60043 (EDITING).fm
Contents
1. 3651 N Highway 89 Chino Valley AZ 86323 928 636 7080 DODGE DAKOTA 3 KIT INSTALLATION INSTRUCTIONS 2000 2002 KIT 60043 A WARNING Installation of a Performance Automotive Group body lift kit will change the vehicle s center of gravity and handling characteristics both on and off road You must drive the vehicle safely Extreme care must be taken to prevent vehicle rollover or loss of control which could result in serious injury or death Avoid sud den sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fas tened A WARNING Before you install this kit read and understand all instructions warnings cautions and notes in this instruction sheet and in the vehicle owner s manual A CAUTION Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components We rec ommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle We strongly recommend that a certified mechanic familiar with the installation of sim ilar components install this kit A WARNING DO NOT combine suspension body or other lift devices Use of vehicle with combined lifts may result i2. 16 on shift lever 17 and transfer case 18 with two rubber bushings 15 f If removed install skid plate 13 on the frame 14 with four bolts 12 1 31 1998 17 Manual Transmission Models Shift Lever a Scribe a line along side of transmission shift lever below bend as shown Cut lever into two pieces through line and de burr as necessary Scribe A Line Kit Extension 18 00 02 Dakota Kit 60043 b Position kit extension transmission shift lever 5 8 x 3 between two pieces of transmission shift lever Ensure kit extension and shift lever scribe lines align and weld extension in place Let shift lever cool c Install insulator two pivot pins washer and lock ing plate on modified lower shift lever Position mod ified lower shift lever in shift tower d Install locking plate with four screws and dust cover on shift tower e Install lower shift boot on cab floor with six screws Install shift console on cab floor with six screws f Install upper shift lever on modified lower shift lever Install upper shift boot on shift console with six SCrews 18 Tack weld two kit bed overload spacers 126 on the frame 14 over the rear wheel wells 127 as shown Dust Cover Locking Plate Screw Shift Tower ia Lower Shift Boot Shift Console 00 02 Dakota Kit 60043 D After installation is complete 1 Install two airbag fuses 10 in the fuse box 11 2
3. Disconnect the neg ative cable 7 first then the positive cable 8 Remove battery 9 from vehicle refer to the owner s manual A WARNING Accidental deployment of the air bag can result in seri ous personal injury or death To avoid accidental deployment during installation of the lift kit the Supple mental Restraint System SRS or airbag must remain deactivated Do not allow anyone near the airbag dur ing installation Refer to the factory service manual or owner s manual for the recommended procedure to disable the SRS After kit installation the SRS must be reactivated before driving the vehicle 7 Remove two air bag fuses 10 from the fuse box 11 see the owner s manual for fuse location 00 02 Dakota Kit 60043 B Get ready to install the kit 1 Manual Transmission Models Shift Lever a Remove six screws and upper shift boot from shift console Slide shift boot up the upper shift lever b Remove upper shift lever from lower shift lever Remove upper shift lever and upper boot from vehi cle c Remove six screws and shift console from cab floor d Remove six screws and lower shift boot from cab floor e Remove dust cover four screws and locking plate from shift tower f Remove locking plate washer lower shift lever pivot pins and insulator from shift tower Locking Plate Washer Not Shown Lower Shift Lever Pivot Pinse Upper Shift j Boot y A Upper
4. Install brake line bracket 57 on kit bracket 118 with kit 5 16 bolt 119 three kit 5 16 washers 119 and kit 5 16 nylock nut 120 d Install plastic clip 55 on bracket 57 e Install brake lines 54 in the plastic clips 55 Reposition automatic transmission shift cable a Install kit bracket 121 and automatic transmis sion cable loop 59 on the brake booster 49 with two kit 1 4 x1 bolts 122 three kit 1 4 washers 123 and a kit 8mm nylock nut 124 b Position automatic transmission cable 58 in the automatic transmission cable loop 59 17 GD OOO a ely 3 i AS 7 00 02 Dakota Kit 60043 A WARNING A certified welder or welding shop should perform all welding 16 Lengthen and install the transfer case shift linkage a Position 4WD shifter in neutral Measure distance center to center between holes in 17 and 18 b Measure length of linkage rod 16 and add 3 for kit linkage extension 125 If total length of 16 and 125 is greater than distance between 17 and 18 shorten kit linkage extension 125 so mea surements are equal c Scribe a line along the transfer case linkage rod 16 Cut linkage into two pieces through line d Position kit linkage extension 125 between two pieces of the linkage rod 16 align two halves of scribed line and weld extension in place e Install transfer case shift linkage
