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FRONT OF VEHICLE – DISASSEMBLY AND ASSEMBLY
1. Park vehicle on level, hard (concrete) surface.
2. Block the rear wheels of the vehicle to prevent vehicle from moving in either direction and set parking brake.
3. Remove the track bar bolt 30 mm (save for later use) on the driver side of the frame mount (Fig.1), and the tie rod end from the pitman arm. Use 15/16 “wrench.
4. Raise the front of vehicle and support with jack stands on the frame behind the front radius arm hangers. Fig.2
5. Remove the front wheels.
6. Support the front axle with a floor jack.
7. Remove lower sway bar end link nuts (save for later use) on both sides using 21mm deep socket. Fig. 3.
8. Remove front shocks (saving lower bolts for reinstallation).
9. Remove brake line bracket from upper spring bucket. 10mm socket. Fig 4
10. Remove the brake line bracket from the lower spring bucket. 10mm socket. Fig 5
11. Remove the front differential breather hose from the front differential (pull carefully, do not tear the hose).
12. Remove the vacuum line from the front differential bracket (carefully unwind) then bend the bracket so that it is vertical instead of horizontal. Fig 6
13. Remove the lines attaching to the sides of each radius arm. 13mm socket. Fig 7
14. Remove the vacuum lines from the mounting bracket that holds the lines to the inner fender liner (pull carefully). Fig 8
15. Remove the track bar bracket. 21mm deep socket on passenger side (3 spots). 18mm socket on driver side (2 spots).
16. Remove pitman arm from sector shaft on steering box. 1-13/16” socket and special pitman arm puller.
17. While supporting front differential, lower the axle with a floor jack, then remove the driver and passenger side coil springs.
18. Install sway bar end link extensions to the OEM sway bar end links using Red Locktite. 3/4” open end wrench. Torque 59 ft lbs. Fig. 9 NOTE: DO NOT OVERTIGHTEN.
19. Install new pitman arm using Red Locktite. 1-13/16” impact socket Torque to 350 ft. lbs. Fig 10
20. Install new track bar bracket. Install all of the frame mounting hardware before you tighten any. This will help insure proper alignment and save you some frustration. Passenger side – 21mm deep socket (3 ea.). Torque 120 Ft. lbs. Driver side – 18mm socket (2 ea). Torque 120 ft. lbs. Fig.10 NOTE: THE NEW TRACK BAR BRACKET INSTALLS TO THE BACK SIDE OF THE CROSSMEMBER.
21. While the frame is still being supported by jack stands also support the front axle with jack stands. Now use a floor jack to support the radius arms while removing the rear radius arm bolt (save for reinstallation) using 24mm wrench and socket. Now carefully lower the back of the radius arms down “one side at a time” about 4.5” and slide the new hangers in place. ( If installing new Revtek Radius Arm part number 6300A please refer to steps 25-28).
22. Install the sleeves between the hanger plates and install the new 3/4′”x 5” bolts with nuts and washers (do not tighten). Fig. 11
23. Install the OEM radius arms to the new hangers using OEM hardware saved in step 25 using 24mm socket and wrench. DO NOT TIGHTEN. Fig 12
24. Tighten the radius arm hanger bolts to 221 ft. lbs. using 1 1/8” socket & wrench.
25. FOR REVTEK RADIUS ARM ONLY! Remove front bolts attaching the radius arm to the front axle and remove factory radius arm. (Save OEM bolts for re-installation).
26. FOR REVTEK RADIUS ARM ONLY! Replace OEM Radius arm with new Revtek Tubular radius arm. Insert factory bolts and nuts in all spots on radius arm. (Use new supplied Revtek all metal locknut on the upper driver’s side only). Do not tighten at this time.
27. FOR REVTEK RADIUS ARM ONLY! Repeat this process on the other side of the vehicle.
28. FOR REVTEK RADIUS ARM ONLY! Please use new zip ties to re-attach the factory line that was on the OEM radius arm.
29. Install the new coil springs (leave the rubber isolator on the spring) and place the entire assembly into the lower spring bucket making sure the spring end at the bottom of the spring touches the stop on the bucket. Raise the axle until the springs are trapped in their location.
30. Install the new R2515S Revtek front shocks using 3/4” ratchet wrench top, 18mm socket bottom. Torque to 111 ft. lbs.
31. Secure the sway bar to the front axle. 21mm deep sockets. DO NOT OVER TIGHTEN!!!. DO NOT CRUSH THE RUBBER BUSHINGS!!!.
32. Install the draglink to the small end of the pitman arm using 15/16” socket or wrench and reinstall cotter key. Torque to 85 ft lbs.
33. Install the factory upper brake line hanger to the new Revtek supplied bracket (P/N PVB-2) using M8 X 1.25 X 16MM bolt and nut then mount the bracket back to the factory location using the new M8 x 35MM bolt and supplied aluminum spacer (P/N PVBS-2). Torque to 13 ft lbs.. Fig 13
34. Install the lower brake line bracket to the lower spring bucket; you may have to manipulate the shape of the bracket a bit. You will need to slide the brake line up inside the OEM bracket a bit for extra length. 10mm socket, Torque to 13 ft. lbs.
35. Re-install front breather line to front axle.
36. Re-install vacuum line to front axle
37. Re-install the vacuum lines to the sides of the radius arms. 13mm socket, Torque to 13 ft. Lbs.
38. Install the vacuum line to the inner fender liner by running a zip tie through the OEM bracket and around the vacuum line. Fig 14
39. Install track bar into the track bar bracket using the OEM bolt (30mm). You may have to jog the steering wheel a bit to get the hole to line up. Torque to 406 ft. lbs.
40. Install tires. Set vehicle on ground and torque wheels to factory specs.
41. Now tighten the radius arm bolts using 24mm socket & wrench. Torque to 221 ft lbs.
42. Make sure you have adequate clearance between tires & brake lines.

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