1999 Chevy Silverado Suspension Drop by DJM

4/6 DJM Calmax Complete Drop Kit Install

Originally published in 1999

1999 Silverado
1999 Silverado with 4/6 Calmax kit by DJM

The essence of restyling is changing a stock vehicle from what the manufacturer considers beautiful to what the restyler thinks is better. Suspension modification is a good example. Consider a 1999 Chevrolet Silverado. Chevy thinks the vehicle looks just fine as it is. But lowering devotees believe it looks even better dropped, say, four inches in the front and six inches in the rear. Now, there was a time when such a dramatic suspension overhaul would have permanently damaged the truck’s ride. But, I’m happy to report that today’s lowering kits are better-engineered, safer and easier to install than ever, and many of the good ones even offer a fairly pleasant ride. The old sarcasm that “a lowered truck is a lowered truck” is not as true as it once was. To prove our point, we followed along with DJM Suspension, Gardena, Calif., while they installed their Calmax Level 2 (4-inch-by-6-inch) drop kit on a white 1999 Silverado. The kit includes a C-notch brace, new control arms, a rear flip kit and the latest components of the suspension-modifier’s art. When finished, we were convinced the lowering business has come a long way, impressed both with the truck’s appearance and ride once this Chevy was slammed into the weeds. Check out the photo gallery below to see how the parts went on, and click on the (  I ) in the picture to read the caption!

1999-silverado-article

[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-16.jpg]1080Check the Mountings
Tighten and check the shock mountings making sure to not over-tighten the top and squish the bushings and see that the pin and bushings are seated properly in the lower shock mount
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-1.jpg]1510Before Measurements
It's important to measure the stock ride height before you begin. The most accurate method is to measure from the center of your wheel to the fender lip. This distance won't change if you upgrade your wheel and tires, and will give you the real drop figures after your done! It will also show any irregularities in the factory ride height.
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-2.jpg]1440Remove the Shocks
To begin we'll start with the front end and remove the shocks. You will need to have the truck on jack stands and then support the lower control arm with a jack before you remove the shocks.
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-3.jpg]1230Remove the Tie Rod End
Remove the cotter key, loosen and remove the castle nut from the tie rod end. Pop the tie rod end out of the spindle and to keep from losing the nut, thread it back on the the tie rod end
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-4.jpg]1300Separate the spindle from the lower control arm
With a hydraulic jack supporting the lower control arm, loosen and remove the castle nut from the lower ball joint. Carefully brake the taper of the ball joint in the spindle, move the spindle out of the way without stressing the break line.
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-5.jpg]1260Remove the Coil Spring
Using the jack, carefully release the load on the coil spring and remove.
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-6.jpg]1110Loosen the Pivot Bolts
Loosen the control arm pivot bolts and allow arm to rotate away from the spindle
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-7.jpg]1140Remove the Lower Control Arms
Support the control arm and remove the pivot bolts. Now remove the factory control arms
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-8.jpg]1270Prep the Calmax Control Arms to Install
These arms have the DJM "Twin Tube" design which allows you to lubricate the control arms pivot points with plenty of grease. Here we are drilling a grease passage through the outer sleeve before installing the inner sleeve or grease zerk.
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-9.jpg]1270Inner Sleeves
Use a file to chase any burrs from drilling the hole then liberally coat the inner sleeve with grease before sliding it into the outer sleeve
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-10.jpg]1170Grease Zerks
Install the grease zerks so you can periodically shoot new grease into the pivot points of the control arms
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-11.jpg]1130Lots of grease
Check the inner sleeve to make sure it moves freely and apply plenty of grease to the shoulders of the urethane bushings
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-12.jpg]1120Install your new Calmax Control Arms
Now your ready to place the arms in the factory mounts, insert the pivot bolts and hand tighten the nuts on the pivot bolts
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-13.jpg]1100Install the Factory Coil
Make sure the control arm can rotate freely and using a hydraulic jack to help, install the factory coil spring
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-14.jpg]1110Lower Ball joint
With the coil spring and spindle arranged, use the jack to help you guide the lower ball joint into the spindle and tighten the castle nut
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-15.jpg]1100Calmax SuperShox
It's time to install your brand new Calmax SuperShox in the factory mounting points
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-17.jpg]1090Tie Rod
Install the tie rod end into the spindle. Now is a good time to inspect and replace if necessary
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-18.jpg]1110Swaybar
Using the swaybar end-links provided, attach the factory swaybar to your new Calmax control arm. You can improve performance by upgrading the swaybar with a Calmax swaybar. Go to djmfactorystore for more info!
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-19.jpg]1080Tighten Pivot Bolts
Now you can tighten the pivot bolts. Again be careful to not tighten too much. There should be no slop, but it does not help to tighten until the nut stops. This will cause the bushings to bulge out, squeak and fail prematurely. Note if you have your Silverado on a rack, let the truck back down on it's wheel before you tighten the pivot bolts, also you may find it much easier to install the swaybar end-links with the truck on it's wheels
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-20.jpg]1270On to the rear
Loosen the u-bolts on the rear axle where the axle is secured to the leaf spring. Of course, you have your truck on jack stands supporting the frame and a hydraulic jack under the differential to suport and control the rear end
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-21.jpg]1290Flipping the axle
When you have removed the u-bolts and spring plates you can carefully move the axle from below the leaf spring to setting on top of the leaf spring (flipping). Of course it's not really "flipping" the axle but you can see how this kit got it's name!
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-22.jpg]1310Locating the axle on the leaf spring
Position the axle in the axle bracket on the leaf spring over the leaf spring center bolt
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-24.jpg]1350U-Bolts
Slip the U-Bolts over the axle and down past the springs
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-25.jpg]1400Spring Plate
Fit the spring plate onto the u-bolts and make sure the u-bolt/spring plate assembly is straight up and down. When everything is good, tighten
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-26.jpg]1580Frame Support (C notch)
Now you have moved the axle on top, use this to position your frame support cutout. This way you make sure to cut your frame directly above your axle. Use the frame support to scribe a line where you need to remove frame material. A sawz-all works pretty good for this!
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-27.jpg]1370Install Support and Air Bag Bracket
Again using the frame support as a template locate and drill out the mounting holes so you can bolt in the frame support
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-28.jpg]1400Bump Stop
Install the provided urethane bump stop on to the frame support
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-23.jpg]1500Adding Air Bags
We added a Air Flex air bag assist kit. The mounting brackets matched up perfectly with the mounting holes on the frame supports on top and the bottom sandwiched with the axle brackets making the install easy
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-29.jpg]1440Shocks
It is very important to have the correct length shocks. The change in suspension travel requires a shorter shock to optimize ride quality
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-30.jpg]1360Fittings
It is very important to have the correct length shocks. The change in suspension travel requires a shorter shock to optimize ride quality
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-31.jpg]1450Plumbing
Carefully plumb your airlines and attach to the bag
[img src=http://djmsuspension.com/wp-content/flagallery/1999-silverado-article/thumbs/thumbs_99-32.jpg]1810After Measurements
Check your installation for loose fasteners and alignment. You should "eyeball" the front end alignment, then drive around the block. Check your installation again before recording an after measurement. When you are satisfied with the installation get a professional alignment and check the measurement again. Compare with the original factory measurements.