Icon 61721 User manual

PART # DESCRIPTION

61721 05-UP FSD 4-5.5” 2.5 VS RR BOLT IN

COILOVER CONVERSION KIT

61721 INSTALLATION INSTRUCTIONS

WARNING!

** READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH

BEFORE BEGINNING INSTALLATION! IF THESE INSTRUCTIONS ARE

NOT PROPERLY FOLLOWED SEVERE FRAME, SUSPENSION AND TIRE

DAMAGE MAY RESULT TO THE VEHICLE!

** ICON VEHICLE DYNAMICS RECOMMENDS THAT YOU EXERCISE

EXTREME CAUTION WHEN WORKING UNDER A VEHICLE THAT IS

SUPPORTED WITH JACK STANDS.

** ICON VEHICLE DYNAMICS RECOMMENDS ALL INSTALLATION TO

BE PERFORMED BY A PROFESSIONAL SHOP/SERVICE TECHNICIAN.

PRODUCT FAILURE CAUSED BY IMPROPER INSTALLATION WILL NOT BE

COVERED UNDER ICON’S WARRANTY POLICY.

1. Using a properly rated jack, raise the front of the vehicle and support the frame rails with jack stands. Ensure the jack stands are

secure and set properly before lowering the jack. NEVER WORK UNDER AN UNSUPPORTED VEHICLE. Remove the front wheels.

2. Remove driver and passenger front shocks with a 3/4” socket/wrench. [FIGURE 1 & 2]

COMPONENTS INCLUDED

(2) 164949R 05+ FSD 4-5.5” 2.5 VS RR BOLT IN

COILOVER

(1) 61721H HARDWARE KIT

(1) 611051 HARDWARE KIT

HARDWARE INCLUDED

61721H HARDWARE KIT

(2) 164017 05+ FSD C/O LOWER MOUNT

(2)

164035 05+ FSD CO CONV 7.5” RESI BRACKET

(2) 167011 05+ FSD 4” BUMP STOP SPACER

(6) 605011 5/16-18 X 0.750 SCREW

(12) 605016 5/16 FLAT WASHER

(6) 605076 5/16-18 LOCK NUT

(6) 605108 3/8-16 X 1.250 SCREW

(6) 605131 3/8 SPLIT LOCK WASHER

(2) 605308 1/2-13 X 3.000 SCREW

(2) 605322 1/2-13 LOCK NUT

(4) 605330 1/2 FLAT WASHER

(2) 605804 M8-1.25 X 120MM SCREW

(2) 605806 M14-2.00 X 30MM SCREW

611051 HARDWARE KIT

(4) 605931 1/2 X 2 1/16 - 3 ID #40 SS HOSE CLAMP

TOOLS REQUIRED

JACK

JACK STANDS

RECIPROCATING SAW

SANDER

DRILL

7/16” DRILL BIT

TORQUE WRENCH

10MM SOCKET / WRENCH

22MM SOCKET / WRENCH

24MM SOCKET / WRENCH

5/16” SOCKET / WRENCH

7/16” SOCKET / WRENCH

9/16” SOCKET / WRENCH

3/4” SOCKET / WRENCH

TECH NOTES

1. RETURNING TO A STOCK COIL SPRING REQUIRES FABRICATION. IF YOU PLAN TO RETURN

VEHICLE TO STOCK AT A LATER DATE DO NOT DISCARD THE COIL CENTERING CUP THAT IS

REMOVED IN STEP 7.

2. YOUR ICON COILOVER ASSEMBLIES COME SHIPPED AT ICON’S RECOMMENDED RIDE HEIGHT.

REDUCING DROOP TRAVEL WILL REDUCE RIDE QUALITY. DO NOT PRELOAD THE COIL BEYOND

1.5” OF EXPOSED THREADS BETWEEN THE BOTTOM OF THE TOP CAP AND THE TOP OF THE COIL

ADJUSTER NUT. ADJUSTING PRELOAD BEYOND THIS SETTING WILL CAUSE THE COIL TO BIND AND

DAMAGE WILL OCCUR TO COILOVER AND/OR VEHICLE.

