6519-888 9/05
A Division of KW AUTOMOTIVE North America, Inc.
3c) The PROTECTIVE SHIELD that shrouds the GAS TANK is mounted with three (3)
mounting bolts on one side(driver’s side), that mount directly to the frame. (Photo 2).
Using a 13mm wrench, remove the bolts completely and set aside. On the inside
(opposite of driver’s side), the SHIELD hangs on four (4) rectangular hooks.(Photo 3)
Lift this side up above the hooks. You should now be able to wiggle the PROTECTIVE
SHIELD down and out. Set this aside. Put the three (3) mounting hardware back in
their respective mounting holes for safe keeping.
3d) Holding the GAS TANK in place are two (2) straps that are mounted at each end of the
TANK (Photo 4). Each strap is mounted directly to the frame on one end only. The
opposite end is attached primarily by a hook attachment.
3e) Remove the two mounting bolts completely. These are located on the driver’s side of
the TANK itself and the inside part of the frame chassis.
3f) Pull the straps down from the driver’s side and un-hook the straps from the other end.
3g) Next locate the three (3) mounting hardware that bolts the GAS NOZZLE INTAKE,
behind the gas door (Photo 5). Remove the three (3) bolts completely.
3h) With the GAS TANK supported from underneath, slowly lower the GAS TANK six(6”) to
(12”) inches, pulling the rubber gas neck down as the GAS TANK travels down.
4. U-BOLT REMOVAL
4a) There are two(2) sets of U-BOLTS, two per each LEAF SPRING, that is attached to the
rear axle. Using a 21mm wrench, (Photo 6) un-bolt all mounting hardware (nuts and
washers) on each U-BOLT. Remove all four (4) stock U-BOLTS completely.
The LEAF SPRING not becomes detached from the rear axle.
5. LEAF SPRING REMOVAL
! CAUTION: LEAF SPRINGS may be under tension. SPRINGS under tension store a great
amount of energy. Use caution during the following steps to avoid personal injury
and/or damage to the vehicle. BE CAREFUL not to damage the brake hoses/and or
driveline when re-locating the rear axle assembly.
5a) With the vehicle raised and the chassis supported with stands, raise the rear axle to
remove the load from the shackle.
5b) Starting with the front end of the LEAF SPRING towards the engine (front), using a
21mm wrench, un-bolt the hardware and remove completely. (Photo7) With the GAS
TANK lowered slightly, you should be able to get to this hardware. Once the bolt is
removed, the LEAF SPRING should be able to sit atop the rear axle.
5c) With the LEAF SPRING sitting atop the rear axle, move back to the REAR SHACKLE
HANGER. (Photo 8) Using a 21mm wrench, un-bolt the hardware and remove
completely.
IMPORTANT NOTE: Once the LEAF SPRINGS have been removed, keep them in tack. Once you
lay them on the ground, keep them in tact by using c-clamps.
