Nissan 40053 User's Manual
Contents
1. N S shaped eS ys Fi Kit Washers 1 4 SAE Electric amp Kit Nut 1 4 Nylock Fan 04 05 Nissan Titan Kit 40053 k Remove two silver clip nuts from radiator and install two kit clip nuts on radiator Radiator Silver Clip Nut Radiator Install two silver clip nuts on two kit bracket spacers as shown Install two kit bracket spacers on radiator with two kit bolts 5 16 X 1 and two kit washers 5 16 USS Silver Clip Nut Kit Bracket Spacers S Kit Bolt 5 16 X 1 Kit Washer 5 16 USS n Kit Zip ties Remove two kit zip ties from core support and radiator Remove the support apparatus from under radi ator and position radiator on lower radiator sup port assembly Ensure radiator lower studs are positioned in the radiator support bushings 21 p Install radiator and two kit bracket spacers on core support with two shoulder bolts Shoulder Bolt Core Sup pon D o Radiator 5 Radiator fan shroud a Remove four nuts from fan pulley Install fan clutch assembly on fan pulley with four nuts Fan Pulley Nuts Fan Clutch MT ore Assembly b Install fan shroud on radiator with two bolts and two lower clips Radiator 04 05 Nissan Titan Kit 40053 c Install upper radiator hose on radiator with hose c Install transmission cooler line brackets on frame clamp with two bolts Hose Clamp Radiator Upper Rad2. 3651 N Highway 89 Chino Valley AZ 86323 928 636 7080 NISSAN TITAN 3 BODY LIFT INSTALLATION INSTRUCTIONS 2004 2005 KIT 40053 A WARNING Performance A y lift kit will change the vehicles center of gravity and handling characteristics both on and off road You must drive the vehicle safely Extreme care must be taken to prevent vehicle rollover or loss of control which could result in serious injury or death Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fastened A WARNING Before you install this a instructions warnings cautions and notes in this instruction sheet and in the vehicle owner s manual A CAUTION F q g the factory recommended procedures for removal and installation of original equipment components We rec ommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle We strongly recommend that a certified mechanic familiar with the installation of sim ilar components install this kit A WARNING DO NOT combine suspension body or other lift devices Use of vehicle with combined lifts may result in unsafe and or unexpected handling characteristics A WARNING y e good working condition Before y
3. 1 4 Nylock EN s N 04 05 Nissan Titan Kit 40053 b Install Kit bracket straight on the wheel well side of the fuel brake line bracket with a kit washer 1 4 SAE and kit nut 1 4 nylock as shown Install two kit brackets and fuel brake line bracket on firewall with two nuts Kit Bracket A Straight Pa Kit Washer 1 4 SAE Kit Nut 1 4 Nylock ee fa f a N a f i l J f h i Fi _ ry r i P Fuel Brake PA F Line Bracket Engine Compartment 1 Steering shaft A WARNING Verify the steering extension is securely installed as specified in the instructions Failure to do so may cause steering malfunction resulting in property dam age or serious personal injury a Install kit extension steering on steering gear box with kit bolt 3 8 x 1 1 4 allen head Do not tighten Carefully extend the mark from the Rack and pinion along kit extension steering Steering Shaft Bolt Kit Extension Steering Kit Bolt 3 87 x 1 1 4 Allen Head Marks Rack amp Pinion b Install steering shaft on kit steering extension ensuring marks on steering shaft kit steering extension and gear box are aligned c Apply a few drops of Loctite to factory bolt and kit bolt 3 8 x 1 1 4 Allen head d Install and tighten bolts to 33 Ib ft Inner fender well drivers side a Install two power steering cooler line brackets on a kit bracket C
