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1. 3651 N Highway 89 Chino Valley AZ 86323 928 636 7080 www p a g net DODGE RAM 1500 2 amp 4WD GASOLINE ENGINES 3 BODY LIFT INSTALLATION INSTRUCTIONS 2009 KITH 60203 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 U2. Remove stud on each rear bumper bracket fuel filler hoses Kit Bracket Rear Bum per Passenger Ground Bolt Cab Cut remove Centering Stud 2 Rear bumper Paint Metal for Protection from A WARNING Elements 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 i 3 rear bumper after it has been lifted can result in death Removed Stud serious personal injury or damage to the vehicle Tow i ell ing after the bumper has been lifted should be accom plished using a rated Class Ill receiver type hitch Rear Bumper a Apply a few drops of kit Loctite to factory Pracket bolts Install kit bracket rear bumper middle on trailer hitch with two factory bolts DO NOT TIGHTEN C Place rear bumper brackets in place with 1 2 bolt Center bracket so that all holes align Kit Bracket Rear Bum per Middle KE Tease Vil Factory Bolts oe Fa Align Factory Holes to New Bumper Bracket ey Use 1 2 Bolt to Secure Rear Bracket Factory Hitch Rear Bumper Brackets 13 2009 Dodge 1500 Kit 60203 d Install rear bumper onto kit bracket DO NOT TIGHTEN Mark rear bumper and clearence bumper for center bumper support bracket Cut about 9 1 2 across amp 1 3 4 in Mark Bracket and trim to clear center support bracket Clearenc
3. with kit bolt 1 4 20 x 1 two kit washers 1 4 20 x 1 and kit nut 1 4 20 Nylock 15 Install wire harness to body mount bracket on driver side with clip kit Bolt 1 4 20 x 1 kit Washers 1 4 SAE kit Nut 1 4 20 Nylock Kit Bracket 3 Ground Factory Bolt Harness Clip Body Mount Bracket 6 Brake line bracket a Install two kit brackets C shaped onto driver side frame with two bolts b Install brake line bracket onto to kit brackets C shaped with two kit bolts 1 4 x 1 four kit washers 1 4 SAE and two kit nuts 1 4 Nylock Kit Bolt Brake Line Bracket 1 4 20 x 1 kit Washers 1 4 SAE Kit Nut 1 4 20 Nylock Kit Brackets C Shaped Bolts Driver Side Frame 2009 Dodge 1500 Kit 60203 7 Install transmission wire harness on frame mount b Scribe a line along side of kit extension shift clip lever Position kit extension between two pieces of transmission shift lever Ensure Trans scribed lines on kit extension and transmission Harness k shift lever align Weld kit extension into place Inside of Vehicle A WARNING c Grind welded surfaces smooth in order to install DO NOT DAMAGE any of the parts attached to the MOHAN e aE OS G shift levers during cutting and or welding Damage to the shift lever equipment could result in serious injury or property damage A WARNING A certified welder
4. 20 x 1 1 4 Bolt 3 8 16 x 1 1 4 Allen head Bolt 12mm 1 50x 100mm Bolt 12mm 1 75 x 180mm Bolt 5 16 x 1 Bolt 7 16 x 1 1 4 Bolt 1 2 x 1 1 4 Nut 1 4 Nylock Nut 5 16 Nylock Nut 7 16 Nylock Nut 1 2 Nylock Washer 1 4 SAE Washer 5 16 USS Washer 7 16 USS Washer 1 2 USS Bracket C shaped Bracket front bumper driver Bracket front bumper passenger Bracket ground strap big hole Bracket rear bumper driver Bracket rear bumper passenger Bracket rear bumper middle Bracket winch Extension steering Extension shift lever Label logo Label warning Label warning rear bumper Loctite 6ml bottle 22 2009 Dodge 1500 Kit 60203
5. Pull slack into parking brake cable Attach lock ing pliers to parking brake cable to allow slack if necessary b Use expanding pliers to disconnect parking brake cable from junction Junction c Remove parking brake cable from driver side frame mount Inside of Vehicle 1 Manual transmission shift lever a Shift transmission into neutral b Unscrew transmission shift lever from shift tower Transmission GN J Shift Lever Dr 4 Rubber Cup Holder Inserts Some of the bolts securing the center console to the floor are underneath the cup holder rubber inserts c Remove bolts and center console from floor 2009 Dodge 1500 Kit 60203 d Remove six bolts and shift lever boot seal from h Remove two plastic shift tabs plastic ball shim floor and mounting plate from shift lever Shift Lever Boot Seal Shim Plastic Shift Tabs Plastic Ball PE e Remove rubber cover from shift tower NOTE The following procedures apply only to vehicles with manual transfer cases Rear of Vehicle Rubber Cover 1 Fuel filler Shift Tower A WARNING Use extreme caution when working near fuel line s and fuel tank s Clean up spilled fuel immediately Any f Remove four Torx bolts from shift tower mount spark could cause an explosion or fire resulting in seri ing plate ous personal injury and or property damage a Remove fuel cap from fuel filler Torx Bolts 2 Ground st