3. YOUR ICON COILOVER ASSEMBLIES COME FACTORY CHARGED TO 250 PSI. RELEASING NITROGEN

PRESSURE MAY LEAD TO SHOCK MALFUNCTION AND REDUCED RIDE QUALITY. FAILURE CAUSED BY

LOW NITROGEN PRESSURE IS NOT COVERED UNDER ICON’S WARRANTY POLICY.

FIG.1 FIG.2

8-5-2021 REV.C

INSTALLATION

7929 Lincoln Ave. Riverside, CA 92504

Phone: 951.689.ICON | Fax: 951.689.1016

3. Remove the track bar bolt at frame. [FIGURE 3]

4. Lower the front axle until the coils can be removed from vehicle. [FIGURE 4 & 5]

5. Remove the lower coil mount with a 22mm socket/wrench and the lines attached to it using 10mm socket/wrench. [FIGURE 6 & 7]

6. Remove the inner fender liner.

7. With a reciprocating saw and a 10” blade, use the coil bucket as a guide and cut out the centering cup from the upper coil mount

on both driver and passenger side. [FIGURE 8]

8. Grind any material that keeps the upper coil bucket from being smooth and ﬂat. [FIGURE 9]

FIG.4 FIG.5

FIG.6 FIG.7

FIG.9FIG.8

FIG.3

FIG.10

9. Locate (164035) reservoir mount which is also the drill template. With a c-clamp or welding vise grips, clamp the reservoir mount

so the 90 degree ﬂange is parallel to the length of the vehicle as shown. [FIGURE 10]

10. Using a transfer punch, mark the locations of all 3 holes in the reservoir bracket.

11. Protecting all components in the engine compartment, using a 7/16” drill bit carefully drill the 3 holes that were marked with the

reservoir bracket.

12. Spray paint the coil bucket to prevent corrosion from the removal of the cup or the drilled holes.

13. Locate (164017) lower shock mount and install using the supplied M14 hardware as shown with a 22mm socket/wrench.

[Torque to 100 ft-lbs] [FIGURE 11]

14. Using the supplied 5/16” hardware, install the factory lines that were attached to the factory lower coil seat with a 1/2” socket/

wrench. [Torque to 24 ft-lbs]

15. Remove the foam bump stop from the factory cup and remove the bolt holding the cup to the chassis with a 10mm socket/

wrench. Locate the billet bumpstop spacer (167011) and bolt (605804). Install in between the factory cup and the frame on both the

driver and passenger side. [Torque to 20 ft-lbs] [FIGURE 12 & 13]

FIG.11

FIG.12 FIG.13

16. Install the driver side coilover: The reservoir hose will point towards the front of the vehicle indicating the driver side. With the

reservoir bracket sandwiched between the coil bucket and the coilover mount, use the supplied 3/8” hardware to fasten the coilover

to the coil bucket. [Torque to 45 ft-lbs] Twist the hose and loop around to the reservoir mount as shown and attach reservoir to

mount using the supplied hose clamps with a 5/16” socket/wrench. [FIGURE 14]

NOTE: failure to use the supplied reservoir bracket will cause the hose ﬁtting to crash into the coil bucket.

17. With the supplied 1/2” hardware, mount the lower eyelet of the shock to the axle. Use a jack to help locate the assembly.

[Torque to 80 ft-lbs] [FIGURE 15]

18. Reinstall the plastic wheel liner. [FIGURE 16]

19. Repeat steps on passenger side. Reattach the trackbar. [Torque to factory spec]

20. Install wheels/tires and remove vehicle from jack stands. [Torque lugs to factory spec]

21. Center the steering wheel by turning the tie rod adjuster. [FIGURE 17]

22. Have the vehicle professionally aligned.

RETORQUE ALL NUTS, BOLTS AND LUGS AFTER 100 MILES AND PERIODICALLY THEREAFTER.

VERIFY ALL FASTENERS ARE PROPERLY TORQUED BEFORE DRIVING VEHICLE.

