Installation Instructions - Fabtech

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Installation Instructions6” Performance Suspension System2003-2008 Hummer H2 SUV & SUT(with Rear Coil Spring Suspension)2003-2005 Hummer H2 SUV(withRear Air Bag Suspension)Fabtech Motorsports 4331 Eucalyptus Ave. Chino, CA. 91710Tech Line 909-597-7800Fax 909-597-7185Web www.fabtechmotorsports.com

2003-2008 Hummer H2 SUV & SUT(with Rear Coil Spring Suspension)2003-2005 Hummer H2 SUV(with Rear Air Bag Suspension)FTS27003BK / FTS27004BKPARTS LISTQty11211111111111421121211 FTS27003Part 6" Kit Box 1DescriptionSpindle -DriverSpindle - PassC.V. SpacerSkid Plate BK OnlyTranny Guard Brk & T SkidDiff Bracket Pass.Diff Bracket Drv.Frt.Sway Bar End Link KitWeld In PlateHdwr Sub-Assembly KitBushing KitHardware KitTrack Bar 7BKFT20198BK9/16"-12 x 3-1/4 Hex bolt9/16" SAE Washer9/16"-12 C-lock Nut9/16"-12 x 1-1/4 Hex bolt1/2"-13 x 1-1/4 Hex bolt1/2" SAE Washer1/2"-13 C-lock NutRR Sway Bar End LinkDrv. Bump StopPass Bump StopTOOL LIST:Qty1111111FTS27004Part 3FT204196" Kit Box 2DescriptionRear CrossmemberFront CrossmemberTorsion Bar Bracket drvHardware KitTorsion Bar Bracket passFront C.V. Drive ShaftHdwr Sub-Assembly KitQty11FT20419Part #FT20200FT20201Hdwr Sub-Assembly KitDescriptionNut Tab Drv. Torsion BrkNut Tab Pass. Torsion BrkQty21481211FT20386Part TAS16Hdwr Sub-Assembly KitDescriptionNut Tab Rear Bump StopBrake Line Tab12mm SleeveSway Bar BushingInstruction SheetLarge WasherStickerDriver Warning Decal(NOT INCLUDED)FLOOR JACK & JACK STANDSASSORTED METRIC AND S.A.E SOCKETS, & WRENCHESLARGE C CLAMP OR C CLAMP VISE GRIPSDIE GRINDER WITH CUTOFF WHEEL OR SAWZALLTORSION BAR REMOVAL TOOLTORQUE WRENCHMIG WELDERDRILL WITH A 5/16” BITCOIL SPRING COMPRESSOR ( used on coil spring rear models only)

2003-2008 Hummer H2 SUV & SUT(with Rear Coil Spring Suspension)2003-2005 Hummer H2 SUVHARDWARE LIST:Qty2248221211421551FT20703 Hardware KitDescription5/8"-11 x 5 1/2" Bolt5/8"-11 x4 1/2" Bolt5/8"-11 Steel Lock Nut5/8" SAE Flat Washer3/8"-16 Nylok Nut3/8" SAE Flat Washer9/16-12 x 5" Bolt9/16" SAE Flat Washer9/16"-12 Steel Lock Nut1/2"-13 x 3 1/2" Bolt1/2" SAE Flat Washer1/2"-13 Steel Lock Nut1/2"-13 x 4 1/4" Bolt10mm-1.5 x 60mm10mm Flat WasherThread Locking Compound(with Rear Air Bag SuspensionFTS27003BK / FTS27004BKQty.2421012221211241FT20703 Hardware KitDescription12mm x 1.75 x 70mm12mm Flat Washers12mm x 1.75 Crown Lock7/16"-14 x 1 1/4" Bolt7/16" SAE Flat Washer7/16"-14 Nylok Nut5/16"-18 x 1" Bolt9/16"-12 x 3 1/2" Bolt9/16" SAE Flat Washer9/16"-12 Steel Lock Nut5/16"-18 x 1" Bolt5/16" Split Washer5/16" SAE Flat Washer5/16"-18 Nylok NutQty.12122422226612108182FT20191 Hardware KitDescription10mm-1.5 x 40mm Bolt10mm Flat Washer3/8"-16 x 1" Bolt3/8" SAE Flat Washer3/8"-16 Nylok Nut1/4"-20 x 3/4" Bolt1/4" SAE Flat Washer1/4" Split Washer7/16"-14 x 1 1/4" Bolt7/16-14 Nut7/16" SAE Flat Washer1/2"-13 x 1 1/2" Bolt1/2"-13 Crown Lock1/2" SAE Flat Washer5/16"-18 x 3/4" Thread Forming BoltBEFORE YOU BEGIN INSTALLATION PLEASE READ THE FOLLOWING:CHECK ALL PARTS INCLUDED IN THIS KIT TO THE PARTS LIST ABOVE BEFORE BEGINNING INSTALLATION OFTHE KIT. IF ANY PIECES ARE MISSING, CONTACT FABTECH AT 909-597-7800READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION! IFTHESE INSTRUCTIONS ARE NOT PROPERLY FOLLOWED, SEVERE FRAME, DRIVELINE AND / OR SUSPENSIONDAMAGE MAY RESULT.NOTE- THIS SUSPENSION SYSTEM REQUIRES WELDING FOR INSTALLATION. ALL WELDING MUST BEPERFORMED BY A CERTIFIED WELDER. ONLY WELD THE SINGLE COMPONENT CALLED OUT IN THESEINSTRUCTIONS. DO NOT WELD ANY OTHER COMPONENTS IN THIS SYSTEM.NOTE- PRIOR TO THE INSTALLATION OF THIS SUSPENSION SYSTEM A FRONT END ALIGNMENT MUST BEPERFORMED AND RECORDED. DO NOT INSTALL THIS SYSTEM IF THE VEHICLE ALIGNMENT IS NOT WITHINFACTORY SPECIFICATIONS. CHECK FOR FRAME AND SUSPENSION DAMAGE PRIOR TO INSTALLTION.DO NOT ALTER THE FINISH OF THESE COMPONENTS, EXAMPLE- CHROMING, ZINC PLATING OR PAINTING.CHANGING THE FINISH CAN CAUSE STRUCTURAL FATIGUE OF COMPONENTS.SUSPENSION SYSTEM MUST BE INSTALLED WITH FABTECH SHOCK ASBORBERS

