Installation Instruction
Contents
1. nut and washer to attach the vacuum line to the new drop bracket Unplug the electrical line at valve and release the plastic clip at the bracket If additional slack is needed remove wire from top of crossmember and route it under the crossmember Begin installing track bar drop bracket by first removing the brakeline clamp screw from the crossmember This is located next to the original frame mount for the track bar After removing the screw push the brakeline up approxi mately 2 for clearance First check the track bar frame mount to ensure that it is a smooth surface Some models have a reinforcement gusset on the edge of the mounting point This must be ground off to make a flat mounting point for the new bracket It is vital that the new bracket mounts to a flat smooth surface Apply loctite to end of 18mm bolt Hold new drop bracket up to OE mount Insert 18mm bolt through the original mount and the drop bracket and start the nut with washer Tighten the nut until it is snug Page 6 012511 012512 012513 35 36 Twist the drop bracket until the extension brace hits the back of the crossmember The brace should sit flat against the crossmember Use a 1 2 drill and start through the hole in the supplied brace and drill through the crossmember being sure to come out just below the weld mount on the front side of the crossmember It may help to drill a smaller pilot hole and then open to 1 2 Fig 11 37 Insta2. lower link rear brackets Support the front axle with a hydraulic jack Remove the tires Remove the brakeline anchor bracket between the upper and lower links behind the coil spring Retain mounting bolt Disconnect the original steering stabilizer from the steering link Disconnect the track bar from the frame end and lower down Disconnect the sway bar at the frame side and lower out of the way Disconnect the drag link from the pitman arm Fig 1 Use a pitman arm puller to remove the pitman arm from the steering sector Install new BDS drop pitman arm and retain with original fasteners Torque to 185 ft lbs Do not attach drag link to the pitman arm at this time Fig 2 Remove lower shock bolts and pull shocks up through the coil spring Lower the front axle to remove the coil spring rubber isolator and 3 bolt shock tower ring Remove the front bump stops from their pocket by working them back and forth with a large set of channel locks Mark the lower link adjustment cams and the surrounding reinforcement bracket so you can realign the cams after installation 012511 012512 012513 Page 3 ll 12 13 14 15 16 17 18 Remove the OE lower control arms from both sides Fig 3 Remove transfer case skid plate and retain front mounting hardware and rear spacer washers Place new bracket 01220 on driver s frame rail with the rear hole aligned with transfer case skid plate bracket mounting hole
3. 102 S Michigan Ave Coldwater MI 49036 Phone 517 279 2135 Web live chat www bds suspension com SOSPENSION E mail tech bds suspension com Part 012511 012512 012513 Product Front Box Kit Application Dodge Pickup 4wd READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE SAFETY WARNING pps Suspension Co recommends this system be installed by a professional technician In addition to these instructions professional knowledge of disassembly reassembly procedures and post installation checks must be known PRODUCT SAF ETY WARNI NG Certain BDS Suspension products are intended to improve off road perfor mance Modifying your vehicle for off road use may result in the vehicle handling differently than a factory equipped vehicle Extreme care must be used to prevent loss of control or vehicle rollover Failure to drive your modified vehicle safely may result in serious injury or death BDS Suspension Co does not recommend the combined use of suspension lifts body lifts or other lifting devices You should never operate your modified vehicle under the influence of alcohol or drugs Always drive your modified ve hicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt PRE INSTALLATION NOTES 1 Special literature required OE Service Manual for model year of vehicle Refer to manual for proper disassem
4. 9 01262 342701 90 402A8 Inst Sheet Warning CD 222780 CTN36 A128 17 23 24 01220 01221 02585 01251 01252 Se ke BP PRN RB Re eB ke Re NOK RP KE N e ONWOAA He AA DO Bolt Pack Ford Bump Stop Ext 1 4 USS washer 1 4 20 x 1 bolt 1 4 prevailing torque nut Bolt Pack Ford Sway Bar Ext 3 8 16 x 1 1 4 bolt 3 8 16 prevailing torque nut 3 8 USS thru hardened washer Dodge Bushing BSDG2 Dodge Lower 7 8 ID Bushing 1 4 28 Grease Zert 60105 90 1 4 28 Grease Zerk 5 Dodge Flat Brake Line Drop Brake Line Drop with Tab Brake Line U Drop Bracket Dodge 5 Track Bar Washer Loctite 8x10 4mil Poly Bag Instruction sheet Warning Card 2x6 BDS 2 Color Stickers 19 1 16 x11 7 8 x6 1 16 Box Sticker Tube 3 4x 120x2 375 Sleeve ER W 3 4x 095x2 25 Sleeve ER W 7 8x 120wall x 2 51 Dom Tube Long Arm Bracket Dodge DS Long Arm Bracket Dodge PS Dodge Track Bar Bracket 5 Dodge Link Relocate Bracket D 5 Dodge Link Relocate Bracket P Page 2 012511 012512 012513 NOTE This kit will only fit models manufactured on or after February 9 1994 due to size of track bar stud INSTALLATION INSTRUCTIONS l 2 fe 10 Park vehicle on a clean flat surface and block the rear wheels for safety Open hood remove the upper shock nuts and retainers Remove the three nuts retaining the upper shock tower and remove the brackets Raise the front of the vehicle and install jack stands under the frame behind the
