Nissan Automobile 4083 User Manual

INSTALLATION INSTRUCTIONS  
98-99 NISSAN FRONTIER 4 WD  
KIT # 4083  
WARNING  
WARNING  
This body lift kit should only be installed on vehicles that  
are in good working condition. Before the installation  
begins, the vehicle should be thoroughly inspected for  
evidence of corrosion or deformation of the sheet metal  
around the factory body mounts. This body lift kit should  
not be installed on any vehicle that is suspected to have  
been in a collision, or misused. Off road use of your  
vehicle with this body lift installed may increase the stress  
Installation of a Performance Accessories body lift will  
change the center of gravity and the handling  
characteristics of the vehicle. Because of the higher  
center of gravity and larger tires, the vehicle will handle  
and react differently both on and off road. You must drive  
it 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.  
applied to the factory body mounts.  
It is not  
recommended that any vehicle, with a body lift installed,  
be involved in any extreme off road maneuvers such as  
jumping. Failure to follow this warning may result in  
serious personal injury and/or serious damage to your  
vehicle.  
WARNING  
Read and understand all instructions, warnings, cautions,  
and notes in this sheet and in your owners manual before  
you begin the installation of this body lift kit.  
WARNING  
Performance Accessories strongly discourages the use of  
a suspension lift kit or any other lift device in addition to a  
body lift kit. A vehicle that uses a combination of lift  
devices not originally engineered to be used together may  
result in unexpected and unsafe handling characteristics.  
Many states now have laws restricting bumper heights  
and vehicle lifts. Local laws should be consulted to  
determine if the changes you intend to make to your  
vehicle complies with state laws.  
CAUTION  
Proper installation of a Performance Accessories body lift  
kit requires knowledge of the factory recommended  
procedures for disassembly an assembly of original  
equipment components. It is recommended that the  
factory shop manual and any special tools necessary to  
your vehicle be on hand during the installation.  
Installation of this body lift kit without proper knowledge of  
the factory recommended procedures may affect the  
performance of these components and the safety of you  
vehicle. It is strongly recommended that a certified  
mechanic who is familiar with the installation of similar  
components install this body lift kit.  
WARNING  
The installation of larger wheel and tire combinations may  
reduce the effectiveness of the Anti-lock Braking System.  
NOTE  
Performance Accessories recommends using the Loctite®  
supplied in the kit, on all hardware unless noted in the  
instructions.  
WARNING  
Always wear eye protection when operating power  
tools.  
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screws are accessed through the wheel well. Remove the  
four bolts that mount the front bumper to the frame.  
Remove the bumper from the vehicle.  
WARNING  
Failure to replace the OEM body mounting hardware  
(except mounting bolts) in the stock locations could result  
in damage to the vehicle and possible personal injury.  
13. Remove the tabs that hold the fender well flaps to  
frame. This will prevent flaps from being damaged while  
lifting.  
18. Using a hydraulic jack and a wooden block, slowly lift  
the passenger side of the cab just high enough to put the  
spacers on the mounting pads. Continually check for any  
hoses, wires, etc. to be sure that everything is flexing  
properly and not binding. Be especially careful of the a/c  
hose at the firewall and at the core support. Place the  
spacer block on top of the mounting pad. Using a 3/8"  
washer in conjunction with the stock washer, install the  
7/16" x 7" bolts at the front two mounts (core support and  
front floorboard) and the 10mm x 180mm bolt at the rear  
cab mount. For the front two mounts, the 3/8” washer  
should be installed on the bolt. The bolt should then be  
inserted from the top through the stock top washer,  
through the body, the spacer, the factory top bushing, the  
frame perch, the bottom factory bushing, the stock bottom  
washer and inserted into the 7/16” nylock nut provided  
with the kit. The 3/8” washer should be installed on the  
10mm bolt, the bolt should be inserted from the bottom  
through the outside support bracket, the bottom stock  
bushing, the frame perch, the stock top bushing, the  
block, and threading into the nut that is captured inside  
the body. Reinstall the two bolts that mount the outside  
support bracket to the bottom of the frame perch. Do not  
tighten any of the bolts at this time.  