2003-2008 Hummer H2 SUV & SUT(with Rear Coil Spring Suspension)2003-2005 Hummer H2 SUV(with Rear Air Bag SuspensionFTS27003BK / FTS27004BKVEHICLES THAT WILL RECEIVE OVERSIZED TIRES SHOULD CHECK BALL JOINTS, TIE RODS ENDS AND IDLERARM EVERY 2500-5000 MILES FOR WEAR AND REPLACE AS NEEDEDTHE INSTALLATION OF THIS SUSPENSION SYSTEM SHOULD BE PERFORMED BY TWO PROFESSIONALMECHANICS.WITH THE INSTALLATION OF THIS KIT YOU MUST RUN A WHEEL WITH A 4 5/8” BACKSPACING.FRONT SUSPENSION INSTRUCTIONS:1.Disconnect the negative terminal on the battery. With thevehicle on level ground set the emergency brake and blockthe rear tires. Jack up the front end of the truck and supportthe frame rails with jack stands. NEVER WORKUNDER AN UNSUPPORTED VEHICLE! Remove thefront tires.2.Locate the torsion bar adjusting cams and threaded bolts.Measure exposed threads of torsion bar adjusting bolts andrecord for reinstallation. Mark torsion bars indicating driverand passenger. Using a torsion bar removal tool unload thetorsion bars and remove the torsion bar adjusters. Retainthe hardware for reinstallation. NOTE- Do not attempt tounload or remove torsion bars without the proper torsionbar tool. Torsion Bars are under extreme spring load.3.Remove the sway bar link ends from the sway bar andlower control arm. Discard links and bushings.4.Remove the stock shocks and discard.5.Remove the stock lower rubber bump stops from the frameand discard.6.Remove the front factory differential skid plate and splashshield and discard. Remove the factory transmission guardand save. Retain the hardware for the transmission guard.Disconnect the tie rod ends from the steering knuckle byloosening the nut and striking the knuckle to dislodge the7.tie rod end. Use care not to damage the tie rod end whenremoving. SEE PHOTO NEXT COLUMN.8.9.Remove the brake hose bracket from the top of the steeringknuckle. Unplug the ABS wire connection from the frameand control arm. Remove the caliper from the rotor andplace above the upper control arm during this portion of theinstallation.Remove the brake rotor from the steering knuckle. Removethe axle nut, washer, and the 4 hub bolts on the backside ofknuckle. Remove the bearing hub assembly including Oring from knuckle. Retain the parts and hardware forreinstallation.

