BM2
Bolt Torque-Tension Relationship
Caution: All material included below is advisory only, and it’s use by anyone is voluntary. Extreme cau-
tion should be used when using a formula for torque/tension realtionships. Torque is only an indirect in-
dication of tension. Under/over tightening of fasteners can result in costly equipment failure or personal
injury. All bolts and nuts used are Grade 5 unless noted in the description. Grade 8 nomenclature will
be shown as G8 in the description. (Fine thread bolts are not shown, call the factory for details)
A) References of left & right are determined by standing behind your Crawler and looking forward.
B) Though the following instructions are inclusive, some of the Steps have already been completed at
the factory...just go on if you find a particular step has already been completed for you.
C) Photos of various assembly Steps are located throughout the instructions and we’ve tried to keep
the more timely photos next to the instructions of the components they describe. NOTE: some photos
show completion of Steps that will come later in the instructions. You will find it helpful though, to look
at photos from other sections of these instruction to see different views of particular parts you are
presently assembling.
D) As many of the components you will be working with are awkward and occasionally heavy, it’s a good
idea to have a helper available for assistance.
E) It can never be mentioned too much; always work on your Crawler with it’s Parking Brake on, the
Engine shut off, the Ignition Key removed [or ignition switch turned to STOP] and the (-) Ground Cable
removed from Battery [if so equipped].
F) The length of a Bolt is determined by measuring the threaded shank below the Bolt’s head.
G) When assembling cylinders, it’s helpful to unscrew the plastic plugs 1/2 way, then put a pin in the
“rod end” tube (chrome movable end) and hit the pin with a mallet to break loose the seal in order to
make lining up the cylinders easier later in assembly steps. (Call the factory with any questions you
may have) Once the “rod end” is out fully, you can remove the plastic plug completely.
BEFORE YOU BEG N YOUR ASSEMBLY...
... a few important facts
should be brought to your attention:
1/4” x 20....................................
5/16” x 18..................................
3/8” x 16....................................
7/16” x 14..................................
1/2” x 13....................................
9/16” x 12..................................
5/8” x 11....................................
3/4” x 10....................................
7/8” x 9......................................
1” x 8.........................................
Bolt Diameter & Thread Count Grade 5 - (3 lines on head) Grade 8 - (6 lines on head)
101 in. lbs......................................
209 in. lbs......................................
31 ft. lbs.........................................
49 ft. lbs.........................................
75 ft. lbs.........................................
109 ft. lbs.......................................
150 ft. lbs.......................................
267 ft. lbs.......................................
429 ft. lbs.......................................
644 ft. lbs.......................................
143 in. lbs.
295 in. lbs
44 ft. lbs.
70 ft. lbs.
106 ft. lbs.
154 ft. lbs.
212 ft. lbs.
376 ft. lbs.
606 ft. lbs.
909 ft. lbs.
