B & W Turnover Ball Gooseneck Hitch Chevrolet/GMC 1999-2007
- REMOVE SPARE TIRE AND HEAT SHIELD The heat shield under the bed floor must either be removed or a section cut out for the hitch assembly to be installed. A) Remove the heat shield from in front of the back crossmember. B) Remove the heat shield from the back of the crossmember located near the front of the wheel well.
- REMOVE EXHAUST BRACKET To ease installation of the center section it is necessary to remove the lower exhaust bracket. Simply pull the hanger rod out of the rubber bracket hole, a 6” to 8” wood block can then be positioned between the exhaust pipe and frame of the truck. This will increase your clearance between the top of the exhaust pipe and the bottom of the truck bed floor. (Caution: Exhaust pipe may be hot).
- MARKING AND CUTTING 4 INCH HOLE IN TRUCK BED. Begin by verifying and measuring the correct hole location in the truck bed floor. Measure from the back end (tailgate end) of the truck bed floor by hooking a tape measure over the back of the truck box and mark the floor at the correct measurement. Next, center the location between the wheel wells. This will be the center point for the four inch hole. This location is critical to the correct installation of this hitch, so measure, mark and saw carefully. If the truck has a plastic bed liner, you may drill through both, but it is more difficult to accurately locate the midpoint between the fender wheel wells, and to be sure that the bed liner does not move while sawing the hole. Make a 4 inch hole at this location using a four inch hole saw, or by marking a 4 inch circle and cutting it out with a saber saw equipped with a metal cutting blade.
- CROSS MEMBER INSTALLATION. Install the two cross members. They will be installed by sliding them from inside the wheel well, above the tire, through the gap between the bed and the truck’s frame and across until they span the frame rails. The gap between the bed and frame is large enough to allow this, but the gap is partially obstructed by a sheet metal flange (about 1” in height) that is hanging down from the bottom of the truck bed floor. (See diagram and photos). A small notch needs to be made in this flange on the passenger side of the truck. Locate the center truck bed cross member. Measure over 2 1/2” from the front of the cross member and make a mark. This will be the center point of the notch that is needed. Mark a 1” wide by 1/2” tall notch. Remove the metal of the marked area with sheet metal shears. This will allow the front angle iron crossmember to be installed.
- CROSS MEMBER INSTALLATION Place the 48” front cross member between the truck frame and bed floor using the notch made in step four. Be sure the holes in the cross member are facing to the rear of the truck. Slide the cross member across both frame rails. Using the rubber O-ring provided, secure a 1/2” x 1 1/2” long bolt into the second hole in the cross member from the driver’s side. Slide the crossmember forward to the front edge of the 4” hole in the bed. Next install the 46 1/2” rear cross member bar between the truck frame and bed floor. Rotate the rear cross member a quarter turn so the threaded holes are offset to the bottom of the bar and slide back until there is enough room for the center section to be placed between the two cross members.
- CENTER SECTION INSTALLATION Raise the center section into position between the crossmembers and carefully move it above the fuel tank from beneath the truck. The receiver socket must be positioned to the rear with the latch pin release arm on the driver’s side. A lifting device, as described on Page 1 will help. The round hitch receiver that protrudes from the top of the center section must fit through the hole in the truck bed floor. Slide the front cross member back against the center section so that the bolt installed previously in the front cross member goes into the center section hole directly across from it. Line up the rest of the holes and attach the two members with 1/2” x 1 1/2” long bolts, lock washers, and nuts. Insert 1/2” x 1 1/2” bolts, with flat and lock washer installed, through the rear leg of the center section into the threaded holes of the rear crossmember and hand tighten.
- INSTALL SIDEPLATES Next install the sideplates. The driver’s sideplate is shown, with the bent flange to the front, and the large hole to the rear. Attach the two pieces of the sideplate together with ½” carriage bolts. The carriage bolts should be inserted into the square holes from the backside of the sideplates and fastened using a flat washer, lock washer and nut on each bolt. This can be completed before installation on the frame rail. Do not tighten at this time. Attach the flange on the sideplate to the front cross member using a ½ x 1 1/2 inch bolt, flat washer, lock washer and nut. Insert the bolt through the flange so that the nut when tightened is on the front side of the cross member. Next attach the rear bar to the sideplate ear threading a ½ inch by 1 ½ inch bolt with flat and lock washer installed into the bar.
- Install the ½-inch x 6 ¼-inch U-bolt from inside the frame through the holes in the sideplate above and below the frame, use a lock washer and nut on each end of the Ubolt. Repeat this procedure on the passenger side of the truck with the other sideplate. (While installing the U-bolts around the frame use caution not to damage or pinch the wiring harness or brake lines). Install the ¾-inch by 2 ½-inch bolt. Place a flat washer and frame insert on the 3/4” bolt and install the bolt from inside the frame through the rear hole in the side plate. The 3/4” bolt fastens with a lock washer and nut. (The holes in the frame and the sideplate are slotted and B&W provides an insert that converts the slotted holes to a 3/4” round hole. When installed correctly the frame insert will seat firmly in the slotted hole in the frame and the slotted hole in the sideplate). When completed, tighten all the hardware in this order: 1. Tighten the center section bolts to the cross members to 80 ft pounds. 2. Make certain the hitch is square with the frame. 3. Tighten the ¾” side plate bolts to 120 ft pounds. 4. Tighten the frame clamping U-bolts slowly, alternating between the top and bottom legs of the U-bolt until equally tightened to 40 ft pounds. 5. Tighten the three carriage bolts on each side to 60 ft pounds. 6. Tighten the side plate to the front and rear cross members to 80 ft pounds.
- INSTALL LATCH PIN RELEASE HANDLE WARNING: LATCH PIN WILL NOT FUNCTION PROPERLY IF HANDLE IS NOT INSTALLED CORRECTLY. Install the latch pin release handle by inserting it through the slot in the end of the center section on the driver’s side of the truck. Align the handle eyelet with the square hole in the latch pin so the handle is in line with the latch pin as shown. Secure the handle to the pin with the 5/16 X 3/4” carriage bolt and 5/16” locking flange nut as shown. Note: The included 5/16” cap screw can replace the carriage bolt if wrench access on the “cab side” of the handle is limited. Tighten the nut until it is secure. Do not over-tighten and deform the handle eyelet.
- INSTALL SAFETY CHAIN BRACKETS To install the safety chain brackets it is necessary to drill four 1/2” holes through the truck bed floor. Drill the holes from beneath the truck, through the two holes located on each side and closest to the round receiver tube in the center section. This will locate the safety chain brackets in the lowest point of the floor corrugation. Drop a U-bolt through each pair of holes from the topside of the truck bed floor. Place a spring and lock nut on each of the four legs. Tighten the lock nuts until flush with the bottom of the U-bolts.
- REPLACE THE EXHAUST BRACKET Replace the exhaust hanger brackets and the spare tire if removed during step 2 of the installation.
For Replacement Parts - (BNWGNXA2061)