5. Fig 4 Place transfer case skid plate washer between new bracket and frame rail Note 25 7 8 center to center distance old mounting point to new mounting point Clamp bracket in place Ensure that the outside plate is flush against frame rail Move lines inside frame rail to a position where they will not be damaged when drilling holes Drill 9 16 holes at bracket mounting points except skid plate mounting hole Note Only drill through the outside portion of the frame rail Install 9 16 x1 1 2 bolts washers and nuts in holes that have just been drilled Do not crush lines inside of frame Torque hardware tol110 ft lbs Repeat for passenger s side 01221 Fig 5 Page 4 012511 012512 012513 19 Mark a line parallel with the bottom of the frame on the lower control arm pockets and cut old pockets off Fig 6 20 Reinstall transfer case skid plate with OE hardware at front mounting location and 1 2 x 1 3 4 hardware at frame mounting points Minor grinding required to enlarge hole diameter Torque hardware to 65 ft lbs Fig 7 21 Grease and install bushings BSDGI1 78 into new control arms 22 Follow appropriate step depending on model year 94 99 Grease and install 24 1 sleeves into non pitched end and 42 1 sleeves into pitched end 00 01 Grease and install sleeves 24 1 into both ends of control arms 23 Install 90 degree grease zerk into both ends of control arms 24 9 Install new
6. bly reassembly procedures of OE and related components 2 Adhere to recommendations when replacement fasteners retainers and keepers are called out in the OE manual 3 Larger rim and tire combinations may increase leverage on suspension steering and related components When selecting combinations larger than OE consider the additional stress you could be inducing on the OE and related components 4 Post suspension system vehicles may experience drive line vibrations Angles may require tuning slider on shaft may require replacement shafts may need to be lengthened or trued and U joints may need to be replaced 5 Secure and properly block vehicle prior to installation of BDS Suspension components Always wear safety glasses when using power tools 6 If installation is to be performed without a hoist BDS Suspension Co recommends rear alterations first 7 Due to payload options and initial ride height variances the amount of lift is a base figure Final ride height dimensions may vary in accordance to original vehicle attitude Always measure the attitude prior to beginning installation POST INSTALLATION WARNINGS 1 Check all fasteners for proper torque Check to ensure for adequate clearance between all rotating mobile fixed and heated members Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring harness Check steering gear for clearance Test and inspect brake system 2 Perfo
7. ets at this time The brackets are the two with a small 90 degree bend Install the bracket with the small leg at the bottom facing toward the front of the vehicle Install original metric bolt in the bottom hole on the bracket and tighten Attach the original brake line anchor bracket to the top hole of the new bracket with the supplied 1 4 x 1 bolt nut and washer supplied and tighten Fig 13 012511 012512 012518 Page 7 44 45 46 47 48 49 50 Loosen the turn buckle clamps on the drag link and rotate 180 degrees This will allow the drag link to be connected with the new pitman arm Install drag link into pitman arm and Torque OE nut to 80 ft lbs Be sure to use a new cotter pin Rotate the turn buckle clamps to the top side of the drag link to gain clearance for the steering stabilizer Tighten turn buckle clamps to 45ft lbs Install new BDS steering stabilizer at this time Swing sway bar back up to the frame mounts Install sway bar drop brackets between the sway bar and the frame with the supplied 3 8 x 1 bolts nuts and washers The solid side of the bracket should be facing out and should slope toward the bumper Torque bolts to 35ft lbs Install tires and lower vehicle to the ground Attach the track bar to the track bar relocation bracket with the original fasteners and tighten to the following specifications Install new cotter pin Tighten track bar at axle end Ball Stud Nut 7O ft