4. from air cleaner base Axle Vent Hose Axle Vent Hose Clip Air Cleaner Base 04 05 Nissan Titan Kit 40053 3 Radiator fan shroud a Remove hose clamp and upper radiator hose from radiator Zip tie upper radiator hose to engine bracket Hose Clamp Radiator Upper Radi ator Hose Zip tie Fan A Shroud Clips ARA TA c Remove two bolts and fan shroud from radiator Lift and remove fan shroud from vehicle Bolts Fan Shroud Radiator d Remove four nuts and fan clutch assembly from fan pulley and vehicle Install nuts on fan pulley Fan Clutch Assembly 4 Radiator a Remove two shoulder bolts from radiator and core support Shoulder Bolt Core Sup ial lt Radiator 5 Inner fender well passenger side a Remove two clips from wiring harness b Remove AC line from clip on inner fender LS AC Line Cip IN inv d Inner Fendere Clips Wiring Harness 04 05 Nissan Titan Kit 40053 c Remove two bolts and transmission cooler line 7 Inner fender well driver side brackets from frame a Remove two bolts and power steering cooler lines from frame Power Steering Bolt Transmission Cooler Lines Cooler Line Brackets Clip Wiring Harness 6 Fire wall a Remove nut and AC selector valve from fire wall 8 Steering shaft a Mark lower steering shaft and rack and pinion as shown Remove bolt and lower steerin
5. 3 EE s ma HEHE ER Bolts Nuts Vee Bracket ss Dp Front Bumper h Install kit edge trim on the cut edge of the front bumper i Install front bumper on front bumper brackets and vehicle with four top bolts Do not tighten j Install front bumper and two kit spacers on front bumper brackets with two kit bolts M8 1 25 X 40mm Do not tighten Kit Bolt M8 1 25 Front X 40mm Bumper Bracket Front Bumper Kit Edge Trim k Install four nuts and two side impact braces on front bumper Nuts Front SS Side Impact Install two side impact braces on two Kit brack ets side impact with four kit bolts 3 87 x 1 eight kit washers 3 87 USS and four kit nuts 3 8 nylock m Install two kit brackets side impact on frame with four bolts Kit Bolt 3 8 x 1 Kit Washer 3 8 USS amp Kit Nut 3 8 Nylock Side Impact Braces Kit Bracket Pa Side Impact i Bolt da P he J LS p Va L ed P Eet b Fik i f w P lt hi S Ned sm vd J h ds WETE 2 y al n Remove eight grill turn clips from core support Install eight grill turn clips on grill 04 05 Nissan Titan Kit 40053 o Install grill on core support and vehicle with eight grill turn clips Core Support Grill g NS l x 4s di Grill Turn Clips If equipped install two tow hooks on frame w
6. 3 8 USS Washer 5 16 USS Washer 7 16 SAE Washer 7 16 USS Washer 8mm Extension steering Rev 03 Copyright 08 05 Performance Automotive Group 04 05 Nissan Titan Kit 40053
7. After you install the kit reactivate the SRS before driving the vehicle i roup recommends using the Loctite supplied in the kit on the threads of all kit nuts and bolts unless specified otherwise in these instructions 04 05 Nissan Titan Kit 40053 Before Starting Installation NOTE Kit parts are prefaced by the word kit and appear in bold print 1 Carefully read all warnings and instructions com pletely before beginning 2 Verify all parts have been received in this kit by checking the parts list at the end of this document lf parts are missing from kit please be prepared to pro vide the following information 1 Name of purchase location 2 Bar Code on side of box 3 Date above bar code 4 Date inside box cover 5 Inspector from inside box cover 3 Only install this kit on the vehicle for which it is specified If anytime during the installation you encounter something different from what is outlined in the instructions call technical support at 928 636 7080 4 Special tools needed a Die grinder or similar tool capable of cutting metal b Welder or access to a professional welding shop 5 Park the vehicle on a clean dry flat level surface and block the tires so the vehicle cannot roll in either direction Engine Compartment 1 Battery cables a Disconnect both battery cables Disconnect neg ative cable first then positive cable Positive Cable j of A
8. Fender Side Impact Braces Bumper EF Se Fascia Nuts Bolts f Install front bumper fascia onto support with six bolts i Install front bumper fascia onto driver and pas senger wheel wells with six screws bs sy iia Wheel Well ae ME Ra ke Core Support a 4 Bolts Front On er Front Bumper Fascia g Install front bumper fascia onto support with three pop up Clips j Remove eight grill turn clips from core support Install eight grill turn clips on grill k Install grill on core support and vehicle with eight Clips grill turn clips Front Core Support Bumper Fascia Grill Grill Turn Clips 2 04 05 Nissan Titan Kit 40053 Install skid plate onto vehicle with four screws 2 Install four bed bushings on four kit bed spacers crush blocks Position four kit bed spacers crush blocks on frame rail as shown Bed Bushing Kit Bed Spacer Crush m Mark and drill two 1 4 holes into skid plate Install front bumper fascia straps onto skid plate with two kit push clips 3 Tack weld four kit bed spacers crush blocks to frame Front Bumper i Fascia After Completing Installation Push Clips Inside Cab Karae EA me N 1 Airbag fuse a Install airbag fuse Bed Spacers Crush Blocks b Install fuse cover 1 Remove four bed bushings from frame pri a ET MR it Bid med MET tL Fri EI Ta ri Hi