6. ake sensor harness on passen rack and pinion Ensure marks on rack and pin ger and driver fender wells ion and intermediate shaft are aligned Driver side Intermediate Shaft Factory Bolt T Kit Extension Steering Kit Bolt 3 8 x 1 1 4 lt lt Allen Head PE Wire Harness E Connectors Rack and Pinion Passenger side 3 Fan shroud a Be sure that the fan clears the fan shroud b Install intermediate shaft on kit extension steering ensuring marks on intermediate shaft and rack and pinion are aligned c Apply a few drops of kit Loctite to factory bolt PX and kit bolt 3 8 x 1 1 4 Allen head a Install airbox cover base and filter on vehicle d Install and TIGHTEN bolts to 33 lb ft 18 2009 Dodge 1500 Kit 60203 b Install airbox cover onto airbox base with four clips Install breather hose on airbox cover TIGHTEN airbox hose clamp at intake housing s AE Airbox 1 8 ka ALLL a Breather Airbox Clips Intake Housing Breather Hose Front of Vehicle 1 Front bumper A CAUTION Factory supplied front two hooks CAN NOT be used if equipped a Place new front bracket over driver frame horn clamp it in place Mark and drill two 1 2 holes Centered where marked Be sure that everything is square NOTE Non Chrome bumper will need to be drilled to 9 16 Repeat to passenger side Front Bum er Brackets kar Fractory Holes Mark a
7. 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 2 Cab passenger side a Remove captive washers from each factory cab body mount bolt Captive Washer b Position a hydraulic jack and a wood block under passenger side of cab under the body seam Slowly lift cab just enough to install a kit block on top of factory upper bushing 2009 Dodge 1500 Kit 60203 c Remove each kit bolt one at atime and apply a A WARNING few drops of kit Loctite to threads Install kit bolt and captive washer Tighten kit bolts to 55 ft Ibs 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 Place kit blocks 3 x 3 on metal cups and upper bushings on each cab mount kit Bolt 12mm 1 75 x 180mm Captive Washer Kit Block Upper rd TN 1 Prepare to lift bed from frame a Loosen but DO NOT REMOVE bed mounting d Lower cab onto kit blocks 3 x 3 EN e Install kit bolt 12mm 1 75 x 180mm into
8. e bumper and check fitment e Install rear bumper onto kit bracket rear bum per middle with two kit bolts 7 16 x 1 1 2 four kit washers 7 16 USS and two kit nuts 7 16 Nylock DO NOT TIGHTEN Kit Bolts 7 16 x 1 1 2 kit Washers 7 16 USS Pe Kit Nuts 7 16 Ny kit Bracket Rear Bum per Middle 14 f Install Ait brackets rear bumper onto bumper with two factory bolts on each side DO NOT TIGHTEN Factory Rolt Factory Hitch kit Bracket Rear Bum Rear Bumper g Align rear bumper to previous bed to bumper measurements TIGHTEN all hardware h Connect wiring harnesses to bumper Wire Harness Connectors i Install license plate onto bumper with two factory Screws 2009 Dodge 1500 Kit 60203 Underside of Vehicle 1 Crush blocks A WARNING A certified welder should perform all welding a Weld two kit blocks 3 crush onto passenger side frame below bed where shown Kit Blocks F 3 Crush b Repeat above step for driver side 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 2 Fuel filler a Tighten gas cap 3 Parking brake cable a Relnstall Parking brake cable 4 Ground strap a Install ground strap onto kit bracket 3 ground big hole
9. each Loosen Bolt cab mount DO NOT TIGHTEN At These Mounts Kit Bolt 12mm 1 75 x 180mm 3 Cab driver side a Repeat previous steps on driver side of cab b Set cab to bed spacing according to previous measurement NOTE The number of bed mounting bolts may vary with the length of the bed 10 2009 Dodge 1500 Kit 60203 2 Remove bolt from each bed mount on passenger side Remove Bolt At These Mounts WW SSN Bed Mounts A WARNING Use extreme caution when lifting the bed from the frame To prevent serious personal injury ensure the lifting device is securely placed Keep your hands out from between the bed and frame A CAUTION To prevent damage to the vehicle while lifting the bed continually check hoses wires brake lines etc to ensure everything is flexing properly and not binding Ensure clearance between bed and cab is maintained 3 Bed passenger side a Using a hydraulic jack and a wood block slowly lift passenger side of bed a little more than 3 b Place a kit block 3 x 3 rear frame mount Kit Block 3 X 3 Kit Bolt 12mm 1 75 x 120mm kit Washer 7 16 USS c Place kit blocks 3 x 3 on two or three other frame mounts T NIAN Kit Block 3 X 3 Kit Bolt 12mm 1 50 x 100mm Kit Washer 7 16 USS d Lower bed onto kit blocks e At rear bed mount install kit bolt 12mm 1 75 x 120mm and kit wa
