This will allow proper compression and extension of the shock as the suspension moves through its range. Make sure to use a level and a steel straight edge to draw this line. Now that the frame has been modified, mate the IRS assembly to the truck's frame to verify fit. You are solely responsible for your safety and should ensure that your vehicle is properly supported while you work on it. This fender-level view shows the tires tucked neatly in the rear fenders. Remove the hub retaining nut. This view is from the outside of the frame rail. Once you are completely satisfied that all the clearances are correct, reinstall the knuckles and brakes. Our story begins with the bed removed from this Ford truck, the rear axle removed and all exhaust, brake lines, etc.
As the centerlines between the existing caliper mounting holes, and the required mounting holes, is only 19mm, some modifications to the knuckle see picture 1 and caliper see picture 2 are required. Bleed the brake system in accordance with the factory service manual. Lower one side of the vehicle and torque the hub retaining nut to lb-ft. Also, as the arc of the Cobra rear rotors is greater than the arc of the stock rear rotors, the caliper must be modified to maintain mm clearance between the outer edge of the rotor and the inside of the caliper see picture 2. With the rear fenders back on the truck, a straight edge is placed on the outside lip of the rear fender. The angle finders are inexpensive and help you to keep things level. Our story begins with the bed removed from this Ford truck, the rear axle removed and all exhaust, brake lines, etc. These adapters get welded to the truck's frame - allowing the IRS assembly to bolt in place. In addition to a level, angle finders come in very handy during this type of installation. Notice that the cut line extends on either side fore and aft of the crossmember Center the ends of this crossmember about the rear mounting bolts The factory shock uses 15mm or 16mm mounting bolts to mount the shock to the lower control arm. Following the chalk line from the inside of the frame The rear leaf springs remain in place and will be removed in the first step. We cut the rivets holding the shackles with a torch, but other methods may be used to remove the springs. I chose instead to adapt the Once the driver's and passenger's side cuts are complete, remove the entire assembly - including the original crossmember. This view shows the inside of the truck's frame. This is where the lower control arm wants to be for optimal performance. Remove and discard the hub retaining nut. Press out the old hub, and press in the new Cobra hub. This bed is not suitable for hauling anything, but allows an excellent view of the IRS Removing the rear fender reveals the clearance between the outside of the bed and the tire. Another view of the passenger's side rear looking forward. As viewed from the rear, verify that the rear mounts are level as well as the new crossmember. Here is an action photo of the frame modification.
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