ROADSAFE SB012 Bolt in Coil Tower Brace Instruction Manual

ROADSAFE SB012 Bolt in Coil Tower Brace

TOOLS REQUIRED TO COMPLETE FITMENT

• 19mm or 21mm impact socket
  – ½ rattle gun

• 3/8 drive ratchet
  – 12mm socket
  – 14mm socket
  – 17mm socket
  – 19mm socket
  – Extension bar

• Ring spanners
  – 12mm
  – 14mm
  – 17mm
  – 19mm
  – 24mm
  – 27mm

• 6mm Allen key
  – 6mm hex bit and adaptor to suit 3/8 drive

• Safety glasses

• Wire brush

• Rated trolley jack

• 2 x rated jack stands

• WD-40 or similar lubricant

• Anti-seize paste

1. Jack vehicle up from rear diff.

2. Find a suitable position on chassis to place jack stand. Placed near rear lower trailing arm mount is suitable.
   a. Lower vehicle onto jack stand.
   b. Remove rear wheels.

3. Whilst weight of diff is taken up by trolley jack, remove (4) sway bar saddle bolts.
   Use caution when removing these bolts as sway bar may be under tension.

4. With the weight of the diff still on the trolley jack, remove (2) lower shock absorber nuts.
   Take note of orientation of washer.
   a. Remove shock absorber from mounting pin on diff housing.
   b. Lower diff slowly, enough to remove coil springs.
   Take care of brake hose stretching.
   c. With coil springs removed, jack diff back up and temporarily refit shock absorbers with washers and nuts, loosely.
   d. Lower diff and remove trolley jack.

5. Remove (4) bump stop mounting bolts, found on the underside of the chassis above diff.
   These bolts commonly snap. Use due care when removing these bolts. Use an appropriate lubricant if required.

6. Clean up any dirt and debris from underneath the coil tower and underneath the chassis (where bump stop mounts) with a wire brush.

7. Identify LH and RH Black Hawk coil tower brace.
   a. Identify counter-sunk bolts and nuts. You will need four of each for each coil tower
   You will be reusing the factory bump stop mounting bolts

8. Place Blackhawk bolt in coil tower brace, up into coil tower.
   a. Fit all bolts and nuts loosely.
   You may find it easier to fit bump stop bolts loosely to avoid brace falling out when fitting upper mounting hardware.
   b. Once upper bolts are in, tighten by hand, remove bump stop mounting bolts and refit bump stop and bolts.
   It is recommended to use anti-seize paste on bump stop mounting bolts.
   c. Tighten up all bolts (6) and nuts (4) per side

9. Now that all bolts are tight, identify LH and RH brace support bars.
   a. LH has saddle – See figure 1.
   
   b. RH has bolt hole for GU (GQ has saddle matching left side). See figure

10. 

11. For GU Patrol, remove rear outer fuel tank mounting bolt. See figure 3.
    

12. Slip RH support bar onto stud of coil tower brace and align with above bolt hole
    a. Refit bolt through support bar and fuel tank mount (GU Patrol).
    b. Tighten fuel tank mounting bolt and nut on tower brace.
    c. Adjust bar length.

13. Slip LH support bar onto stud on coil tower brace and align saddle to sit against tubular cross member on the outside of upper trailing arm mount.  See figure 4.
    
    a. Fit supplied U-bolt and nuts around cross member.
    b. Tighten saddle nuts (2) and nut on tower brace.
    c. Adjust bar length.
    d. Fit fur clip and or cable tie around wiring loom, to avoid wiring rubbing through. See figure 5.
    

14. Support weight of diff with trolley jack.
    a. Remove shock absorbers nuts and remove shock absorbers.
    b. Lower diff down.
    Remember to use care with brake hose.

15. Refit springs.
    Rotate spring into lockout in spring perch on diff housing.

16. With the springs in place, raise diff up, refit shock absorbers and tighten mounting nuts.

17. With the weight of the diff still on the trolley jack, refit sway bar saddles and bolts and then tighten bolts.
    Put all bolts in (4) finger tight before tightening.
    This may be easier to do with vehicle on the ground at road height.

18. Now is a good time to check that all nuts and bolts are tight.
    Ensure all nuts and bolts are tightened appropriately to relevant manufacturers, torque specifications.

19. Refit rear wheels
    Ensure the correct procedures are followed when tightening the vehicles wheels; refer to owner manual.

20. Jack vehicle up and remove jack stands. Lower vehicle back onto the ground. The work is now complete!

Customer Support

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A division of Specialist Wholesalers Pty. Ltd. ABN 64 163 280 279
VIC PH: 03 8687 1700 | QLD PH: 07 3737 7420 | Email: sales@roadsafe.com.au

References

• roadsafe.com.au

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