FABTECH FT28009 Coil Assist Kit Installation Guide

Product Information

The FTS28009 Rear Block Kit is a suspension upgrade kit designed for use in 2015-2021 Mercedes Sprinter 2500 4WD vehicles. This kit includes various hardware subassemblies, spacers, ubolts, and blocks required for installation. The kit also includes instructions, stickers, driver warning decal, and a registration card. The kit is manufactured by Fabtech Motorsports and is available for purchase from their website.

Required Tools

• Basic Hand Tools
• Floor Jack
• Jack Stands
• Assorted Metric and S.A.E sockets, and Allen wrenches
• Torque Wrench

INSTALLATION INSTRUCTIONS

NOTE: TO ORDER WEARABLE REPLACEMENT COMPONENTS DO NOT USE PART NUMBERS SHOWN ON THIS INSTRUCTION SHEET. GO TO FABTECH WEBSITE AND LOOK UP WEARABLE REPLACEMENT PARTS TO FIND THE PROPER PART NUMBER TO ORDER.

TOOL LIST

Required Tools (Not Included)

• Basic Hand Tools
• Floor Jack
• Jack Stands
• Assorted Metric and S.A.E sockets, and Allen wrenches Torque Wrench

PRE-INSTALLATION NOTES

For technical assistance call: 909-597-7800 or e-mail: info@fabtechmotorsports.com READ THIS BEFORE YOU BEGIN INSTALLATION

• Check all parts to the parts list above before beginning installation. If any parts are missing contact Fabtech at 909-597-7800 and a replacement part will be sent to you immediately.
• This suspension and shocks have been designed to be installed on a stock vehicle.
• Read all instructions thoroughly from start to finish before beginning the installation. If these instructions are not properly followed severe frame, driveline and / or suspension damage may occur.
• Check your local city and state laws prior to the installation of this system for legality. Do not install if not legal in your area.
• Prior to the installation of this suspension system perform a front end alignment and record. Do not install this system if the vehicle alignment is not within factory specifications. Check for frame and suspension damage prior to installation.
• The installation of this suspension system should be performed by two professional mechanics. This suspension must be installed with Fabtech shock absorbers.
• Installation of all fasteners requires the use of provided thread locking compound with proper torque values as indicated throughout the installation. Apply thread locking compound upon the final torque of the fastener.
• WARNING- Installation of this system will alter the center of gravity of the vehicle and may increase roll over as compared to stock. Extreme care should be taken to operate the vehicle safely at all times to prevent rollover or loss of control resulting in serious injury or death.
• Vehicles that receive oversized tires should check ball joints, uniballs, tie rods ends, pitman arm and idler arm every 2500- 5000 miles for wear and replace as needed.
• Verify differential fluid is at manufactures recommended level prior to kit installation. Installation of the kit will reposition the differential and the fill plug hole may be in a different position. (For example, if the manufacture recommends 3 quarts of fluid, make sure the diff has 3 quarts of fluid). Check your specific manual for correct amount of fluid.
• Read all warnings and warranties on the last page of these instructions before starting installation.

