INSTALLATION INSTRUCTIONS FOR REAR WEIGHT JACKERS PL510 / PL610

 

(1) JACK UP CAR AND REMOVE REAR WHEELS.

 

(2) REMOVE THE REAR SPRINGS AND DISCONNECT THE REAR SHOCK AT THE CONTROL ARM.  NOTE: THIS INSTALLATION IS EASIER IF THE CONTROL ARMS ARE ALSO REMOVED.

 

(3) IF THE STOCK RUBBER ISOLATOR IS STILL ON THE UPPER SPRING LOCATOR, REMOVE IT NOW AND CLEAN THE AREA AROUND THE BASE OF THE SPRING LOCATOR.  THE IDEA IS TO EXPOSE THE SPOT WELDS THAT ATTACH THE LOCATOR TO THE CHASSIS.

 

(4) DRILL THE SPOT WELDS OUT USING A SPOT WELD DRILL OR GRIND THEM USING A GRINDER.  THE GOAL IS TO GET THE SPRING LOCATOR OFF OF THE CAR WITHOUT PUTTING ANY HOLES THRU THE SHEET METAL, AS THIS AREA SUPPORTS THE WEIGHT JACKER AND SPRING.  USE CARE WHEN DOING THIS OPERATION.  ONCE YOU HAVE THE LOCATOR REMOVED, MAKE SURE THE SURFACE IS FLAT.

 

(5)  INSIDE THE CAR, LOCATE THE SEATBELT MOUNTING NUT IN THE SPRING POCKET AREA.  YOU WILL NEED TO OPEN A 2-1/8" DIAMETER HOLE CENTERED ON THIS NUT.  THE NUT ON THE WEIGHT JACKER WILL FIT INTO THIS HOLE FROM THE BOTTOM OF THE CAR.  BE SURE THE HOLE IS BIG ENOUGH THAT NEITHER THE NUT NOR THE WELD KEEP THE WEIGHT JACKER PLATE FROM SITTING FLAT AGAINST THE BOTTOM OF THE SPRING POCKET.

 

(6) USING THE WEIGHT JACKER PLATE AS A PATTERN, DRILL SIX (6) 3/16" DIAMETER HOLES THRU THE SPRING POCKET SHEET METAL.  BE SURE TO CENTER THE WEIGHT JACKER IN THE POCKET.  IT IS HELPFUL TO DRILL ONE HOLE AND INSTALL A BOLT TO LOCATE AND HOLD THE PLATE IN PLACE.

 

(7) ONCE ALL (6) HOLES ARE DRILLED, REMOVE THE PLATE AND DEBURR THE HOLES TOP AND BOTTOM.  PAINT THE MOUNTING AREA TO PREVENT RUST.

 

(8) INSTALL THE WEIGHT JACK PLATE FROM THE UNDERSIDE OF THE CAR AND PLACE THE REINFORCEMENT RING ON TOP (INSIDE THE CAR). INSTALL THE FLATHEAD SCREWS, WASHERS, AND NUTS.

 

(9) INSTALL THE ALUMINUM SPRING PERCH TO THE WEIGHT JACK BOLT AND BEND THE COTTER PIN TO RETAIN IT.  (BE SURE THE THRUST WASHER IS IN THE BOTTOM OF THE PERCH BETWEEN THE SCREW AND THE ALUMINUM.)

 

(10) INSTALL THE WEIGHT JACKER SCREW INTO THE NUT ON THE PLATE (YOU WILL WANT TO LUBRICATE THIS.) AND RUN IT UP UNTIL THE PERCH CONTACTS THE PLATE.  (THIS WILL AID INSTALLATION OF THE SPRING.)

 

(11) REASSEMBLE THE REST OF THE CAR (SPRING, CONTROL ARM, SHOCK, ETC.) AND REINSTALL THE WHEELS.

 

(12) THE RIDE HEIGHT CAN NOW BE SET BY PLACING A 1/2" RATCHET WITH A 3/4" SOCKET ON THE BOLT.