9. LE models Front bumper brackets 4 SE amp LE models Front bumper a Remove four bolts and two front bumper brack a Remove four bolts nuts and two brackets from ets from frame front bumper Front Bumper Bracket Bolt b Measure and mark 3 down on front bumper brackets Drill 1 2 holes where marked c Cut and flatten front bumper bracket as shown D POSION KONI bumper on front bumper brackets and visually inspect and the frame cross mem ber where interference occurs along the bottom edge of the front bumper When cutting the front bumper Performance Automo tive Group recommends several small cuts and multi ple test fittings on the front bumper brackets to achieve the desired fit ut amp latten c Remove front bumper and mark a line following the bottom edge of front bumper at a distance of 1 3 4 inches from the edge as shown TE RE Ed Ad ior K sd ll sye ke ao gt ial see d Install two modified front bumper brackets on frame with four bolts Front Bumper Bracket 1 3 4 Bolt d Cut front bumper where marked as shown 24 04 05 Nissan Titan Kit 40053 e Mark and cut frame crush zone driver and pas senger side as shown Frame Crush Mark amp Cut Before Mark amp Cut f Position front bumper on frame crush zone and check for interference Trim as little as neces sary g Install two brackets on front bumper with four bolts and nuts pa
10. amp Kit Tube Spacer Trim S Kit Bolt M10 1 25 X 100m Frame Cross Chain iF F e Install bell bracket spring plate U bracket and cotter key on chain and winch mechanism Plate Spring Bell bracket f Install spare tire according to owners manual Ensure chain operates without catching on frame cross member 4 Fuel filler A WARNING Use extreme caution when working near the fuel lines and the fuel tank Clean up spilled fuel immediately A spark could cause an explosion or fire resulting in seri ous personal injury and property damage 04 05 Nissan Titan Kit 40053 a Push fuel filler rubber gasket and fuel filler onto bed Fuel Cap b Install fuel filler bracket on bed with bolt Fuel Filler Bracket Bolt c Install kit cut hose on canister hose with kit Zip tie Canister Hose Kit Hose Cut P7 e a j A ar ra a is a TA TE d Install fuel cap on fuel filler Frame 1 Side step driver side a Install side step on three side step brackets with six bolts Side Step ae 2 Drive line hoop a Install four kit bracket spacers on the body with four bolts b Install drive line hoop on four kit bracket spac ers with four kit bolts 3 8 X 1 eight kit wash ers 3 8 USS and four kit nut 3 8 nylock Drive Line Hoop UBS ER Kit Bolts 3 8 X 1 Kit Washers 3 8 USS amp Kit Nut 3 8 Nylock 04 05
11. engage the nylock portion of the nuts a Position support apparatus under radiator Support od Apparatus 19 04 05 Nissan Titan Kit 40053 d Install kit brackets upper radiator support and kit brackets lower radiator support on lower radiator support with twelve kit bolts 1 4 x 1 1 2 and twelve kit nuts 1 4 nylock Kit Bracket Upper Radiator Support Lower Radiator Support Kit Bracket ad Lower 7 Radiator Support Kit Bolt 1 4 X 1 1 2 amp Kit Nut 14 WE Nylock e Position and mark holes from kit bracket upper backing plate on side support as shown Drill 1 4 holes where marked Side Support Kit Bracket Upper Backing a a Plate i 20 f Install lower radiator support assembly and kit bracket upper backing Plate on side supports with six kit bolts 1 4 x 1 twelve kit washers 1 4 SAE and six kit nuts 1 4 nylock Kit Bolt 1 4 X 1 Kit Kit Bracket Upper Washers 1 4 SAE amp Backing Plate Kit Nut 1 4 Nylock Radiator Radiator Support Bushings Lower Radia tor Support Bolt Electric Fan Core Support h Position electric fan on lower radiator support with two tabs i Install kit bracket S shaped on electric fan with Kit nut 1 4 nylock and kit washer 1 4 SAE j Install kit bracket S shaped long on core sup port with bolt Core Support Bolt Kit Bracket oe rd