5. 3 Manual shift lever extension 5 8 x 3 Lower radiator hose extension Ground strap extensions Rubber clad clamp Zip ties 36 clamps 22 Front bumper inner bracket Front bumper outer bracket Rear bumper bracket Rev 02 Copyright 08 05 Performance Automotive Group 00 02 Dakota Kit 60043
6. kit retaining bolt 95 Do not A CA Se N P Gass tighten z k x c Install steering shaft 63 on kit steering extension eai lt gee ANS 96 or 97 with the stock retaining bolt 61 ao 6 d Tighten bolts 61 62 and 95 to 20 lb ft 12 00 02 Dakota Kit 60043 10 Install the fan shroud a Remove two clamps 98 and lower radiator hose 99 Turn hose 180 degrees and reinstall b Join upper fan shroud 41 and lower fan shroud 46 c Position fan 43 and fan shroud 41 in the vehi cle d Install fan shroud 41 on the radiator 85 with four bolts 45 Do not tighten e Install fan 43 on the water pump 44 with four bolts 42 f Adjust fan to fan shroud and fan to hose clear ance Ensure fan cannot contact hoses or the fan shroud Tighten four bolts 45 g If lower radiator hose 99 appears to be too close to fan 43 cut hose and install hose extension 99a with two kit clamps 99b h Connect washer fluid hose 40 and two connec tors 38 and 39 on the fan shroud 41 i Fill radiator 35 refer to the owner s manual V 8 ENGINE 13 00 02 Dakota Kit 60043 i Install four wire harness clips 36 in core support 22 holes where possible j Use kit zip ties 100 to secure wire harness 37 to the a c lines 101 11 Check battery positive cable 8 length If positive cable is not long enough to reach the battery 9 a Remove
7. 0 and in the bed mounting pad 94 Do not tighten e Lower the bed onto the spacer blocks 89 and 90 Install the bed driver s side spacer blocks a Repeat steps C 5 a through e for the bed driver s side Finish the bed spacer block installation a Adjust the cab to bed clearance using the mea surements from step C 1 a b Remove eight bed mounting bolts 91 one ata time coat threads with Loctite and reinstall Tighten to 55 lb ft DO OQD W ge OS 00 02 Dakota Kit 60043 A WARNING Use extreme caution when working near the fuel lines and the fuel tank Clean up spilled fuel immediately A spark could cause an explosion or fire resulting in seri ous personal injury and property damage 8 Install the fuel filler hose a Install fuel filler hose 71 and vent hose 72 on fuel tank 73 with two clamps 70 b Position fuel filler neck 69 in bed 6 straighten tabs 68 and install three screws 67 Bend tabs over screws Install gas cap 66 37 1498 Pairk 9 Install kit steering extension A WARNING Verify the steering extension is securely installed as specified in the instructions Failure to do so may cause steering malfunction resulting in property dam age or serious personal injury a Coat threads of retaining bolts 61 62 and 95 with Loctite w A s AN b Install kit steering extension 96 on steering rack We D aA Er Ps 64 and 65 with the
8. All warranty information instruction sheets and other documents regarding the installation of this product must be retained by the vehicle owner Information contained in the instructions and on the warranty card will be required for any warranty claims The vehicle owner needs to understand the modifications made to the vehicle and how they affect vehicle handling and performance Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury Accessories Kit 6617 Gap Guards 00 02 Dakota Kit 60043 E Kit Parts List Qty DO i NAA NNN NN N OI W O A AA O O O D O Description 3 x 3 blocks 3 x 2 blocks Front inner bumper brackets Front outer bumper brackets Rear bumper brackets Brake line bracket Transmission cable bracket Overload spacers no hole Warning to driver sticker Logo sticker 6ml bottle Loctite Bolt pack BP60043 12mm x 160mm bolts 10mm x 100mm bolts 1 2 USS washers 7 16 USS washers se 8700 steering extension 3 8 x 1 1 4 socket head bolt Hardware pack HP60043 Bolts 7 16 x 1 1 2 bolts 7 16 x 1 bolts 5 16 x 1 bolt 1 4 x 1 bolts Washers 7 16 USS washers 5 16 SAE washers 1 4 SAE washers Nuts 7 16 nylock nuts 5 16 nylock nuts 1 4 nylock nut 8mm nylock nut Miscellaneous Transfer case linkage rod extension 1 2 X
