Roadmaster 1109-174 User manual

85-4607 rev. 00 11-10
ROADMASTER, Inc. • 6110 NE 127th Ave. • Vancouver, WA 98682 • 800-669-9690 • www.roadmasterinc.com
part #1109-174 1-5/8” diameter
Auxiliary Rear Anti-Sway
Bar Kit for Kodiak
4500-5500
INTRODUCTION
Thank you for purchasing this anti-sway bar kit. This kit is designed to improve the handling characteristics of your Kodiak
4500/5500 by reducing the body roll and balancing the weight transfer during cornering. The anti-sway bar kit is engineered
for long life and trouble-free performance. For maximum suspension control, use this kit along with our front anti-sway bar kit.
All the hardware needed for installation is included in this kit. Refer to the PARTS LIST in these instructions to identify the parts.
SUGGESTED TOOLS
The following tools are suggested to complete the installation procedures:
• Standard socket and wrenches
Installation Instructions
Thank you for purchasing anti-sway
bar kit. Please read through these
instructions before installation.
Note: do not remove the factory anti-sway bar. This kit is designed to
support the factory anti-sway bar — not replace it.
•If raising the vehicle to install the anti-sway bar, always support
the vehicle with jack stands at both frame rails or at the rear axle
before working underneath. Ensure that the jack stands are securely
positioned, and are rated at or above the weight of the vehicle.
•The installer must read the instructions and use all bolts and parts
supplied. Use only the parts supplied by ROADMASTER to install
this kit.
•Minor modifications are sometimes necessary due to slight vehicle
variations, even for the same year, make and model.
•Regardless of year, make and model, a wide range of options for
specific applications may or may not interfere with the installation.
It is the installer’s responsibility to make certain that equipment is
not damaged once the suspension solution travels through the full
range of motion. Failure to ensure adequate clearance could result
in non-warranty property damage, personal injury or even death.
Failure to follow these instructions
can result in property damage, per-
sonal injury or even death.
WARNING
•If running changes were made by the manufacturer after this kit
was designed, there may be weldments, braces, gussets, or other
structural items which interfere with the installation. It is the in-
staller’s responsibility to allow for these running changes without
sacrificing the structural integrity of the anti-sway bar. Failure to
securely fasten the anti-sway bar could result in property damage,
personal injury or even death.
•ROADMASTER will not be responsible for any damage or injury
resulting from any modification or alteration.
•Check ALL the fasteners for tightness before and after road testing
the vehicle.
•Do not use this document for custom fabrication, as it may not
show all parts or structural components.
•Do not use an air impact wrench when re-installing bolts, as stripped
threads may result.
•This anti-sway bar is only warranteed for the original installation.
Installing a used anti-sway bar on another vehicle is not recom-
mended and will void the warranty.
Note: for use with vehicles equipped with
Granning Air Ride systems only

PARTS LIST
2 • Kodiak 4500/5500 Rear Anti-Sway Bar Kit 800-669-9690
5
5
13
3
4
12
6
16
13
Part #1109-174
Part # Description Qty
1 B141 Bracket 2
2 B629 Front bracket left 1
3 B630 Front bracket right 1
4 B451 End link 2
5 B606 Bracket 1
6 205222-10 Bushing 2
7 205223-50 Bushing 8
8 205522-00 Sleeve 4
10 350101-80 ½’ x 3” NC bolt 2
11 580272-00 Anti-sway bar 1
9 350099-80 Bolt 2
12 350096-80 ½” x 1¾” NC bolt 4
13 350308-00 Cut washer 2
14 350347-00 9/16” cut washer 4
15 350259-00 ½” NC nylon nut 12
16 400011-30 Aqualube grease 1
17 B700 ¾” Wrench 1
18 *350308-40 ½” Cut washer 4
19 *B619 Bracket 1
20 *350097-00 1/2” x 2” NC GRD5 4
21 *350099-80 1/2” x 2-1/2” NC GRD8 2
8
15
10
1
7
9
14
11
* Not shown

The following instructions must be followed in the order listed to ensure a proper installation
and to preserve the ROADMASTER warranty.
INSTALLATION
800-669-9690 Kodiak 4500/5500 Rear Anti-Sway Bar Kit • 3
1. Install the Frame Brackets
Note: do not remove the factory anti-sway bar. This kit is designed
to support the factory anti-sway bar — not replace it. Start by
removing the two mounting bolts on the rear leaf spring hanger
bracket. There are three bolts on each side of the leaf spring
hanger, and we are using the upper and the lower bolts (middle bolt
is not used) on the forward side of the hanger. Attach the bracket so
that the larger hole is on the axle side. A ¾” wrench is included in
the kit for this job (Figure 1, 2, 3, 4, 5).
2. Install the Axle Brackets
Loosen all four of the u-bolt nuts on each side. Remove the rear
u-bolt nuts and install the bracket. Re-tighten all ubolt nuts in an X
pattern. Be sure the lower axle plate is seated flush and torque to
the manufacturer’s specifications (Figure 7, 8).
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Front of vehicle Front of vehicle

Front of vehicle


Front of vehicle


INSTALLATION
3. Install the Anti-Sway bar.
Start by bolting the B632 bolt to the endlink and frame bracket
using the ½ x 2.5” bolt, with the bolt head facing towards the
outside. Use the supplied 9/16” cut washer on the inside. Grease
the bushings with the supplied lube and install on the anti-sway bar.
Place B141 bushing clamps over bushings (Figure 8, 10).
Next, bolt the anti-sway bar to the end links. The bolt head should
be to the inside (Figure 9).
Now, rotate the anti-sway bar into position on the axle plates and
secure loosely with the ½” x 1¾” bolts.
Once everything is in place, tighten all hardware.
4. Test drive.
Test drive and listen for any unusual noise, re-check all fasteners.
Figure 8
Figure 9
Figure 10
Do not tow or hoist the vehicle using the anti-sway bar or its
mounting brackets as attachment points. The anti-sway bar is not
designed to carry the weight of the vehicle and may collapse, which
will damage the anti-sway bar components, the suspension, or other
components. The vehicle will detach or fall, which may cause severe
personal injury.
Failure to follow these instructions may result in property damage,
personal injury or even death.
The anti-sway bar is not a load-bearing component
WARNING
4 • Kodiak 4500/5500 Rear Anti-Sway Bar Kit 800-669-9690
Figure 7