12. miles and after off road use All body lift components should be visually inspected and fasteners retorqued during routine vehi cle servicing ANGAUTION Performance Automotive Group does not recommend any particular wheel and tire combinations for use with its body lifts and cannot assume responsibility for the customers choice of wheels and tires Refer to your owner s manual for recommended tire sizes and warn ings related to the use of oversized tires Larger wheel and tire combinations increase stress and wear on steering and suspension components which leads to increased maintenance and higher risk for component failure Larger wheel and tire combinations also alter speedometer calibration braking effectiveness center of gravity and handling characteristics Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle All warranty information instruction sheets and other documents regarding the installation of this product must be retained by the vehicle owner Information contained in the instructions and on the warranty card will be required for any warranty claims The vehicle owner needs to understand the modifications made to the vehicle and how they affect vehicle handling and performance Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury Depending on the vehicle configuration automatic or manua
13. 53 2 Remove three bolts washers and small bushing from three bed mounts on passenger side Bed Mount Washers amp N Small Bushing A WARNING Use extreme caution when lifting the bed from the frame To prevent serious personal injury ensure the hydraulic jack is securely placed Keep your hands out from between the bed and frame A CAUTION To prevent damage to the vehicle while lifting the bed continually check hoses wires brake lines etc to ensure everything is flexing properly and not binding Ensure clearance between bed and cab is maintained 3 Bed passenger side a Using a hydraulic jack and a wooden block slowly lift passenger side of bed a little more than 3 Install three kit blocks 3 x 3 on three frame mounts and bed with three kit bolts M10 1 25 x 120mm kit washers 7 16 USS and small bushings DO NOT tighten Kit Bolt M10 1 25 x 120mm Small Bushing amp Washer 7 16 USS Kit Block 3 x 3 Frame Mounts ERA AE oe ee ET lige PES Re BEES DEPT h b Lower bed onto kit blocks c Repeat previous steps on driver side of bed d Check bed to cab spacing according to previous measurement e Remove each kit bolt one at a time Apply a few drops of Loctite to threads and install kit bolt washer and small bushing Tighten kit bolt to 45 ft Ibs Rear of Vehicle 1 Rear bumper A WARNING The following procedure is intended only
14. Battery oa z i a m T 7 as sd x fi F sl a z N r Tag F Gi 4 J F med 5 i d p r j Negative Cable a Bf a wa we i A 4 2 d Measurements 1 Measure and record distance between front bumper and fenders Driver Side Passenger Side 2 Measure and record distance between rear bumper and bed Driver Side Passenger Side 3 Measure and record distance between cab and bed Driver Side Passenger Side Inside Cab 1 Airbag fuse NOTE The location of the airbag fuse may vary check the owner s manual a Remove fuse cover 04 05 Nissan Titan Kit 40053 b Remove airbag fuse Airbag Fuse A WARNING Accidental deployment of the air bag can result in seri ous personal injury or death To avoid accidental deployment during installation of the lift kit the Supple mental Restraint System SRS or airbag must remain deactivated Do not allow anyone near the airbag dur ing installation Refer to the factory service manual or owner s manual for the recommended procedure to disable the SRS After kit installation the SRS must be reactivated before driving the vehicle A CAUTION If the following step is not performed the airbag clock spring could be damaged Do not turn the steering wheel while the steering shaft is disconnected c Strap steering wheel to prevent accidental movement Prepare to Install Kit Front of vehicle 1 SE amp
