Here's the incorrect instructions I was provided. That triangle drain plug cover is clutch, but its just a plate with the holes countersunk so you can put flathead bolts into it and get them to bolt into the main plate. The instructions have the hardware list, but these are for the gen 1 plates, not what you and I have. I have fucking PTSD from just thinking about what I went through by myself to get this up. However, its indestructible and I'm super happy with it after hanging my truck up on the rocks at Uwharrie. Here's some tips and some of the major areas it differs:
- The 2 piece gas tank plates. Bolt these together on the ground well, very well. Then follow the instructions and once your brackets are installed use a jack with a board to press the skid up to the gas tank. You will likely have to raise and lower it a few times and adjust the brackets to get it to line up. The tolerances are extremely tight. Don't be scared to drill out if you need an extra 1/32nd of an inch. Hit it with some spray paint to prevent rust.
- Speaking of which, dont do this with a lot of gas in the tank. You are removing and then replacing some of the bolts that mount it.
- The front plate's wings (step 25). The motor mounts don't look at all like the picture and yours look like mine. Go under there BEFORE you start doing anything with the wings, a flashlight, and some spare nuts. Look up and you'll need to find the existing bolts in there and figure out what size they are. DO NOT REMOVE THE EXISTING NUTS. The wings should fit over them and you use the excess bolt to put a nut on. I think I put a washer in between the exisitng bolt and wing. You'll understand what I mean when you see it. Basically this whole area is bullshit and you'll have to engineer it yourself. Just do it before you start.
- One of the black brackets will bolt to the center of the midplate and requires you to use self-tapping screws to mount ti to the tub. This wont fit either and you'll need to come up with a spacer or re-bend it, or redrill it. Again, some bullshit you'll have to re-engineer on your back. I did this step last since the whole system needs to move a bit during install.
- If you have a lift and installed spacers under the driveshaft carrier bearing then dealing with the gas tank bracket over there might be tough. I had to grind a little extra clearance off the spacers because they touched the bracket. So get ready to redo that whole thing.
- My life was a ton easier by getting 1.25"x3/4" bots instead of the supplied ones. Sometimes 1" is all that will fit in tight spots, but that extra quarter inch will bve a life saver other times. Also get stover nuts, lock washers and blue loctite for everything.
- You'll need regular & ratcheting wrenches as well as sockets and extensions. Also one of those magentic extendo wands for when you drop bolts in the plate and cant reach them.
- Keep al the hardware barely hand-tight until the end. You will need some play in the whole thing as you move from one section to the next. It sucks to have to go back through and loosen some of this stuff to get 1/32 towards the end.
I forget how long it took me, something north of 12 hours. I was constantly putting it up, finding issues, lowering peices, fixing issues, then putting pieces back on. I did have a couple of things loosen up after the first couple of hundred miles that required some adjustments and more loctite. Even with stovers and loctite the bolts from the front wings to the front plate come a little loose once a year (engine vibrations) and I have to go crank them down as routing maintenance. But like I said, it was worth it. I overcame all the bullshit and now all 4 wheels could come off my truck on the highway and I'd be ok.