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2005 Nissan Frontier - The New Frontier

2005 Nissan Frontier Calmini Compression Struts
Calmini's compression struts used factory holes to bolt onto the transmission crossmember.
2005 Nissan Frontier Die Grinder
The front crossmember interfered with the new Calmini piece, so a die grinder was used to remove about an 1/8-inch from the passenger side.
2005 Nissan Frontier Sander
Skidplate bolts also kept the front crossmember from aligning, so Jorg hit them with a disk sander to make some room.
2005 Nissan Frontier Drilling
Bumpstop spacers used factory holes and self-tapping bolts, but the holes needed to be drilled first.
2005 Nissan Frontier Front Sway Bar Drop Brackets
Front sway-bar drop brackets placed the sway bay in front of the new crossmember.
2005 Nissan Frontier Knuckles
Jorg placed the new knuckles next to the old ones and transferred the hubs and ABS sensors onto the new pieces. On Nissan trucks, the hubs simply bolt on with four bolts, and the ball joints stay in the control arms, which made this lift a lot faster than others.
2005 Nissan Frontier Stainless Steel Brake Lines
New braided stainless brake lines were zip-tied to the new knuckle and the ball joints received new cotter pins. The tie rods were flipped since the steering rack stayed in the factory location. Those also received new cotter pins to finish up the front suspension.
2005 Nissan Frontier Carriage Works Grille
We installed this glossy black Carriage Works grille in our driveway. The first step was to remove the Nissan emblem by compressing the barbs that held it to the grille.
2005 Nissan Frontier Toggle Bolts
Next, four toggle bolts were threaded onto the center grille piece.
2005 Nissan Frontier Factory Honeycomb Grille
The toggle bolts were pushed through the factory honeycomb grille and were held in place to make sure they grabbed while they were tightened.
2005 Nissan Frontier Lower Grille
The lower grille used threaded clips and an angle bracket to mount onto vertical plastic bars in the lower grille opening. First, the bracket was mounted onto the grille to locate where the holes would be drilled.
2005 Nissan Frontier Threaded Clip
After the location was marked and drilled with a 3/16-inch bit, a threaded clip was used to mount the bracket in the lower grille opening. The lower grille was inserted in the opening and tightened. The total time for grille installation was 20 minutes.
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