15. LE models Front bumper a If equipped remove two wiring harness connec tors from running lights Wiring Er mm m me er ir Connector RE E 2 yy EE HE TE i n i hot T k Running Lights b Remove four bolts and skid plate from frame and vehicle c If equipped remove four bolts and two tow hooks from frame Tow Hooks Frame Bolts d Remove four bolts and two side impact braces from frame Side Impact Braces Frame e Remove four nuts and two side impact braces from front bumper Side Impact Front 04 05 Nissan Titan Kit 40053 f Remove grill from core support and vehicle by releasing eight grill turn clips 7 N es ae N M Top of Grill ee Kn 7 E Y g Remove six bolts and front bumper from front bumper brackets and vehicle Brackets XE models Front bumper a Remove eight turn clips and grill from vehicle b Remove two screws and three pop up clips from front bumper fascia and skid plate Clips Front Bumper Fascia m c Remove six screws from driver and passenger front bumper fascia and wheel wells Wheel Well Front Bumper Fascia O4 Oo Nissan Titan Kit 40053 d Pull driver and passenger wheel well back and remove four bolts from front bumper fascia and front fenders Front Fender Fascia Bolts e Remove six bolts and front bumper fascia from vehicle f Remove two clips a
16. Nissan Titan Kit 40053 3 Side step passenger side a Install side step on three side step brackets with six bolts 4 Frame rail passenger side a Enlarge hole in wiring harness bracket too 1 4 Install kit bracket L shaped on wiring harness bracket with kit bolt 1 4 x 1 two kit washers 1 4 SAE and a kit nut 1 4 nylock Wiring Harness Bracket Ed vd ad i N ii 1 F j Y Emy TOTA i ib r ka Ed OT Ee Ty age ti eats a Pi of en T ye vy ae asa j as ed KitBracket L shaped Wiring Harness Bracket ANOTE It maybe necessary to slightly bend tab on the back side of wiring harness bracket to fit over the top of the frame b Install wiring harness bracket and kit bracket L shaped on frame with bolt Kit Bracket L shaped Wiring Bracket The Ps 7 hig Y c Install plastic cover on wiring harness bracket d Install two wiring harness push clips and wiring harness on top of frame body mount perch Harness Push Clips Plastic P oe y Gans j ie EA a ap ee a ae BA J l N z SE ER a BR SE N i I Fa r t r af j T wm ns Fi 7 a J ia Fa To b a 5 Fuel lines at the fire wall a Install kit bracket S shaped on the engine side of the fuel brake line bracket with a kit washer 1 4 SAE and kit nut 1 4 nylock as shown Fuel Brake Line Bracket Kit Bracket S shaped Kit Washer ee 1 4 SAE ad Kit Nut
17. astic housing from frame cross member Body Mount af a Perch BOET N c Remove two bolts and spare tire winch mecha Y eee nism from frame cross member Plastic Housing Rear of Vehicle 1 Fuel filler A WARNING Use extreme caution when working near fuel lines and fuel tank Clean up spilled fuel immediately A spark could cause an explosion or fire resulting in serious personal injury and property damage a Remove bolt and fuel filler bracket from bed 3 Rear bumper wiring driver side a Remove wiring harness and clip from bumper Fuel Filler Bracket Bolt Wiring Har ness amp Clip 10 04 05 Nissan Titan Kit 40053 b Remove three wiring harness push clips from 4 Rear bumper passenger side rear bumper bracket a Remove wiring harness connector push clip from frame Rear Bumper Bracket Push Clips c Disconnect two wiring harness connectors from wiring harness d Remove two rear bumper Install Kit Cab Light N I Connector Ed 1 Prepare to lift cab from frame Rear a Loosen but DO NOT remove three cab mount ing bolts on driver side Bushing Core Support Mount 14 04 05 Nissan Titan Kit 40053 b Remove three bolts from cab bushings on pas C Install a kit bolt M12 1 25 x 180mm on each senger side cab mount DO NOT tighten Bushing Kit Block 3 x 3 Kitbolt M12 1 25 im Cab Mount d Lower cab onto Kit bl
18. g shaft from rack and pinion AC Selector Valve af ee Lower Steer ing Shaft Bolt 8 04 05 Nissan Titan Kit 40053 9 Fuel lines at the fire wall b Reposition catalytic converter ground strap on body so end link connector is pointing forward a Remove two nuts and fuel brake line bracket from fire wall End Link gt o o b Connector Body SS RT gt Ground Strap Nut Fuel Brake Line Bracket Nut A J 3 Side step passenger side a Remove six bolts and side step from three side step brackets Frame 1 Side step driver side a Remove six bolts and side step from three side step brackets 4 Frame rail passenger side a Remove plastic cover from wiring harness bracket 2 Drive line hoop a Remove four bolts and drive line hoop from vehi cle Plastic Cover Wiring Har ness Bracket Drive Line Hoop EE 9 04 05 Nissan Titan Kit 40053 b Remove bolt and wiring harness bracket from b Remove fuel cap from fuel filler Push fuel filler frame rubber gasket and fuel filler toward inside of bed Fuel Cap Fuel Filler Rubber Gasket Wiring Har ness Bracket c Remove two wiring harness push clips and wir 2 Spare tire cranking mechanism ing harness from frame body mount perch a Lower the spare tire according to the manufac turers specifications Push Clips Wiring Harness b Remove three push clips and pl