9. Install battery 9 and connect both battery cables Be sure to reconnect the positive cable 8 first then the negative cable 9 3 Install the spare tire 1 a To remount crank rod 3 on vehicle drill a 5 16 hole in the crossmember 128 as shown b Install Ait clamp 129 with kit 1 4 x 1 bolt 130 kit 1 4 washer 131 and kit 1 4 nylock nut 132 Ensure bolt is installed up toward bed c Install crank rod 3 in kit clamp 129 d Remove license plate and drill 3 4 hole in plastic part of rear bumper 34 as shown Install plastic collar 5 Ensure you can successfully lower crank rod 3 through hole Reinstall license plate 4 Apply kit warning sticker on the dash in plain sight of all vehicle occupants 20 00 02 Dakota Kit 60043 5 Double check the vehicle A WARNING Retorque all fasteners after 500 miles and after off road use All body lift components should be visually inspected and fasteners retorqued during routine vehi cle servicing a Check all mounting hardware to ensure it is prop erly tightened b Check all wires hoses cables etc to ensure they have been properly connected and there is ample slack With the number of hoses on this vehicle it is vital that this be checked thoroughly c Check vehicle electrical system d Start vehicle and check the steering in both direc tions to ensure that there is no bind Check clutch operation Check the ope
10. Shift Lever Screw 4 Shift Console Lower Shift Lever Screw Shift Toer AT i 00 02 Dakota Kit 60043 2 4WD Models Remove the shift transfer case shift linkage a If present on your vehicle remove four bolts 12 and skid plate 13 from the frame 14 under the transmission and transfer case b Remove two rubber bushings 15 and transfer case shift linkage 16 from shift lever 17 and trans fer case 18 1 31 1998 3 Remove the front bumper a Remove nine panel clips 19 plastic cover 20 and rubber cover 21 from the core support 22 b If present on your vehicle disconnect two wire harness connectors 23 from the driving lights 24 3 7 1998 c Remove four nuts 25 bolts 26 and two front bumper outer brackets 27 from the frame 14 d Remove four bolts 28 and front bumper 29 from two frame 30 inner mounts 3 13 1998 4 00 02 Dakota Kit 60043 4 Remove the rear bumper a Disconnect two wire harness connectors 31 from the license plate lights 32 b Remove six nuts 83 and rear bumper 34 from the frame 14 3 13 1998 5 Remove the fan shroud a Drain the radiator 35 into a clean pan refer to the owner s manual b Remove four wire harness clips 86 and wire har ness 37 from the core support 38 5 00 02 Dakota Kit 60043 c Disconnect two connectors 38 and 39 and washer fluid h
11. bolt 102 and cable 8 from frame rail 52 b Install kit extension strap 103 on frame rail 52 with bolt 102 c Install cable 8 on kit extension strap 103 with kit bolt 104 lock washer 105 and nut 106 d Strap cable 8 to the power steering hose 107 with kit zip tie 108 11 30 1999 14 00 02 Dakota Kit 60043 12 Install the front bumper a Coat threads of bolts 26 28 111 and 114 with Loctite b Install two Ait inner front bumper brackets 109 on YS frame 14 inner mounts with four bolts 28 the C n Ho should open to the rear of the vehicle Center ir dhe brackets on mounts and tighten bolts to 55 lb ft gen z w re 7 c Install two kit outer brackets 110 on the frame 14 with four bolts 26 and nuts 25 Do not tighten d Install front bumper 29 on two kit inner brackets 109 with four kit 7 16 x 1 1 2 bolts 111 eight 7 16 USS washers 112 and four 7 16 nylock nuts 113 Insert bolts with heads facing center of vehi cle Do not tighten e Install front bumper 29 outer brackets 27 on two kit outer brackets 110 with four 7 16 x 1 bolts 114 eight 7 16 USS washers 115 and four 7 16 nylock nuts 116 Insert bolts with heads facing cen ter of vehicle Do not tighten f Adjust bumper to body clearance and tighten bolts 26 28 111 and 114 to 55 lb ft g If removed connect two wire harnes
12. ctivated Do not allow anyone near the airbag dur ing installation Refer to the factory service manual or owner s manual for the recommended procedure to disable the SRS After you install the kit reactivate the SRS before driving the vehicle Performance Automotive Group recommends using the Loctite supplied in the kit on the threads of all kit nuts and bolts unless specified otherwise in these instructions 00 02 Dakota Kit 60043 A Before you start As you read through this procedure note that each part referenced has the same callout number through out Also the part number in the text matches the cor responding part number in the art Kit parts are prefaced by the word kit in italics 1 Read all warnings and instructions completely and carefully before you begin 2 Check to make sure the kit is complete refer to the Parts List section E 3 Only install this kit on the vehicle for which it is intended If anytime during the installation you encounter something different from what is outlined in the instructions call technical support at 928 636 7080 4 Park the vehicle on a clean dry flat level surface and block the tires so the vehicle cannot roll in either direction 5 Lower spare tire 1 to the ground refer to the owner s manual a Remove clip 2 and crank rod 3 from winch 4 b Remove crank rod 3 and plastic collar 5 from bed 6 6 Disconnect both battery cables