INSTRUCTIONS

REAR SUSPENSION

1. Disconnect the negative terminal on the battery. Jack up the rear end of the truck and support the frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE! Remove the rear tires.
2. Supporting the rear axle. Remove the factory shocks, save hardware.
3. Remove the factory ubolts and factory blocks. Remove the factory bumpstop by removing the two bolts on each bumpstop unit. Disconnect the factory brakeline bracket.
4. Install the new block using the supplied ubolts and hardware. The smaller taper will face the front of the vehicle. NOTE: Install two FT120 (Spacer) onto each ubolt before the washers and nuts. When installing the hardware install FT19019 & FT19020 (Driver & Pass brakeline bracket) to the inside front ubolt thread. SEE FIGURES 1-3. Torque to 90 ft-lbs. Reattach the factory brakeline bracket to the new one using the supplied 5/16” hardware. Torque to 17 ft-lbs.
5. Disconnect the adjuster bracket on the driver side of the rear axle tube. Using the factory hardwrae install FT19027 (Linkage bracket) like shown in FIGURE 4. Torque to 9 ft-lbs.
6. Install FT19016 (Rear Bumpstop) using the supplied M10 bolts and washers. Torque to 49 ft-lbs. SEE FIGURE 5
7. If installing FTS7231 (Performance Shocks) do so know with the supplied bushings and washers. NOTE: Install one FT120 on the backside of the upper shock to space it away from the frame. Torque hardware to 102 ft-lbs. SEE FIGURE 6
8. If installing FTS81165 (Dirt Logic Shocks) do so know with the supplied bushings and washers. NOTE: Install one FT120 on the backside of the upper shock to space it away from the frame. Torque hardware to 102 ft-lbs. SEE FIGURE 6
9. Install tires and wheels and torque lug nuts to wheel manufacturer’s specifications. Turn front tires left to right and check for appropriate tire clearance. Note – Some oversized tires may require trimming of the front bumper & valance.
10. Check front end alignment and set to factory specifications. Readjust headlights.
11. Recheck all bolts for proper torque. RE-TORQUE ALL NUTS, BOLTS AND LUGS AFTER 50 MILES AND PERIODICALLY THEREAFTER UNTIL TORQUE VALUES ARE RETAINED.
12. Recheck brake hoses, ABS wires and suspension parts for proper tire clearance while turning tires fully left to right.
13. Check ball joints, uniballs bearings, bushings and all steering components every 2500-5000 miles for wear and replace as required.
14. Install Driver Warning Decal. Complete product registration card and mail to Fabtech in order to receive future safety and technical bulletins on this suspension.
15. Review all included warnings and warranties with consumer

Product Warranty & Warnings

• Fabtech provides a Limited Lifetime Warranty to the original retail purchaser who owns the vehicle, on which the product was originally installed, for defects in workmanship and materials.

• The Limited Lifetime Warranty excludes the following Fabtech items; bushings, bump
  stops, ball joints, Uniball bearings, tie rod ends, limiting straps, cross shafts, heim joints and driveshafts. These parts are subject to wear and are not considered defective when worn. They are warranted for 60 days from the date of purchase for defects in workmanship.

• Dirt Logic take apart shocks are considered a serviceable shock with a 1-year warranty against any manufacturer’s defects. If a shock fails within the initial year of ownership, the owner
  must ship the shock to Fabtech for inspection and service. If after examination the shock is determined to have failed due to neglect, damage caused by improper installation, or any reason other than “normal wear and tear,” the owner of the shock will be responsible for all service costs. Costs include labor, parts, and shipping. Service seal kits are available separately for future maintenance.

• All other shocks are covered under our Limited Lifetime Warranty.

• Fabtech does not warrant any product for finish, alterations, modifications and/or installation contrary to Fabtech’s instructions. Alterations to the finish of the parts including but not limited to painting, powder coating, plating and/or welding will void all warranties. Some finish damage may occur to parts during shipping, which is considered normal and is not covered under warranty.

• Fabtech products are not designed nor intended to be installed on vehicles used in race applications or for racing purposes or for similar activities. This warranty does not include coverage for police, taxi, first responder vehicles, race vehicles, or vehicles used for government, commercial or fleet purposes. Also excluded from this warranty are sales outside of the United States of America.

• Installation of most suspension products will raise the center of gravity of the vehicle and will cause the vehicle to handle differently than stock. It may increase the vehicle’s susceptibility to a rollover, on road and off road, at all speeds. Extreme care should be taken to operate
  the vehicle safely at all times to prevent rollover or loss of control resulting in serious injury or death.

• Oversized tires and wheels may decrease the vehicle’s braking capacity. Drivers should always brake early and be aware of the increased the stopping distance of the vehicle. Drivers should adjust their driving habits to the effectiveness of the braking. Adjust your driving habits to these changes.

• Failure to drive safely may result in serious injury or death to driver and passengers. Driver and passengers must ALWAYS wear your seat belts, avoid quick sharp turns and other sudden maneuvers

Instruction Sheet Part# – FT28009i

Contact

• Address: Fabtech Motorsports  4331 Eucalyptus Ave. Chino, CA 91710
• Tech Line: 909-597-7800
• Fax: 909-597-7185
• Web: www.fabtechmotorsports.com

References

• Fabtech® - Suspension Lift Kits & Truck Accessories

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