19. i ator Hose Bolt Transmission Cooler Line Brackets d Install three hoses on two fan shroud clips 7 Air handling system a Install air intake hose on engine with hose clamp Fan gt Shroud Clip kR 6 Inner fender well passenger side a Install a lower clip on wiring harness b Install AC line on clip on inner fender AC Line Clip jy XS iN b Install two clips hose clamp axle vent hose and Inner Fender axle vent hose clip on air cleaner base Axle Vent Hose Axle Vent Hose Clip Air Cleaner Base 22 04 05 Nissan Titan Kit 40053 c Install air cleaner cover on vehicle Front bumper Air Cleaner TR 2 ee 1 Lower radiator Cover N Clips A NOTE Hose Clamp Check drain plug a Fill cooling system according to manufacturers specifications Air Cleaner Base b Install lower fan shroud on fan shroud and vehi cle d Install push clip and wire harness on air cleaner cover Air Cleaner Cover Push Clip Wire Harness Lower Fan c Install hose clip metal transmission cooler hose and transmission cooler hose on fan shroud and e Position intake cover on engine mark and trim lower fan shroud where interference occurs f Install intake cover on engine with two bolts and Lower Fan two locator nipples Shroud Hose Clip Metal Trans Cooler Hose Mark And Trim 23 04 05 Nissan Titan Kit 40053 3 SE amp
20. ith four bolts D Tow Hooks Frame Bolts If equipped install two wiring harness connec tors on running lights q Wiring Harness Connector lt a Ti Pd i Y i K ij ee ll a Running Lights mL i d Aa s h MERE s aa oe Hi ee Far 5 XE models Front bumper a Install two side impact braces on two kit brack ets side impact with four kit bolts 3 87 x 1 eight kit washers 3 8 USS and four kit nuts 3 8 nylock 26 b Install two kit brackets side impact on frame with four bolts Kit Bolt 3 8 x 1 Kit Washer 3 8 USS amp Kit Nut 3 8 Nylock Side Impact Braces Kit Bracket N Side Impact ei Te Bolt Frame j i S 2 a t m j ka i di ET i F _ ad K kl Me N n N an i d EE ae BEE a as ra di uy i n 4 a yt P z FT r N is Hie sa 5 Ma ace Ed Mark and cut two side bumper braces as shown C d Install two side bumper braces onto front bumper with two bolts two kit blocks 2 diame ter two kit bolts 8 1 25 x 90mm and two kit washers 8mm Kit Bolt 8 1 25 x 90mm Kit Washer 8mm Side e Bumper Da Brace Kit Block 2 Dia 04 05 Nissan Titan Kit 40053 e Install two side impact braces onto two side h Install front bumper fascia onto front fenders with bumper braces with four nuts four bolts ET Side Bumper Braces Front
21. l transmission 2WD or 4WD cab length bed length etc some parts may not be used 04 05 Nissan Titan Kit 40053 Accessories The following accessories are available Urethane Gap Guards 30 04 05 Nissan Titan Kit 40053 Kit Parts List QTY DESCRIPTION 12 Block Big 4 Block Mini 12 Bolt 1 4 x 1 1 2 10 Bolt 1 4 x 1 Bolt 8 1 25 x 90mm Bolt 10 1 25 x 100 mm Bolt 10 1 25 x 120 mm Bolt 12 1 25 x 180 mm Bolt 3 8 x 1 Bolt 3 8 X 1 1 4 Socket Bolt 5 16 x 1 0 Bolt 7 16 14 x 1 1 2 Bolt 8 1 25 x 40 mm Bracket C Bend Bracket J Bend Bracket L Bend Bracket S Bend w Stud Long Bracket S Bend w Stud Short Bracket Side Impact Left Bracket Side Impact Right Bracket Hitch Bumper Support Bracket Rad Left Support Assy Bracket Rad Right Support Assy Bracket Lower Radiator Support Bracket Upper Backing Plate Bracket Rear Bumper Left Bracket Rear Bumper Right Bracket w stud Clip push Extension steering Guard Edge Black 39 Hose 3 4 x 2 Label Logo Nut 1 4 Nylock Nut 3 8 Nylock Nut 7 16 Nylock Nut Clip U Nut Spacer Spare Tire Winch Spacer Block 3 w Hole Spacer Block 3 w Holes Spacer Metal Tube Tie Zip O1 ANOANN SAN ANAANNAFANN FAFA B BHAA ANAN 0HDHDONYN 31 QTY 20 12 10 18 DESCRIPTION Warning Rear Bumper Bracket Washer 1 4 SAE Washer