10. Remove the upper and lower ball joint nuts. Disconnect theupper and lower ball joints from the steering knuckle bystriking the knuckle with a large hammer next to each balljoint on the knuckle to dislodge the ball joints. Use carenot to hit the ball joints when removing. Retain the nuts anddiscard knuckle. SEE PHOTO BELOW.11. Disconnect the CV half shafts from differential housing andremove the axle assembly.16. With the differential housing out of the truck locate themounting bushing eye on the upper front side of thedifferential housing and mark the housing with a cut linesmooth to the housing. Using a sawzall, cut the entire earoff the housing. Take care not to cut into the flat portion ofthe housing. SEE PHOTOS BELOW.Before Cut12. Remove the lower control arms from the frame along withthe torsion bar and retain the arms, torsion bar, andhardware for reinstallation. SEE PHOTO BELOW.After Cut & Sanding Surface Smooth17. Locate the C shaped Fabtech differential bracket FT20062and install bushings and sleeve in bracket from BushingKit.13. Disconnect the front drive shaft from differential housingand transfer case, and retain the bolts and u joint clamps forreinstallation, discard drive shaft. NOTE: A new C.V.drive shaft will be install later (included in this kit).14. Disconnect the differential housing electrical connectionand vacuum line from the differential housing.15. Remove the stock differential rear crossmember anddiscard. Remove the differential housing assembly fromvehicle. To ease removal, turn the steering wheel to the leftfor better centerlink clearance.18. Place differential bracket to the differential housing andremove the appropriate 5 housing bolts. The bracketshould be positioned with the bushing eye to the top side ofthe housing. Using the provided the 10mm x 1.5 x 60mmbolts and washers in the hardware kit attach the differentialbracket to housing using thread lock compound and torqueto 30 ft lbs. Note- Some leakage of the differential oil isnormal during this process. Recheck and fill diff housingwith oil once the differential is mounted in vehicle. SEEPHOTO NEXT PAGE.

Diff Housing Bracket19. Locate the rear driver side lower control arm pocket,measure 1-3/4” from the backside of the pocket and mark avertical cut line around entire pocket. Using a Sawzall ordie grinder cut the backside of the pocket. SEE PHOTOBELOW.21. Locate and install the Fabtech rear crossmember into thefactory lower control arm pockets using the stock hardwarewith the nuts towards the rear of the truck. Leave loose22. Locate the supplied large bushing halves and long sleevefrom the bushing kit. Install into the differential mount onthe rear crossmember.23. Locate and install the Fabtech Passenger side Diff bracketFT20164 to the bottom of the factory frame mount. Attachusing the supplied ½” x 3 ½” bolt, nut, and washer. Torqueto 70 ft lbs. SEE PHOTO BELOW.View from the front of the truck looking back20. With the back of the pocket now removed place theFT20075 plate against the frame and weld in place. Let theplate cool and paint with a corrosive resistant paint orundercoating. SEE PHOTO IN NEXT COLUMN.24. Place the differential housing into the Fabtech rearcrossmember using the supplied ½” x 4 ½” bolt, nut, andwashers along with the supplied large FT55-1 washersattach the differential. SEE PHOTO ON NEXT PAGE.

25. Attach the Fabtech front crossmember into the lowercontrol arm pockets using the stock hardware.26. Position the front differential urethane bushing mount intothe front crossmember tabs. Locate and install thedifferential skid plate around the differential housingbushing using the supplied 9/16”x 5” bolt, nut, andwashers. Using the supplied 3/8” x 1” bolt and washerattach the rear of the skid plate to the rear crossmember.Leave loose. If installing the optional Fabtech FullDifferential Skid Plate FTS97000BK do so at this time,and discard the supplied FT20187 skid plate.31. Locate the factory brake line mount on top of the uppercontrol arm. Remove the brake line mount, and route theline with bracket to the bottom side of the control arm. Drilla guild hole directly below the original hole on the uppercontrol arm. Mount the factory bracket to the bottom sideof the control arm using the supplied 5/16 thread formingbolt. SEE PHOTO BELOW.27. Reconnect the electrical connection and the vacuum line tothe differential housing.28. Install the lower control arms into the new crossmembersUse the 5/8” x 4 ½” (front crossmember) and 5/8” x 5 ½”(rear crossmember) bolts, nuts, and washers from hardwarekit. Leave loose.29. Torque the following bolts - Driver side front and rear diffbushing bolts to 70 ft lbs, Passenger side diff bushing boltsto 70 lbs, Crossmember frame pocket bolts to 105 ft lbs,Control arm bolts to 105 lbs, Crossmember tab bolts to 25ft lbs. Recheck all bolts on the front end for proper torquebefore proceeding to next step.30. Locate the two bump stop mounts on the Fabtech rearcrossmember and install one of the supplied low profilebump stops to each side of the crossmember. SEE PHOTOBELOW.32. Lo

Installation Instructions . 6” Performance Suspension System . 2003-2008 Hummer H2 SUV & SUT (with Rear Coil Spring Suspension) 2003-2005 Hummer H2 SUV (with Rear Air Bag Suspension) Fabtech Motorsports 4331 Eucalyptus Ave. Chino, CA. 91710 . Tech Line 909-597-7800 Fax 909-597-7185 Web www.fabtechmotorsports.com

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