8. lbs Axle Bracket Bolt 130 ft Ibs Tighten upper and lower link bolts making sure the alignment cams are in line with the original marks Lower Arm Axle Nut siaconecenescenecenses 140 ft lbs Frame NU sicsciccsdcescesces 140 ft lbs Upper Arm Axle Nut cc cece 120 ft Ibs Frame Nut 0005 120 ft Ibs Complete a fu 1l steering cycle to ensure that nothing is hitting Check the clearance between the sway bar end links and the drag link tie rod assembly It may be necessary to trim grind for needed clearance NOTICE TO DEALER INSTALLER These instructions the warning card and included decals must be given to the owner of this BDS Suspension product For questions technical support and warranty issues relating to this BDS Suspension product please contact your dis tributor installer before contacting BDS Suspension directly Sold Installed by Page 8 012511 012512 012513
9. ll a 1 2 x 2 1 2 bolt with washer through the brace and crossmember On the front side of the crossmember 38 39 40 install the step washer over the weld mount to create a flat surface Install the nut and torque to 70 75 ft lbs Be sure not to crush the crossmember Then torque the 18mm bolt to 200 ft lbs Fig 12 Move the brake line clamp back down and drill a new 19 64 hole Install new poly bumpstops in the original pockets A jack may be used to force the bumpstops into the original pocket or use a wood block and a 2x4 for leverage Insert 3 bolt shock tower ring inside the top of the coil tower Start a couple of nuts on the ring to hold it up in place See dual shock instructions if installing 41 Install coil springs and place rubber isolators on the tops of the coils Turn the coils so the end of the bottom wraps 42 43 is toward the center of the vehicle Lift up on jack under the differential to place a small load on the coils to hold them in place Remove the nuts that you previously installed on the 3 bolt ring Install new shocks down through the coils springs and install bolt at the bottom Install original shock tower bracket over the 3 bolts of the ring Install nuts on the 3 bolts and tighten Install shock to the top of the tower with the shock fasteners per their instructions If installing dual shocks refer to those instructions at this time Install the supplied brake line relocation brack
10. long arm with pitched end located in axle pocket grease zerks facing down Follow appropriate step depending on model year Fig 8 94 99 Use new 5 8 x 4 1 2 bolts washers and nuts 620 in new mounting bracket and OE hardware at axle pocket 00 01 Use all OE hardware 012511 012512 012513 Page 5 29 26 ZT a4 ei j i Repeat for driver s side Remove the OE upper control arms Prior to installing the upper link relocation brackets check the holes on each side of the upper link axle mounts to ensure that a 12mm bolt fits through them If not drill out the holes to 1 2 Fig 9 amp 10 28 29 30 Ol 32 33 34 Install relocation bracket over the original mount note there is a left right hand Y Note The longer lower leg goes toward the center of the vehicle Install a 12mm x 110mm 4 1 2 bolt using the 3 4 x 2 375 sleeve inside the original axle mount to maintain spacing Install the shorter bushings and sleeves into the upper links Install the upper link by sliding them through the relocation bracket to the original frame mount Install original bolts but do not tighten at this time Remove the screw retaining the steel vacuum lines to the passenger s side of the frame at the drop point going to the vacuum actuator valve Install the furnished drop bracket 1 wide x 4 long using the original screw at the frame Use the supplied 1 4 x 1 bolt
11. rm steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating mobile or heated members Inspect rear brake hoses at full extension for adequate slack Failure to perform hose check replacement may result in component failure Longer replacement hoses if needed can be purchased from a local parts supplier 3 Perform head light check and adjustment 4 Re torque all fasteners after 500 miles Always inspect fasteners and components during routine servicing rev 8 7 2014 012511 012512 012513 Page 1 PARTS LIST 012511 Parti Qty Description 02322RB 2 Dodge Blue 5 1 2 Bump Stop CTN28 1 46 7 8 x3 x1 Carton 01222 2 Lower Control Arm Dodge 01223 2 Upper Control Arm Dodge 01045 l Sway Bar Drop Bracket PS 01044 l Sway Bar Drop Bracket DS 012512 Part Qty Description 082402R l 00 01 Dodge Pitman Arm DS 200 610 1 Dodge 5 Bolt Pack 4 1 2 USS washer 16 1 2 SAE washer 8 12mm 1 75mm x 40mm bolt 2 12mm 1 75mm x 110mm bolt 10 12mm 1 75mm prevailing torque nut 611 1 Dodge 5 Bolt Pack 1 18mm 2 5x70mm bolt 1 18mm washer 1 18mm 2 5 torque nut 1 1 8 x 2 cotter pin 1 1 2 13x2 1 2 bolt 1 1 2 USS washer 1 1 2 SAE washer 1 1 2 13 torque nut 613 l Bolt Pack Dodge 4 Long Arm 6 9 16 12 x 1 1 2 bolt 12 9 16 SAE flat washer thru hardened 6 9 16 12 prevailing torque nut BP123406 BP123401 3522RB 3521RB 516 60107 01257 01258 0125
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