22. m Ag mms a TA mi Bed Bushing E op i PL a Ee g SR mm n c Remove strap from steering wheel Engine Compartment 1 Battery cables 28 04 05 Nissan Titan Kit 40053 a Connect both battery cables Connect positive cable first then negative cable Positive Cable Negative Cable EJ amp B EE AA ey vee r E Se i ra F i A tt ta Miscellaneous 1 Apply kit label warning to dashboard in plain sight of all vehicle occupants 2 Adjust headlights 3 Check all fasteners to ensure they are tight 4 Ensure all wires hoses cables etc are properly connected and there is ample slack AAWARNING If the engine cooling system is hot the coolant will be HOT and UNDER PRESSURE To prevent serious personal injury wait until the cooling system is com pletely cool before removing the cap from the radiator 5 Start engine and top off cooling system Purge air from cooling system according to manufacturer s instructions Install radiator cap 29 Dynamic Vehicle Check 1 Test drive vehicle Check steering in both directions to ensure that there is no bind Check operation of clutch brake system and parking brake Check operation of transmission and transfer case Ensure there is full engagement in all gears and 4WD ranges Check battery connections and electrical component operations AAWARNING Retorque all fasteners after 500
23. nd foam support from front bumper Front Bumper Foam Support Clips g Remove six bolts four nuts and two side bumper braces from front bumper and side impact braces h Remove four bolts and two side impact braces from frame Side Impact i Remove four bolts and skid plate from frame and vehicle Dr ie a pr riy TE Skid Plate M ge i the ee oe RY pe Nes ES Fs Ee ed DE ER ar nd e ET a EE Pa N ser 5 ra a TE Pd EI a ee EE a ae r of 04 05 Nissan Titan Kit 40053 Engine Compartment 1 Lower radiator a Remove hose clip and metal transmission cooler hose from fan shroud Lower Fan Shroud Hose Clip Metal Trans Cooler Hose b Remove transmission cooler hose and lower fan shroud from fan shroud and vehicle Lower Fan c Drain cooling system into a clean container according to manufacturers specifications 2 Air handling system a Remove push clip wire harness and wire har ness connector from air cleaner cover Push Clip Wire Harness Connector Air Cleaner Cover b Remove two clips hose clamp and air cleaner cover from air cleaner base Air Cleaner Cover Clips Hose Clamp Air Cleaner Base c Remove two bolts and intake cover from engine d Remove hose clamp and air intake hose from engine Position intake hose to the side Bolts Air Intake so Hose N e Remove axle vent hose and axle vent hose clip
24. ocks 37 x 3 A WARNING Use extreme caution when lifting body from frame To prevent serious personal injury ensure the hydraulic jack is securely placed Keep your hands out from a Repeat previous steps on driver side of cab between the body and frame b Check cab to bed spacing according to previous ACAUTION measurement Continually check hoses wires lines etc to be sure that everything is flexing properly and not binding or damage M a Bah rd Be especially N c Remove each kit bolt one at a time and apply a ful of the a c hoses at the fire wall the belt pulley and few drops of Loctite to threads and install kit at the core support Ensure brake lines stretch while bolt M12 1 25 x 180mm Tighten kit bolts to lifting Bending the lines to gain ample slack may be 45 ft Ibs necessary Be extremely careful not to kink the lines 3 Cab driver side 2 Cab passenger side Bed slowly lift passenger side of cab a little more than 3 a Loosen but DO NOT remove bed mounting bolts on driver side A CAUTION The kit blocks must be installed in addition to the fac tory bushings Installing the kit blocks without the fac Bed Mount tory bushings could result in damage to the vehicle or i serious personal injury b Install a kit block 3 x 2 on the core support bushings and two kit blocks 3 x 3 on bush ings on each cab mount bushings 12 04 05 Nissan Titan Kit 400
25. ou install the kit thor oughly inspect the vehicle for corrosion or deformation of the sheet metal around the factory body mounts If the vehicle is suspected to have been in a collision or misused do not install this kit Off road use of your vehicle with this kit installed may increase the stress applied to the factory body mounts We do not recom mend that any vehicle with a body lift kit installed be involved in any extreme off road maneuvers such as jumping Failure to observe this warning may result in serious personal injury and or severe damage to your vehicle A WARNING Viany states and municipalities have laws restricting bumper heights and vehicle lifts Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law ZN WARNING e installation of larger tires may reduce the effective ness of the Braking System A WARNING Always wear eye protection when operating power tools A WARNING betore you install this kit block the vehicle tires to pre vent the vehicle from rolling A WARNING ACC deployment of the air bag can result in serl ous personal injury or death To avoid accidental deployment during installation of the kit the Supple mental Restraint System SRS or airbag must remain deactivated Do not allow anyone near the airbag dur ing installation Refer to the factory service manual or owner s manual for the recommended procedure to disable the SRS