14. Remove the screws that mount the scuff plate to the  
door jamb area on both sides of the vehicle. Remove the  
kick panels from both sides. Place the manual  
transmission in neutral. Remove the screws that mount  
the shift boot to the floorboard. Pull the boot back to  
expose the top of the transmission. Remove the c-clip that  
holds the transmission shift lever in the top of the  
transmission. Remove the spacer washer that is under the  
C-clip. Unbolt the transfer case shifter from the transfer  
case. Remove both levers from the vehicle. You may  
want to wrap a rag around the bottom of the shift lever to  
prevent any oil from dripping on the carpet. Pull the  
carpeting back to expose the two body mounting bolt  
access covers. Remove the plastic access covers from  
the floorboard and discard. Be sure that the transmission  
is in neutral. Remove the shift lever from the transmission.  
WARNING  
Use extreme caution when working near fuel lines and  
fuel tank. Clean up spilled fuel immediately. Any spark  
could cause an explosion or fire resulting in serious  
personal and property damage.  
15. Remove the screws that mount the fuel filler neck to  
the body. Loosen the hose clamp that mounts the filler  
hose to the fuel tank. Loosen the clamp that mounts the  
vent hose to the tank. Remove the entire filler neck and  
hose assembly from the vehicle.  
19. Repeat step #18 for the driver’s side of the cab. Adjust  
the cab to bed clearance. Install the outside support  
plates to the cab using the stock bolts. Attach the outside  
support plates to the stock outside support brackets using  
two 7/16” x 1” bolts, four 7/16” SAE washers, and two  
7/16” nylock nuts on each side of the cab and tighten  
securely. Remove cab-mounting bolts, one at a time,  
apply Loctite®, reinstall bolt and tighten to vehicle torque  
specifications.  
16. Disconnect the license plate lights from the rear  
bumper. Remove the six bolts that mount the rear bumper  
to the frame. Remove the bumper from the vehicle.  
17. Measure the distance between the cab and the bed.  
Record this measurement to insure proper alignment of  
the cab and bed after the lifting operation has been  
completed. Remove the bolts at the rear cab mount that  
mount the body to the side of the rear cab mount. There  
are two bolts inserted from the inside of the frame mount  
and are threaded into the body. There are two more bolts  
that are inserted from the bottom and thread into the  
mounting pad. When the rear cab bolt is removed, the  
bracket can be removed. Loosen, but do not remove all  
six cab-mounting bolts. They are located as follows; in the  
front fender well, in the front floorboard, and at the rear of  
the cab screwing up into the cab. The front two mounting  
bolts are installed from the top and the rear bolt is  
installed from the bottom.  
20. Loosen, but do not remove all six bed-mounting bolts.  
Remove the mounting bolts from the passenger side of  
the bed only. Using a hydraulic jack and a wooden block  
slowly lift the passenger side of the bed just high enough  
to place the spacer blocks on the frame. Install the new  
mounting bolts in the following positions; ½ x 5” at the  
front bed mount, ½” x 4 ½” at the middle bed mount, and  
½ x 5 1/2" at the rear bed mount. The bolts should have a  
½” USS (large) washer installed and then the bolt should  
be inserted through the thick rubber bushing, through the  
frame, through the thin rubber bushing, through the  
spacer, and through the bottom support rail of the bed.  
Install a ½” USS washer and nylock nut on each bolt. Do  
not tighten at this time.  
21. Repeat step # 20 for the driver’s side of the bed.  
Realign the bed to the cab. Refer to the measurements  
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made earlier. One by one remove each bed-mounting  
bolt. Remove bed-mounting bolts, one at a time, apply  
Loctite, reinstall bolt and tighten to vehicle torque  
specifications.  
tube with the rubber bushing onto the studs at the top of  
the radiator. Reinstall the stock upper radiator mount. The  
hole in the stock mount should align with the hole in the  
tube. Mount the tube to the stock bracket using a 3/8” bolt,  
two 3/8” USS washers, and a 3/8” nylock nut on each  
side. Do not tighten at this time. Be sure that the radiator  
is secure. Tighten all radiator mounting hardware  
securely. Install the fan shroud to the radiator using the  
stock hardware. Check the fan to fan shroud clearance.  
Be sure that the fan cannot make contact with the shroud.  
Tighten the fan shroud mounting hardware securely.  
Install both radiator hoses to the radiator. Tighten the  
hose clamps securely.  
WARNING  
Failure to install the steering extension properly could  
result in loss of steering causing damage to the vehicle  
and possible personal injury.  
