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Tools Needed:
- ⅜” & ½” Ratchets
- ½”, 9/16”, ¾”, 1 ⅛”, 12mm, 17mm, 19mm Sockets
- ½”, 9/16”, ¾”, ⅞”, 11/16”, 1”, 1 ⅛” Wrenches
- 7/32”, ⅝” Allens
- Flathead Screwdriver
- Side Cutters
- Grinder
- Torch
- Welder
- Hammer
- Floor Jack and Jack Stands
- Torque Wrench
- Tape Measure
- Drill & 3/4” Drill Bit
- Power Steering Fluid (Royal Purple Recommended)
Installation Notes:
- 1. Read all instructions completely and carefully before you begin.
2. Check to make sure the kit is complete and that no parts are missing. If anything is missing, please contact Trail-Gear at (559) 252-4950.
3. Park vehicle on a clean, dry, at, level surface and block the tires so the vehicle can not roll in either direction.
Installation Instructions:
- 1. Before starting installation, take some measurements of your truck so that you can determine proper set up of your
new 3 link kit. Take these measurements at ride height on a level surface. Measure your current wheelbase and front
axle pinion angle. Record the data in the table on the last page of these instructions.
2. Mark the center-line of the front axle on each side of the
frame. These marks will provide a reference when all
brackets are cut off.
3. Remove axle, cut off front suspension of the truck, and
grind smooth.
4. If you are using a OEM housing. Cut spring perches and
shock mounts off of axle and grind smooth. If you are
using a Rock Assault housing with spring perches already
installed, you will need to leave the short side
(passenger) perch in place and cut off only the front and
rear portion of the perch leaving the truss in place.
5. Position axle on bench and raise the pinion until the
pinion angle matches the angle measured in step 1.
6. Mark axle 3 inches in from range on each side. Place the outside of the Lower Link bracket on the line and level them
to the axle. This will place the link brackets level at ride height with the desired pinion angle. Tack weld them in place.
If you are using a Rock Assault housing , place the brackets against the weld on the drop range. Approx 3” from the
knuckle ball range.
9. Place the vehicle at ride height. This will be critical if you
are matching a leaf spring ride height in the rear. Place the
axle in the desired position (forward/aft), and center it
under the truck. Measure the length needed for the lower
links(should be the same). Cut the tubing and tack the
bungs into place. Install the joints and bolt the links into
place. Ensure the tie rod and drag link are parallel.
10. With the axle set in position forward and aft, and centered,
place a jack stand under the pinion and set the previously
measured pinion angle. Place the upper link bracket on top
of the axle(the exact placement will vary from truck to truck).
It is best to “cheat” the bracket out over the diff to allow
room for the pan hard bar to compress past the bracket. The
link bolt should be about flush with the differential mounting
surface.
11. With the axle completely located, Install the axle side
panhard bracket. If you are using Rock Assault housing ,
place the bracket in top of the old spring perch and tack
in place. With the tie rod in place , turn the steering lock
to lock to ensure the tie rod does not contact the
panhard bracket.
12. Tack the bungs into the panhard tube and install
rod ends. Bolt the panhard to the axle side
bracket. Bolt the frame side bracket to the other
end of the panhard. Now swing forward and aft
until the panhard bar is parallel with the tierod, and
is at the same downward angle as the drag link.
Once this is set , tack the bracket into place.
13. Cut shock “mock-up” strips to the proper application
length for the shock that you will use. We recommend
14” shocks for this kit. Note: These shock strips will
only work with Fox 2.0 air shocks.
13. Continued - Once all links and panhard have been installed, raise the
vehicle/ lower the axle to maximum droop. The upper
link will touch the bottom of the upper link bracket and
or the u joint will start to bind. This will be full extention
when shocks are installed. Using the shock strips as a
guide, fabricate suitable shock mounts(we used a 15”
hoop as an example). With the long shock strips installed
(full droop) ensure that the drag link will drop bellow the
steering arm and is not bound up.
13. Continued
13. Continued
14. Once you have set full droop, compress the axle and
install the short shock strips. Ensure the panhard is not
contacting the oil pan (this may not always be possible).
If the panhard is contacting the oil pan you will need to
limit the suspension up travel to accommodate by using
bump stop’s(recommended). Also , ensure that the
tie rod end at the pitmen arm does not contact the
tie rod tube when suspension is compressed.
15. Using the shock strips, ex the suspension to full
compression, full extension, full ex right and full ex
left. Verify that there is no binding or metal to metal
contact
16. Install air shocks, do not pressurize. Flex suspension
again. Check for shock clearance with the frame, tires,
and shock mounts. Flex to full compression, full extension,
full flex left, and full flex right.
17. Remove shocks and links. Fully weld all brackets, paint
as desired and reinstall all shocks and links.
17. Continued
18. Add nitrogen pressure to shocks. We recommend
3”-4” of up travel at ride height.
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