FIG.14

FIG.17

FIG.16FIG.15

2.5 VS SERIES SHOCK & COILOVER TECHNICAL INFORMATION

MAINTENANCE

ICON shock absorbers are a high quality rebuildable race style shock absorber designed for optimal performance. With a unit of this caliber on your vehicle, routine

maintenance is required to keep them looking and operating in like new condition. Residual oil and assembly lube may be present at all seal paths from the factory out of the

box and is considered normal. Pooling of oil however is not acceptable at any time and one should contact the ICON dealer where purchased.

BELOW ARE GUIDELINES BASED ON HOW YOU USE YOUR VEHICLE BUT YOUR MILEAGE MAY VARY:

STREET USE:

• Send in for factory servicing every 40,000 miles or if a leak develops, ride quality decreases, or they begin to make excessive noise.

• Remove any buildup of road salt, mud, or debris from shocks and coil springs anytime accrued

• Clean with mild soap and water with each oil change or anytime you notice build up.

• Wax the cylinders yearly with automotive wax to prevent corrosion.

• Check nitrogen pressure yearly. (252004 charge needle assembly available at any ICON distributor)

• Check bearings for excessive wear yearly.

• DO NOT apply any type of lube to the upper and lower bearings.

STREET/DIRT:

• Send in for factory servicing every 15,000 miles or if a leak develops, ride quality decreases, or they begin to make excessive noise.

• Clean with mild soap and water with each oil change, oroad trip, or anytime you notice build up.

• Wax the cylinders yearly with automotive wax to prevent corrosion.

• Check nitrogen pressure each dirt outing. (252004 charge needle assembly available at any ICON distributor)

• Check bearings for excessive wear yearly.

• DO NOT apply any type of lube to the upper and lower bearings.

DIRT USE:

• Send in for factory servicing every 1,000 miles.

• Check nitrogen pressure each outing. (252004 charge needle assembly available at any ICON distributor)

• Remove any buildup of mud or debris from shocks and coil springs after every outing.

SELF-SERVICE:

• Contact ICON for service kits & tools at (951) 689-4266.

PRODUCT REGISTRATION

Please visit: http://www.iconvehicledynamics.com/tech-support/registration/ to register your product.

ICON VEHICLE DYNAMICS SHOCK ABSORBER WARRANTY

This shock absorber has a 1 year warranty against any manufacturer’s defects. If a shock fails within the initial year of ownership, the shock must be shipped to ICON Vehicle

Dynamics for inspection and service. If a shock is inspected and it has been determined the shock failed due to neglect, damage caused by improper installation or any other

reason besides “normal wear and tear”, the owner of said shock is responsible for all service costs. This includes labor, parts, and shipping.

ICON Vehicle Dynamics warrants to the original retail purchaser who owns the vehicle on which the product was originally installed. ICON Vehicle Dynamics does not warrant

the product for ﬁnish, alterations, modiﬁcations and/or installation contrary to ICON Vehicle Dynamics instructions. ICON Vehicle Dynamics products are not designed, nor are

they intended to be installed on vehicles used in race applications, for racing purposes or for similar activities. (A “race” is deﬁned as any contest between two or more vehicles,

or a contest of one or more vehicles against the clock, whether or not such contest is for a prize). This warranty does not include coverage for police or taxi vehicles, race

vehicles, or vehicles used for government or commercial purposes. Also excluded from this warranty are sales outside of the United States of America and Canada.

ICON Vehicle Dynamics’ obligation under this warranty is limited to the repair or replacement, at ICON Vehicle Dynamics’ discretion, of the defective product. Any and all costs

of removal, installation or re-installation, freight charges and incidental or consequential damages are expressly excluded from this warranty. Items that are subject to wear are

not considered defective when worn and are not covered.

ICON Vehicle Dynamics components must be installed as a complete kit as shown in our current application guide. Any substitutions or exemptions of required components will

immediately void the warranty. Some ﬁnish damage may happen to parts during shipping and is not covered under warranty.

This warranty is expressly in lieu of all other warranties expressed or implied. This warranty shall not apply to any product that has been improperly installed, modiﬁed or

customized subject to accident, negligence, abuse or misuse.