22. Install the steering extension into the lower coupler of  
the steering shaft. Be sure that the extension is installed  
so the mounting bolt will slide across the flat on the  
steering extension. Install the stock retaining bolt in the  
steering shaft. If the bolt will not easily slide across the flat  
on the steering extension, the extension has been  
installed incorrectly. Do not tighten the retaining bolt at  
this time. Extend the mark on the lower part of the  
steering shaft down onto the extension. Install the upper  
part of the steering shaft into the upper coupler inside the  
engine compartment. Be sure to align the marks made  
earlier. Install the stock retaining bolt in the upper coupler.  
Align the mark on the steering extension with the mark on  
the gearbox. Install the steering extension on the gearbox  
splined shaft. Install the retaining bolt in the steering  
extension. Do not tighten the retaining bolt at this time. Be  
sure that all marks are properly aligned and that there is  
ample engagement at all unions.  
25. Fill the cooling system as much as possible at this  
time. It will need to be topped off after the vehicle has  
been started.  
26. Reroute the vacuum brake-booster hose over the a/c  
hose at the firewall. Bend the bracket that mounts the a/c  
hose to the firewall forward to a 45-degree angle. This  
should give the hose ample slack. Reconnect the hose to  
the brake booster. If the line still feels tight, it may be  
necessary to carefully bend the steel portion of the line to  
gain more slack in the line.  
27. Check the a/c line at the core support. Be sure that  
there is enough slack in the line to remount it to the core  
support. If there is not enough slack, carefully bend the  
line to gain more slack. Be sure that there is ample slack  
in the line. Install the bolt that mounts the a/c line to the  
core support. Tighten securely.  
23. Using the new lower radiator support as a template,  
Mark the lower core support for alignment of the new  
support. Align the holes in the new bracket with the stock  
mounting holes. Mark the core support for proper  
alignment of the new support after the stock mount has  
been removed. Using a die grinder or hacksaw cut away  
the bottom radiator mount from the core support. Be  
especially careful of the a/c condenser when cutting the  
sheet metal. Cut to the outside of each mounting hole  
approximately 1 ½” to 2” and flush with the vertical  
surface of the core support (allow enough room for the  
radiator to slide past the remaining sheet metal without  
hitting). Place the new lower radiator support bracket on  
the core support. Be sure that the bracket is aligned with  
the marks made earlier and that the bracket is positioned  
flush against the core support with the lip resting on top of  
the core support. Using the bracket as a template, mark  
the top of the core support through the holes in the  
bracket. Remove the bracket. Drill a ¼” hole at both  
locations. Mount the bracket to the core support by install  
a ¼” x 1” bolt with a ¼” washer through the bracket, and  
the core support. Install a ¼” washer and nylock nut on  
the bolt from the bottom of the core support. Tighten the  
¼” hardware securely.  
28. Using two 10mm – 1.25 x100 bolts with a 3/8” washer  
on each bolt, and the two 3” long tubes mount the cab  
safety loop to its original location. It may be necessary to  
bend the loop slightly to align the loop to the mounting  
holes with the spacer tubes installed. Tighten safety loop  
mounting bolts securely.  
WARNING  
Use extreme caution when working near fuel lines and  
fuel tank. Clean up spilled fuel immediately. Any spark  
could cause an explosion or fire resulting in serious  
personal and property damage.  
29. Lengthen the fuel filler hose. Cut the filler hose toward  
the bottom below the first bend. Install the 1 3/4" fuel filler  
extension between the two sections of the filler hose.  
Install a #28 hose clamp at each end of the extension.  
Tighten both hose clamps securely. Remove the vent  
hose from the filler neck. Install the new vent hose to the  
filler neck vent. Install a #10 hose clamp and tighten  
securely. Install the filler assembly in the vehicle. Using  
the stock clamp, reconnect the filler hose to the fuel tank.  
Using a #10 hose clamp, reconnect the large vent hose to  
the fuel tank. Tighten all hose clamps securely. Install the  
screws that mount the filler neck to the body. Tighten  
24. Install the radiator on the new lower support bracket.  
Remove the two rubber bushings from the plastic studs on  
the top of the radiator. Install the rubber bushings into the  
large hole in the 2” x 3” x 1” rectangular tube. Slide the  
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securely. Replace the fuel cap.  