13. iver s a ay 7 side front wheel well 51 Ensure cable has ample 9 SNINU slack to allow for lifting Bey 7 k daoia ee ey aa f Remove bolt 60 and loop 59 from driver s side front wheel well 51 7 00 02 Dakota Kit 60043 A CAUTION If the following step is not performed the airbag clock spring could be damaged Do not turn the steering wheel while the steering shaft is disconnected Ensure steering shaft does not turn independently of the steering gearbox This could cause the air bag system to malfunction resulting in serous personal injury or dam age to the equipment 8 Remove steering shaft a Remove bolt 61 loosen bolt 62 and remove steering shaft 63 from top of the steering rack 64 and 65 A WARNING Use extreme caution when working near the fuel lines and the fuel tank Clean up spilled fuel immediately A spark could cause an explosion or fire resulting in seri ous personal injury and property damage 9 Remove the fuel filler hose a Remove gas cap 66 Remove three screws 67 bend two tabs 68 and let fuel filler neck 69 drop down from the bed 6 b Remove two clamps 70 fuel filler hose 71 and vent hose 72 from the fuel tank 73 3 7 1998 8 00 02 Dakota Kit 60043 C Install the kit 1 Prepare to lift cab from frame A WARNING Use extreme caution when lifting body from frame To prevent serious personal injury en
14. n unsafe and or unexpected handling characteristics A WARNING This kit should only be installed on a vehicle that is in good working condition Before you install the kit thor oughly inspect the vehicle for corrosion or deformation of the sheet metal around the factory body mounts If the vehicle is suspected to have been in a collision or misused do not install this kit Off road use of your vehicle with this kit installed may increase the stress applied to the factory body mounts We do not recom mend that any vehicle with a body lift kit installed be involved in any extreme off road maneuvers such as jumping Failure to observe this warning may result in serious personal injury and or severe damage to your vehicle A WARNING Many states and municipalities have laws restricting bumper heights and vehicle lifts Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law ZS WARNING The installation of larger tires may reduce the effective ness of the braking system A WARNING Always wear eye protection when operating power tools A WARNING Before you install this kit block the vehicle tires to pre vent the vehicle from rolling A WARNING Accidental deployment of the air bag can result in seri ous personal injury or death To avoid accidental deployment during installation of the kit the Supple mental Restraint System SRS or airbag must remain dea
15. on four kit spacer blocks 80 on top of the passenger side core support and frame mounting pads 78 c Install a kit 12mm x 160mm bolt 81 12mm x 140mm for a 2 kit and a kit 1 2 USS washer 82 through the bottom bushing retainer 83 bottom bushing 84 frame mounting pad 78 upper bush ing 85 upper bushing retainer 86 kit spacer block 80 and in the body mounting pad 87 Do not tighten d Lower cab 74 on the kit spacer blocks 80 RT Wos 3 Install the cab driver s side spacer blocks a Repeat steps C 2 a through d for the cab driver s side 4 Finish the cab spacer block installation a Adjust cab to bed clearance using the measure ments from step C 1 a b Remove eight bolts 81 one at a time coat threads with Loctite and reinstall Tighten to 55 Ib ft 10 00 02 Dakota Kit 60043 5 Install the bed passenger s side spacer blocks a Loosen but do not remove eight bed mounting bolts 88 b Remove four bolts 88 from the bed 6 passen ger side c Using a hydraulic jack and a wooden block slowly lift the bed 6 passenger side just high enough to position the kit spacer blocks 89 and 90 on the frame 14 The small spacer blocks 90 go on the rearmost mounts d Install a Ait 10mm x 100mm bolt 91 10mm x 80mm for a 2 kit a kit 7 16 USS washer 92 and a kit 3 8 washer 93 through the frame mounting pad 78 kit soacer block 89 or 9
