Installation Guide:

The installation of this Body Lift Kit requires minimal mechanical knowledge and
tools. It is important to follow these instructions, also helpful to have a
spotter/another person helping you while you jack the body off the chassis. Always
keep an eye on all lines and pipes when lifting and do not ever put yourself in-
between or under a suspended load. Safety first!!

Tools Required

• Socket Set;
• Combination Spanners;
• Good Stable Jack;
• CRC/WD40/INOX (spray oil);
• Optional – fish oil/cavity wax.

Items Included in this Kit

• 14 x 1” Blocks @ 75mm diameter (through drilled) (“75mm blocks”) (N.B. IF RG KIT WAS PURCHASED – Six (6) blocks will have a larger hole drilled in them, these are for the main cabin i.e. to suit the larger bolts).
• 2 x 1” Blocks @ 55mm diameter (“55mm blocks”)
• 1 x Bolt and Hardware kit for ‘front’;
• 1 x Bolt and Hardware kit for ‘cabin’;
• 1 x Bolt and Hardware kit for ‘tub’;
• IF TRAY PURCHASED – 1 x Tray Add On Kit.

STEPS:

WARNING:- If you have bar work on the tub/tray (headboard) or you have a sports bar, you are best to go from side to side when installing the lift, not front to back as the instructions say below, as your cabin may hit the bar as you are lifting the front up.

• First of all, it is best to spray all your body mount bolts on your car with oil (CRC/WD40/INOX) and let it soak. By the time you finish spraying the last bolt, the first one should be right to go. Hopefully, by spraying the bolts, it will make the bolts easier to undo and remove.
• Undo the fuel filler plate (the bolt that is seen from the fuel filler) from the tub and allow it to slump. Also, you may need to remove your fuel filler cap as it will hold up and not fall through when you lift the body.
• I recommend at this point disconnecting the battery, just in case you happen to arch it out or pinch a lead. Keep in mind that disconnecting the battery may affect the electronics of the car.
• Start by loosening all the body mounts (These steps will differ for Space Cabs and Single Cabs). The mounts locations are as follows:-

• Two (2) mounts at the front of the car – seen from the wheel arch. (“front mounts”)
• Six (6) mounts under the main cabin – three (3) each side. (“cabin mounts”)
• Six (6) mounts under the tub – three (3) each side (“tub mounts”)
• Loosen the Steering clamp in the engine bay as it will need to be
  replaced with an extension if required.
• Lift the cabin by:-
• Front Mounts - fully undo the two (2) front mounts.
• Cabin Mounts - leaving the rear two (2) cabin mounts loose, fully undo the remaining front four (4) cabin mounts
• This will allow you to carefully jack up the front of the cabin only enough to slip in the very front two (2) blocks. (N.B. Leave the rear two (2) cabin mounts in to keep the cabin located). IMPORTANT:- If you have a standard front bumper bar, you will need to either remove the bar or loosen off the bottom mounting points from the bar to the chassis (Reinforcement Bar), to allow that to lift away from the chassis. This MUST be done before you jack the front of the cabin up.
• As you are jacking the front of the cabin up slowly, have a spotter help you by looking around to see if anything on the car is stretching or pulling.
• As soon as the cabin is high enough to fit the 75mm blocks in, do so and fit the two (2) 170mm bolts with their nylock nuts and washers. Do not tighten these front mounts up fully yet.
• Now proceed to undo the rear two (2) cabin mounts fully (seeing as the front two (2) are now located).
• Lift carefully and from the front to the back fit the 75mm blocks in with the 180mm bolts and loosely tighten them by hand until all the cabin blocks are in with their bolts.
• During the lift of the cabin it is extremely important that you keep an eye on all the parts stretching and pulling, to ensure that they are not locking out. Also check that the steering shaft is sliding ok.
• Now tighten up all the cabin bolts and any other hoses and lines you may have had to loosen for this stage.
• Lift the tub by:-
• The tub is the same process as the cabin, loosen all six (6) bolts and leave in the rear two (2) bolts to keep the tray/tub from falling/moving.
• Undo the other four (4) and jack up the front of the tub it to slip in the 75mm blocks and the 90mm bolts.
• Once the front (4) are loosely secured proceed to fit the rear two (2).
• 55mm blocks - These are the two (2) extra blocks for the loading of the tub. These extra mounts are only located to the chassis as there is no way of bolting them to the tub. This is ok with the use of the screw heads to locate, the blocks are then secured under compression. The location of the load points are directly above the axel either side.
• Check all the mounting bolts are tight. (It is always a good idea to double check your bolts).

Optional (but recommended)

When fitting the bolts you can spray fish oil or cavity wax in there to help prevent seizing of the bolts. I have used grease in mine as I go through a lot of water and beach work.

I always recommend to check your bolts every time you do a service, the same as you would your wheel nuts.

If you have any issues please contact me and I am more than happy to assist.

All the best with your 4weeling. Stay safe.