4x4 front air bag bracket install instructions
first loosen the front wheels then jack up the truck and support it securely on jack stands, make sure you jack it high enough so the front tires are 1 foot from the ground
follow the torsion bar all the way back to the cross member that supports the adjusting block,bolt and key,
remove both adjusting bolts with a 18mm socket
using a 2 jaw puller push up the torsion bar key from the dimple enough so you can pull out the adjusting block, do so on both sides
remove both front wheels
remove all bumpstops, one is located above the lower controll arms and one below the upper controll arms (optional)
using a cutting torch,sawzall,or grinder with a cutoff wheel, cut off the outer half of the lower bumpstop brackets (optional)
check all controll arm bushings,wheel bearings, ball joints before going further, replace as neccesary
remove both front shocks
cut the passenger side upper shock mount so that it is parrallel with the controll arms
install the front wheels and remove jack stands, you may need to place the jack on the body mounts so you can remove it
if the truck is not as low as you would like put the truck back on jack stands and cut more off the lower bumpstop brackets
if the truck is too low jack up the truck and place blocks of wood under the frame untill it is at your desired height
step on the airbag so its completely deflated and install a plug in the air port
test fit the airbag/airbag brackets, trim as neccessary so both brackets sit flat against the airbag end plates
grind away all surfaces that will be welded to bare clean metal
tach weld brackets in place
recheck bracket placement so the bag sits flat inside the brackets an bolt/port holes line up
weld all brackets at ALL points of contact, make sure upper brackets are welded with a large continous bead around frame and shock mount
allow to cool then installl airbag into brackets
trace around bottom airbag end plates on top of bottom brackets and remove airbags
drill holes as neccesary to mount the bottom airbag studs or bolts
jack the truck up and down to check for any airbag interferance
check for any cracks in welds periodically