WARNING  
Raising the rear bumper is intended to enhance the  
appearance of the vehicle only. The rear bumper will no  
longer be rated for towing of any kind. Attempting to tow  
with the rear bumper after it has been raised can result in  
damage to the vehicle and possible personal injury. A  
class III receiver hitch must be installed in order to tow  
with the vehicle after the rear bumper has been raised.  
WARNING  
A certified welder should perform all welding.  
30. Lengthen the transmission shift lever. Scribe a line  
along the side of the shift lever below the bend. Be  
extremely careful during this procedure to not damage any  
of the parts that are attached to the shift levers. Cut the  
lever into two pieces through the line. Insert the shift lever  
extension between the two parts of the shift lever. The  
tapered end of the extension goes toward the bottom.  
Both parts of the shift lever should slide into each end of  
the extension. Be sure that the lever is all the way in the  
extension and that the scribe lines are aligned with the  
mark on the extension. Using the holes in the extension  
as a guide, drill a 1/8” hole through each part of the shift  
lever and the opposite side of the extension. Install a 1/8”  
x ¾” roll pin at both ends of the extension. To lengthen  
the transfer case lever, scribe a line along the shaft above  
the two bottom bends and cut the shaft through the  
scribed lines. Place the extension pin between the two  
pieces and align the scribed lines before welding the  
extension in place.  
34. Install the rear bumper. If you wish to tow with the rear  
bumper, reinstall the bumper in the stock location using  
the stock brackets and mounting hardware. To raise the  
rear bumper, remove the two bolts that mount each rear  
bumper bracket to the bumper. Drill a new mounting hole  
in the bumper side of the stock bumper. Hold the bumper  
bracket against the frame in the stock location. Pivot the  
rear of the bracket upward until the last hole on the  
bracket is aligned with the bottom of the slotted hole in the  
frame. The first hole in the bracket should still align with  
the last stock hole in the bumper. The center mount hole  
should also align with a hole in the frame. Mount the  
brackets to the frame using the 7/16” x 1” bolts, 7/16’ USS  
washers, and 7/16” nylock nuts provided. Do not tighten.  
Mount the bumper using the 7/16” x 1” bolts, 7/16" USS  
washers, and 7/16” nylock nuts provided. The rear  
bumper should align with body. Adjust the bumper to body  
clearance. Tighten all bumper-mounting hardware  
securely. Reconnect the license plate lights to the  
bumper.  
31. Replace the shift lever in the vehicle. Insert the  
transmission shift lever into the top of the transmission.  
Be sure that it is all the way in and replace the cover.  
Install the spacer shim. Install the retaining clip. Bolt the  
transfer case shifter to the transfer case and adjust the  
linkage as outlined in the factory repair manual. Check  
the shift lever and transfer case shifter operation. Be sure  
that there is complete engagement in all gears and  
ranges. Replace the shift boot and housing assembly.  
Tighten all mounting screws securely. Check the shift  
lever and transfer case shifter operation again.  
35. Reinstall the air cleaner. Install the top of the housing.  
Install the air intake duct to the upper radiator mounting  
brackets. Install the mounting screws and tighten  
securely.  
WARNING  
All welding should be performed by a certified welder only.  
32. Replace the carpet and matting to its original position.  
Replace both kick panels and both doorjamb scuff plates.  
Tighten the mounting screws securely.  
36. Install the four bed overload pads on the frame over  
the wheel wells. Remove the rubber pads bolted to the  
frame and place the overload pads where the rubber pads  
were. The pads need to be tack welded to the frame only.  
33. Using the stock bolts, mount the front bumper  
brackets to the frame. Tighten the mounting bolts so the  
brackets cannot move, but so the bumper can still be  
adjusted. Slide the front bumper onto the relocating  
brackets. Align the holes in the stock bumper brackets  
with the holes in the new bumper brackets. Reinstall the  
bumper on the vehicle. Mount the bumper to the  
relocating brackets using two 7/16” x 1" bolts, four 7/16”  
USS (large) washers, and two 7/16" nylock nuts. Adjust  
the bumper to body clearance. Tighten all bumper-  
mounting hardware securely. Reconnect the wires to the  
driving lights.  
37. Reconnect both battery cables. Be sure to reconnect  
the positive cable first, then the negative cable. Reinstall  
the airbag fuse if equipped.  