16. ose 40 from the fan shroud 41 d Remove four bolts 42 and the fan 43 from the water pump 44 and allow fan to rest inside the shroud e Remove four bolts 45 and fan shroud 41 from the radiator 35 and allow shroud to rest against the engine f Remove fan shroud 41 and fan 43 from the vehicle and separate upper fan shroud 41 from lower fan shroud 46 h Cut the lip from the lower fan shroud 46 as shown 3 7 1998 a 6 00 02 Dakota Kit 60043 6 Remove firewall mounted ground wires a Ensure two ground wires 47 on the firewall 48 have ample slack to allow for lifting Ensure ground wire on driver s side is routed over the brake booster 49 b If ground wire on the driver s side is not routed over the brake booster 49 remove two nuts 50 and reroute the ground wires 47 c Install two ground wires 47 on the firewall 48 with two nuts 49 7 Driver s side frame rail a Remove plastic cover 50 from driver s side front wheel well 51 and top of the frame rail 52 b Remove wire harness panel clip 53 from the top of the frame rail 52 c Remove brake lines 54 from plastic clips 55 on the frame rail 52 d Remove two bolts 56 and brake line bracket 57 from the frame rail 52 3 7 1998 e If equipped with automatic transmission remove automatic transmission cable 58 from the auto matic transmission cable loop 59 on the dr
17. ration of the brake system and the parking brake Check both shift levers oper ation Ensure that there is proper engagement in all gears and 4 wheel drive ranges A WARNING If the engine cooling system is hot the coolant will be HOT and UNDER PRESSURE To prevent serious personal injury wait until the cooling system is com pletely cool before removing the cap from the radiator e Check coolant level Fill coolant to the proper level refer to the Owner s Manual f Test drive vehicle in all gears and 4 wheel drive ranges Pay close attention to all vehicle systems Check all hardware again in 500 miles and as part of your regular maintenance schedule g Adjust headlights A CAUTION Performance Automotive Group does not recommend any particular wheel and tire combinations for use with its body lifts and cannot assume responsibility for the customer s choice of wheels and tires Refer to your owner s manual for recommended tire sizes and warn ings related to the use of oversized tires Larger wheel and tire combinations increase stress and wear on steering and suspension components which leads to increased maintenance and higher risk for component failure Larger wheel and tire combinations also alter speedometer calibration braking effectiveness center of gravity and handling characteristics Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle
18. s connectors 23 on driving lights 24 h Install rubber cover 21 and plastic cover 20 on core support 22 with nine panel clips 19 t Wii T1998 3 7 1998 15 00 02 Dakota Kit 60043 13 Install the rear bumper A WARNING The following procedure is intended only to enhance the appearance of the vehicle The rear bumper will no longer be rated for towing of any kind Towing with the rear bumper after it has been lifted can result in death serious personal injury or damage to the vehicle Tow ing after the bumper has been lifted should be accom plished using a rated Class III receiver type hitch a Coat threads of nuts 33 with Loctite b Install two kit brackets 117 on frame 14 with six nuts 33 c Install rear bumper 34 on kit brackets 117 with four nuts 33 Do not tighten f Adjust bumper to body clearance and tighten nuts 33 to 55 Ib ft g Connect two wire harness connectors 31 on license plate lights 32 16 00 02 Dakota Kit 60043 14 Install brake lines A CAUTION Ensure brake lines stretch while lifting Bending the lines to gain ample slack may be necessary Be extremely careful not to kink the lines 15 a Check brake lines 54 removed from clips 55 on the driver s side frame rail 52 If necessary care fully straighten lines to gain more slack b Install Ait bracket 118 on frame rail 52 with bolt 56 c
19. sure the lifting device is securely placed Keep your hands out from between the body and frame a Measure distance between the cab 74 and the bed 6 Record measurement for later cab to bed alignment reference in the instructions b Loosen but do not remove eight cab mounting bolts 75 A CAUTION Continually check hoses wires lines etc to be sure that everything is flexing properly and not binding or damage to the vehicle could result Be especially care ful of the a c hoses at the fire wall the belt pulley and at the core support Ensure brake lines stretch while lifting Bending the lines to gain ample slack may be necessary Be extremely careful not to kink the lines A WARNING The kit blocks must be installed in addition to the fac tory upper and lower bushings Installing the kit blocks without the factory upper and lower bushings could result in damage to the vehicle or serious personal injury c Remove bolt 76 and washer 77 from the pas senger side core support frame mounting pad 78 d Remove three bolts 76 and washers 77 from the passenger side frame mounting pads 78 and cab mounting pads 79 EMETIK ET 00 02 Dakota Kit 60043 2 Lift cab and install cab passenger side spacer blocks a Using a hydraulic jack and a wooden block slowly lift the cab 74 passenger side just high enough to position the kit spacer blocks 80 on the frame mounting pads 78 b Positi
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