26. shaped and a kit bracket J shaped with two kit bolts 1 4 x 1 four kit washers 1 4 SAE and two kit nuts nylock 1 4 b Install kit bracket C shaped and a kit bracket J shaped on frame with two bolts Kit Bolt 1 4 X 1 Kit Washer 1 4 SAE amp Kit Nuts Nylock 1 4 Kit Bracket J shaped Kit Bolt 1 4 X 1 Kit Washer 1 4 SAE ee amp Kit Nuts Nylock 4 8 ME Kit Bracket C shaped 7 c Install wiring harness on frame with Kit zip tie Harness i 04 05 Nissan Titan Kit 40053 3 Fire wall b Mark and cut lower radiator support and ribs as shown a Install AC line bracket on fire wall with nut Lower Radiator Support amp Ribs b Install kit bracket on AC selector valve with kit nut 1 4 nylock and kit washer 1 4 SAE c Install kit bracket on fire wall with nut Nut Kit Bracket Kit Nut 1 47 Nylock amp Kit Washer 1 4 mE SAE AF e Kit Zip tie er y J oe pd Lower Radiator Support amp Ribs c Position and mark twelve holes from kit brack ets upper radiator support on lower radiator AC Selector support Drill 1 4 holes where marked d Install kit zip tie on hose of AC selector valve A CAUTION and electrical contro box as shown In the step below ensure that you do not over tighten the bolts and nuts On some of the bolts tighten only 4 Radiator enough to ensure the bolt threads
27. to enhance the appearance of the vehicle The rear bumper will no longer be rated for towing of any kind Towing with the rear bumper after it has been lifted can result in death serious personal injury or damage to the vehicle Tow ing after the bumper has been lifted should be accom plished using a rated Class III receiver type hitch a Measure and mark a line 3 3 8 from top of the bumper brackets down the flat side as shown Bumper Brackets Measure amp Measure amp Mark c Cut and remove area of rear bumper brackets marked with an X where shown 04 05 Nissan Titan Kit 40053 d Position kit brackets rear bumper on bumper brackets ensure that cutting allows brackets to Tit flush together e Remove four squeeze clips and center bumper cover from rear bumper Squeeze co Rear Bumper f Install kit brackets rear bumper on bumper brackets with six kit bolts 7 16 x 1 1 2 twelve kit washers 7 16 USS and six kit nuts 7 16 nylock Do not tighten g Install rear bumper and kit bracket rear bumper on frame with six bolts Do not tighten Kit Bolts 7 16 x 1 1 2 Kit Washers 7 16 USS amp Kit Nuts 7 16 Nyloc Kit Brackets Rear Bumper h Install kit bracket hitch support on hitch and rear bumper with four kit bolts 7 16 x 1 1 2 eight kit washers 7 16 SAE and four kit nuts 7 16 nylock Rear ure E mad Kit Bolts 7 16
28. x 1 1 2 Washers 7 16 SAE amp Kit Nuts 7 16 sia ME Kit Bracket Hitch et Hitch i Check measurements taken earlier and tighten all bumper and bumper bracket bolts j Install center bumper cover on rear bumper with four squeeze clips 2 Rear bumper wiring a Install wiring harness on bumper Wiring Har es ness amp Clip Bumper 04 05 Nissan Titan Kit 40053 b Install and connect two wiring harness connec tors on rear bumper and wiring harness Wiring Harness Connector Bumper Bracket Wiring c Install kit Zip tie on wiring harness 3 Spare tire winch mechanism a Remove cotter key U bracket plate spring and bell bracket from chain and winch mechanism Chain Cotter Key U bracket Plate Spring Z eee rd Bell bracket Z de b Position chain through and position winch mechanism on top of frame cross member with kit bolt M10 1 25 X 100mm and kit tube spacer Do not tighten Mark where chain con tacts frame cross member and remove winch mechanisism Winch Mechanism Frame Cross Member Kit Bolt M10 1 25 X 100mm c Trim frame cross member as shown d Install chain through and position crank mecha nism on top of frame cross member with two kit bolts M10 1 25 X 100mm kit washers 7 16 SAE and kit tube spacers Ensure crank mechanism and chain operates correctly through frame cross member Kit Washers 7 16 SAE
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