BMR Suspension KM003 - Manual

LS1 TUBULAR K-MEMBER INSTALLATION
PART # KM003, KM003-1
Required Tools:
y
Jack and jack stands or service lift
y
Wrenches - 8mm, 10mm, 11mm, 13mm, 15mm, 18mm
y Sockets - 10mm, 13mm, 18mm, 21mm
y Various ratchet extensions and universal joints
y Pry
bar
y
Brass hammer or pickle fork
Installation Procedure:
1. Using an 8mm wrench, remove the positive cable on the battery.
2. Using a 15mm wrench, loosen the serpentine belt tensioner and remove the belt from the alternator.
3. Lift car so that factory k-member is at least 18” from ground. Support car with jack stands under frame rails.
4. Remove front wheels/tires.
5. Using a 13mm socket and wrench, remove the front sway bar.
6. Using an 18mm wrench, remove both power steering lines and cap hoses to prevent fluid loss.
7. Using a 13mm and a 15mm socket, remove all 3 bolts holding the alternator in place, unplug wiring harness, and remove the
alternator. This is necessary in order to access the factory motor mount bolt.
8. Support the motor with a jack and a block of wood under the oil pan.
9. Using an 18mm socket and wrench, remove the drivers’ side motor mount bolt.
10. Using a 13mm socket, remove the two bolts holding the starter in place. Starter may be removed completely or it may hang,
suspended by the battery cable.
11. Using a 13mm socket, remove all 4 bolts holding the passenger side motor mount to
the motor. This will require a combination of extensions and flexible u-joints in order
to access all of the bolts.
12. Remove the cotter pins from both outer tie rod ends. Using an 18mm wrench, loosen
both castle nuts until the nut is flush with the top of the stud. Using a brass hammer,
tap the castle nut until the tie rod breaks loose from the spindle (see image below).
This may also be accomplished by using a pickle fork, if available.
13. Using a 15mm wrench and 18mm socket, loosen both rack and pinion mounting bolts.
It is not possible to remove the drivers side bolt until the k-member is lowered.
14. Using an 11mm wrench, remove the steering shaft bolt located directly above the rack
and pinion.
15. Using a 10mm socket, remove all 4 brake line retaining tab bolts that attach to the
side of the k-member.
16. Using a 21mm socket and wrench, remove both lower A-arm mounting bolts for both the drivers and passengers’ side.
17. Using an 18mm socket, remove all six k-member mounting bolts.
18. Lower k-member enough to remove the drivers’ side rack and pinion bolt. Remove rack and pinion assembly.
19. At this point it may be necessary to utilize a second person. While holding the A-arm assemblies out of the way, lower the k-
member out of the car. Take care not to damage any of the brake lines or starter wiring harness when removing the k-member. It
is not necessary to remove the brake lines when performing this install.
20. Remove the passenger side motor mount from the stock k-member and install on motor.
21. Lift BMR k-member up into car. This will require aligning multiple points at the same time so again, additional help will be
required. It may be necessary to use a pry-bar in order to align all of the mounting points and position the k-member into place.
Install and tighten all 6 mounting bolts.
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