Project Ronix Rig - Part Two Flying High With a Cognito Lift and King Off-Road Shocks
Written by Chris Neprasch Photos by Chris Neprasch And Manufacturers
Page 2 of 3
10. Here is the pitman/idler support kit. On 4WDs, the top of the driver side upper differential mount may need to be trimmed about 1/4-inch off the top to make room for the nut. Unscrew the factory lock nuts that hold the drag link to the pitman and idler arms using a 21mm deep socket. Unscrew the nut holding the idler arm to the idler arm pivot with a 24mm boxed end wrench.
11. Apply a small amount of thread locker on all of the threads. Thread one 5/8-inch jam nut all the way onto both rod ends. Insert the rod end through 5/8-inch hole on both pitman and idler arm brackets then thread a second jam nut onto both ends, but don't tighten. Install one lock washer over each drag link stud then install the pitman and idler brackets where hardware was previously removed so that the lock washer is between to Cognito rod end and drag link.
12. Reinstall the factory lock nut on the pivot side of the idler arm that was previously removed and reinstall the lock washer and nut on the pivot shaft of the steering box. Using the supplied gold nuts for factory threads and silver shank nuts for the aftermarket threads, apply thread locker on the threads and insert a shank nut onto each of the drag link studs, passing through the rod ends and locking against the lock washer and drag link. Jam each support bracket between the jam nuts, then tighten shank nuts with 7/8-inch socket and 15/16-inch boxed wrench.
13. The front lift system includes: front crossmember, rear crossmember, torsion bar crossmember, compression struts, sub-frame connectors, differential mounts, and spindles all black powder coated. Also pitman/idler arm supports and all hardware.
14. During installation of the Cognito kit, it's important not to tighten any hardware until instructed to. Using the rear lower control arm pockets and factory bolts, bolt the Cognito rear crossmember into place. Insert polyurethane bushings and crush sleeve into passenger differential drop. Using factory hardware, bolt the Cognito passenger diff mount to the factory diff mount. Use supplied hardware to fasten lower end of Cognito diff mount to pocket on rear crossmember. Next, use supplied hardware to mount lower driver ear of factory diff to Cognito's diff.
15. Insert supplied bolts inside the frame hole just above the front lower control arm pocket and through the holes in the frame. Using factory hardware from the front lower control arm, bolt the Cognito front crossmember to the frame. On 4WD models, use one of the factory differential bolts and nuts to fasten the top diff-mounting ear to the pocket on the Cognito front crossmember.
16. Using supplied hardware, mount the driver and passenger Cognito sub frame connecter tubes between the lower pockets of the front and rear Cognito crossmembers. At this time, tighten all installed hardware.
17. To install the optional tubular upper control arms, insert supplied polyurethane bushings, crush sleeves and grease fittings into the ends of the UCA. Using factory nuts, bolts and eccentric washers, mount the upper control arms to the frame with the bump stop tabs pointed to the rear of the truck. Mount the ball joint to the spindle using supplied hardware and route the brake ABS lines away from any moving parts. There are provisions on the Cognito UCA for the factory brake line bracket.
18. Here are the two spindles side by side. Disassemble the bearing hub assembly and brake rotor shield from each of the factory spindles. Also remove the O-ring from the bore of the spindles, taking care not to damage them. Transfer all of the parts over to the Cognito spindle, making sure the bore and O-ring grooves are clear from debris and torque bearing hubs to factory specs.
19. Hang the spindle assembly in place from the ball joint on the upper control arm. Attach appropriate lower control arms to lower pockets of Cognito front and rear crossmembers using supplied hardware, which also fasten into place the subframe connector tubes between lower control arm mounting points. Attach the lower control arm ball joint to the lower spindle and tighten.
20. 4WD models require the installation of spacers to get the axle to fit properly. Install the spindle end of the front axles, then use the supplied hardware to fasten the axles to the differential. Install brake rotors and calipers to the spindle and tighten. The anti-sway bar may also be attached to the lower control arm, but shouldn't be tightened until the suspension is compressed.
21. Press the wide polyurethane bushings and sleeves into the ends of the Cognito compression strut tubes. Attach one end of the tubes to the rear crossmember with supplied hardware. Attach the other end to strut tubes to compression strut crossmember. Swing it into place and using the crossmember as a template, drill four 1-inch holes into the frame.
22. Press the narrow polyurethane bushings and sleeves into the Cognito torsion bar brackets. Unclamp the compression strut crossmember, drop it down slightly and mount the Cognito torsion bar brackets in place against the bottom frame rail. Raise the compression strut bar bracket and mount them to the frame using supplied hardware.
23. Insert the factory torsion bar crossmember onto the Cognito torsion bar drops with factory hardware. Install the torsion bars into the lower control arms the same way they were removed, place the adjusters inside the crossmember and slide the torsion bars into place. Load the bars and replace the adjuster nut. Unload bars and insert the adjuster screw into the nut and adjust to factory specs.
24. The optional dual shock front hoops use factory holes for two of the three bolts. On the driver side a lower steering box bolt will need to be removed from the frame. Mount the hoops with supplied hardware, then scribe the location at the rear for drilling. Remove the hoop, drill the hole and then reinstall using supplied hardware.
25. Using supplied hardware, mount the dual shocks starting at bottom mount located on the upper control arm. Once they are loosely fastened, swing the shocks up and mount the tops at the dual hoop.
26. To bring the rear up, we used lifting blocks. The blocks were installed by supporting the rear axle, removing the shocks and then undoing the U-bolts one side at a time. Once one side was loose, the axle was dropped down far enough to push the block into place. Longer U-bolts were used to hold the axle into place. The process was then repeated for the other side.
27. Lifting the back also required the use of longer shocks, although they do retain factory mounts. We headed to King Off-Road again and had them set us up with a pair of Pre-Runner Piggyback 2.5 shocks to match the ones on the front.
28. With the help of Cognito, King, Cooper and American Racing Wheels, the Sierra has taken on a totally different look. Although it sits a lot higher, the ride is, if anything, better than factory thanks to the R&D put into the lift by Cognito and King getting the valving for the GMC dead on. As with any time you change major suspension components, an alignment is needed. Shocker Motorsports got it close enough to drive to the shop and an hour later we were back on the road.