6612-888 9/05
A Division of KW AUTOMOTIVE North America, Inc
e) Slowly lower the vehicle onto the stands and, before placing the vehicle’s weight on them,
again check that they properly and securely contact the frame rails as described above.
Check for possible interference with any lines, wires, or cables.
f) Remove the rear wheels from the vehicle.
SAFETY REMINDER: Check for safe vehicle stability before proceeding under the vehicle to begin the
following procedures. Never work under a vehicle supported by only a jack. Always use properly rated
support stands to support the vehicle.
g) On Step side models, remove the rear inner-fender liners from the vehicle.
h) Using the floor jack located directly below the differential, lift the axle housing just enough to
remove a significant portion of the axle load from the leaf springs. This step is required to
minimize the load applied to frame rails during notching operations. BE CAREFUL NOT TO
LIFT THE VEHICLE OFF OF THE SUPPORT STANDS.
i) Support the axle housing with two (2) additional support stands at this height. Make sure the
support stands securely contact the axle housing tubes so that the axle housing cannot fall
when detached from leaf springs.
j) Remove the rear shock absorbers from the vehicle (Photo 1). Keep the factory hardware for
use during re-assembly.
2. FRAME NOTCH SUPPORT (C-SECTION) INSTALLATION LEFT-HAND
Due to the design of the included Frame Notch Supports (heretofore referred to as “C-sections”), pickup
box removal is not required with this kit. However, some installers may prefer to remove the box to
facilitate access to the frame. If it is decided to remove the vehicle’s bed assembly, please refer to the
appropriate General Motors Service Manual for recommendations regarding Pickup Box Removal
Procedures.
Safety Reminder: Proper use of safety equipment and eye/face/hand protection is absolutely
necessary when performing the following procedures!
a) Working from the LH rear wheel opening, remove the small plastic clip (Photo 2), which secures
the rear brake line and wiring harness to the top of the frame rail. This is accomplished by
removing the small rivet from its’ mounting hole. The clip is located on the top of the LH frame
rail just rearward of the fuel tank. This clip will not be reused.
!To avoid chassis damage, perform the following procedures to only ONE frame rail at a time.
b) Remove the rear brake line bracket from the top of the driver’s side (LH) frame rail (Photo 3) by
removing two hex-head sheet metal screws using a 13mm wrench. The bracket is located
above and just behind the rear axle. To avoid damage, temporarily secure the rear brake line,
bracket and brake hose, away from the frame rail, using zip ties or elastic straps secured to the
rear axle housing or frame cross-member.
c) Remove factory jounce stop by loosening and removing the attachment nut, located within the
frame rail internal support, using a 15mm wrench.
d) Clean frame rail area (Photo 4) with solvent to remove the factory coating. CAUTION: Do not
use flammable solvents around sparks or open flames.
e) Using the supplied steel template, align slot in template with the slot located on the LH frame rail
above and just behind rear axle housing (Photo 5). Also, align the top and bottom edges of the
template parallel with the frame rail edges. Be sure that the arrow is pointing forward (towards
front of truck). If necessary, fasten template to frame rail using clamps.
! It is very important that the template be positioned exactly as shown/described, so that the C-
Section Assembly fits over the frame rail properly. Check for proper alignment PRIOR to cutting
frame! Also, be aware that this template properly aligns the C-Section notch with the axle ONLY WHEN
using the stock leaf springs, hangers, shackles, and other stock components.
f) Using a felt tipped pen, mark the exact shape of the C-Notch opening onto the outside face of
the LH frame rail (Photo 6).