38. Place the warning sticker on the dash in plain sight of  
all vehicle occupants.  
CAUTION  
All fasteners should be retorqued after 500 miles and after  
off road use. All body lift components should be visually  
inspected and fasteners retorqued during routine vehicle  
servicing.  
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39. Double-check the vehicle. Check all mounting  
hardware to be sure that it is properly tightened. Check all  
wires, hoses, cables, etc. to be sure that there is ample  
slack. Check the vehicle electrical system. Start the  
vehicle. Check the steering in both directions to be sure  
that there is no bind. Check clutch operation. Check the  
operation of the brake system and the parking brake.  
Check both shift levers’ operation. Be sure that there is  
proper engagement in all gears and 4 wheel drive ranges.  
Check coolant level. Caution: never open a closed  
cooling system after the vehicle has been started. Only fill  
the cooling system if the cap has been removed while the  
vehicle was still cold. Fill the coolant to the proper level.  
Reinstall the radiator cap. Carefully check all hoses to be  
certain that they have been connected properly and that  
there is ample slack. With the amount of hoses on this  
vehicle, it is vital that this be checked thoroughly. Test-  
drive the vehicle in all gears and 4 wheel drive ranges.  
Pay very close attention to all vehicle systems. Check all  
hardware again in 500 miles and as part of your regular  
maintenance schedule.  
Kit Parts List.  
Quantity  
Description  
6
3” x 3” blocks  
6
3” x 2” blocks  
1
1
1
2
1
1
2
4
3” Lower Radiator Support  
Bracket, Front - Right  
Bracket, Front - Left  
Outer Cab Support Plates  
Bracket, Power Steering Reservoir  
Bracket, Parking Brake  
Spacers, Bed W/ Holes  
Spacers, Bed W/O Holes  
Extension, Fuel Filler  
Extension, Shift  
1
1
1
1
1
Hose, Rubber ½” - 19”  
Hose, Rubber ¼” - 17”  
Instruction Sheet  
1
Loctite  
1
Logo Label  
1
Warning Label  
Bolt Pack  
2
4
2
2
2
6
6
6
4
6
1
1
Bolt, M10-1.25 x 180 (Fine Thread)  
Bolt, 7/16-14 x 7”  
Bolt, ½-13 x 4-1/2”  
Bolt, ½-13 x 5”  
Bolt, ½-13 x 5-1/2”  
Nut, Nylock ½-13  
Washer, ½ USS  
Washer, ½” Thick  
Nut, Nylock 7/16-14  
Washer, 3/8” USS  
Bolt, 3/8-24 x 1-1/4”  
Steering Extension  
CAUTION  
Performance Accessories does not recommend any  
particular wheel and tire combinations for use with its  
body lifts and can not assume responsibility for the  
customer’s choice of wheels and tires. Your owner's  
manual can be referenced for recommended tire sizes  
and warnings 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 with an  
experienced local off road shop to find what wheel and tire  
combinations work best with your vehicle.  
Hardware Pack  
2
5
5
10  
4
Bolt, M10-1.25 x 100 (Fine Thread)  
Bolt, ¼-20 x 1”  
Nut, Nylock ¼”  
Washer, ¼” SAE  
Bolt, 5/16-18 x 1”  
4
8
2
2
Nut, Nylock 5/16-18  
Washers, 5/16 USS  
Bolt, 3/8-16 x 1”  
Nut, Nylock 3/8-16  
Washer, 3/8 USS  
NOTE  
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 that have  
been made to his vehicle and how they affect the  
handling and performance of the vehicle. Failure to  
provide the customer with this information can result in  
damage to the vehicle and possible personal injury.  
4
16  
16  
24  
8
4
4
Bolt, 7/16-14 x 1”  
Nut, Nylock 7/16-14  
Washer, 7/16 USS  
Washer, 7/16 SAE  
Clamp, Hose #6  
Clamp, Hose #10  
Clamp, Hose #28  
2
2
Pin, Roll 1/8” x 1”  
1
1
1
2
Extension, 3” Shift Pin  
Hose, Vacuum Extension Tube  
Hose, Heater Extension Tube  
Hose, Extension, Fan Shroud/Heater  
Rev 03, Copyright 04/06  
Performance Automotive Group  
6
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