approximately 1
½” to 2” and flush with the vertical surface of the core support
(allow enough room for the radiator to slide past the remaining
sheet metal without hitting). Place the new lower radiator
support bracket on the core support. Be sure that the bracket is
aligned with the marks made earlier and that the bracket is
positioned flush against the core support with the lip resting on
top of the core support. Using the bracket as a template, mark the
top of the core support through the holes in the bracket. Remove
the bracket. Drill a ¼” hole at both locations. Mount the bracket
to the core support by install a ¼” x 1” bolt with a ¼” washer
through the bracket, and the core support. Install a ¼” washer
and nylock nut on the bolt from the bottom of the core support.
Tighten the ¼” hardware securely.
27. Install the radiator on the new lower support bracket.
Remove the two rubber bushings from the plastic studs on the
top of the radiator. Install the rubber bushings into the large hole
in the 2” x 3” x 1” rectangular tube. Slide the tube with the
rubber bushing onto the studs at the top of the radiator. Reinstall
the stock upper radiator mount. The hole in the stock mount
should align with the hole in the tube. Mount the tube to the
stock bracket using a 3/8” bolt, two 3/8” USS washers, and a
3/8” nylock nut on each side. Do not tighten at this time. Be sure
that the radiator is secure. Tighten all radiator mounting
hardware securely. Install the fan shroud to the radiator using the
stock hardware. Check the fan to fan shroud clearance. Be sure
that the fan cannot make contact with the shroud. Tighten the fan
shroud mounting hardware securely. Install both radiator hoses
to the radiator. Tighten the hose clamps securely.
28. Reconnect the upper heater hose to the heater core at the
firewall. It may be necessary to remove the tie wrap around both
hoses to gain enough slack to reconnect the upper hose. The
lower heater hose needs to be lengthened. Cut the hose below the
top bend. Install the 4" heater hose extension. Fasten using two
#10 hose clamps. Install the heater hose to the heater core at the
firewall. Tighten all heater hose clamps securely. Refill the
cooling system as much as possible at this time. It will need to be
topped off after the vehicle has been started.
29. Reroute the vacuum brake booster hose over the a/c hose at
the firewall. Bend the bracket that mounts the a/c hose to the
firewall forward to a 45-degree angle. This should give the hose
ample slack. Reconnect the hose to the brake booster. If the line
still feels tight, it may be necessary to
carefully bend the steel
portion of the line to gain more slack in the line.
30. Check the a/c line at the core support. Be sure that there is
enough slack in the line to remount it to the core support. If there
is not enough slack,
carefully bend the line to gain more slack.
Be sure that there is ample slack in the line. Install the bolt that
mounts the a/c line to the core support. Tighten securely.
31. Disconnect the vacuum that runs between the bottom of the
intake and the cruise control mechanism on the passenger side
fender well. Cut the hose approximately in the middle. Install the
3" long hose extension between the two pieces of the hose.
Install two #6 hose clamps to hold the extension in place.
Tighten securely. Reinstall the hose to the bottom of the intake
and to the cruise control mechanism.
32. Reroute the hose that was connected to the vacuum module
in front of the cruise control. Reroute the hose on the other side
of the steel lines that comes up from the frame. This will give
enough slack to reconnect to the vacuum module. It may be
necessary to
carefully bend the steel portion of the line to route it
properly.
33. Reconnect the engine to body ground wire to the body. The
ground wire can be reconnected to the lower of the two holes in
the bell housing area. Tighten the mounting bolt securely.
34. Mount the parking brake cable-relocating bracket to the
stock bracket using two 5/16 x 1" bolts, four 5/16" USS washers,
and two 5/16" nylock nuts. Mount the parking brake cable to the
new bracket using the stock bolt. Remount the two brackets that
hold the cable to the bell housing. Tighten all parking brake
hardware securely. We recommend the use of loctite or a similar
adhesive on mounting hardware.
35. Using two 10mm – 1.25 x100 bolts with a 3/8” washer on
each bolt, and the two 3” long tubes mount the cab safety loop to
its original location. It may be necessary to bend the loop slightly
to align the loop to the mounting holes with the spacer tubes
installed. Apply the loctite® adhesive to the bolts according to
the loctite® application instructions. Tighten safety loop
mounting bolts securely.
WARNING
Use extreme caution when working near fuel lines and fuel tank.
Clean up spilled fuel immediately. Any spark could cause an
explosion or fire resulting in serious personal and property
damage.
36. Lengthen the fuel filler hose. Cut the filler hose toward the
bottom below the first bend. Install the 1 3/4" fuel filler
extension between the two sections of the filler hose. Install a
#28 hose clamp at each end of the extension. Tighten both hose
clamps securely. Remove the large vent hose from the filler
neck. Install the new vent hose to the filler neck vent. Install a
#10 hose clamp and tighten securely. Remove the small hose
attached to the left nipple of the box on the filler neck. Replace it
with the 1/4" hose provided in the kit. Install a #6 hose clamp
and tighten securely. Install the filler assembly in the vehicle.
Using the stock clamp, reconnect the filler hose to the fuel tank.
Using a #10 hose clamp, reconnect the large vent hose to the fuel