10. er 20 After Completing Installation Engine Compartment 1 Airbag fuse A NOTE The location of the airbag fuse may vary check the owner s manual a Install airbag fuse s b Install fuse cover 2 Connect both battery cables Connect positive cable first then negative cable Positive Cable Negative Cable Miscellaneous 1 Apply kit label warning to dashboard in plain sight of all vehicle occupants 2 Check all fasteners to ensure they are tight 3 Ensure all wires hoses cables etc are properly connected and there is ample slack 2009 Dodge 1500 Kit 60203 Dynamic Vehicle Check 1 Test drive vehicle Check steering in both directions to ensure that there is no bind Check operation of clutch brake system and parking brake Check operation of transmission and transfer case Ensure there is full engagement in all gears and 4WD ranges Check battery connections and electrical component operations 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 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 u
11. mp drill 1 2 Holes Factory Frame Horn 19 Align Bumper Frame Brackets b Place new frame brackets behind the frame horn Center the holes use 1 2 hardware two secure The brackets to the factory frame Do NOT TIGHTEN Front Bracket Front frame Four 1 2 hardware c Chrome bumper only Place two 5 8 washers on drivers side top stud on bumper Then use one 5 8 washer on each lower stud Between bumper and bracket Use your factory nuts on the studs NOTE Non Chrome bumper use three 5 8 washers on top and two on each lower stud d Apply afew drops of kit Loctite onto threads of studs Align bumper then tighten all hardware Use Two 5 8 Washers Use One 5 8 Washer il pel Til K gin BE fri p Pug ER le i VE i a e Install front grill brace with factory hardware f Install trim peace over bumper gill support Install each bolt at each corner Under inner fender cover Ensure both edges of fender well fit on backside of bumper edge 2009 Dodge 1500 Kit 60203 g Install front grill using factory hardware Front bumper trim peace Remove bolts Front trim bolts h Connect fog light harness at driver side of front bumper and install onto front bumper if equipped Fog Light Connector Fog Light Front Bumper i 2009 Install push clips and lower splash guard on bumper core support and fan shroud Splash Guardr Front Bump
12. oid accidental deployment during installation of the 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 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 2009 Dodge 1500 Kit 60203 Before Starting Installation Engine Compartment 1 Disconnect both battery cables Disconnect nega NOTE tive cable first then positive cable Kit parts are prefaced by the word kit and appear in bold print 1 Carefully read all warnings and instructions com pletely before beginning Positive Cable Negative Cable 2 Verify all parts have been received in this kit by checking the parts list at the end of this document If parts are missing from kit please be prepared to pro vide the following information 1 Name of purchase location et ADAG TUSE 2 Bar Code on side of box 3 Date above bar code 4 Date inside box cover 5 Inspector from inside box cover NOTE The location of the airbag fuse may vary check the vehicle owner s manual 3 Only install this kit on the vehicle for which it is specified If anytime during the ins
13. per if equipped Fog Light Connector Fog Light Front Bumper f Remove three bolts for drivers side factory tow hook and remove tow hook Repeat to passen ger side 2009 Dodge 1500 Kit 60203 g Remove six nuts and front bumper from frame horns Nuts Front Bumper Front Tow Hooks Engine Compartment 1 Airbox a Release four clips from airbox cover Remove breather hose from airbox cover Loosen clamp and airbox hose at intake housing Intake Housing Airbox Hose Airbox Breather Hose Airbox Base b Remove airbox cover base and filter from vehi cle c Remove lower fan shroud section Will not be reused Upper Fan gt Shroud Removed Lower Fan Shroud Upper Fan Shroud 2 Steering Shaft 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 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 a Strap steering wheel
14. rap Mounting a Remove bolt and ground strap from frame near fuel filler hoses Shift Tower 3 Rear bumper Mounting Plate 7 2009 Dodge 1500 Kit 60203 a Remove wire harness connectors from rear d Remove two nuts on each side of bumper bumper Bumper Bracket Wire Harness Connectors e Remove two bolts from rear bumper and trailer hitch if equipped f Remove rear bumper 4 Spare tire winch a Lower spare tire to ground and remove see owner s manual for procedure b Remove retaining clip and ratchet tube from Spare tire winch Ratchet Tube Spare av Tire Winch c Remove Spare tire winch 8 2009 Dodge 1500 Kit 60203 d Remove plastic ratchet tube guide from cross member Ratchet Plastic Guide Cross member Install Kit Cab 1 Prepare to lift cab from frame a Loosen but DO NOT REMOVE cab mounting bolts on driver side Loosen Bolt At These Mounts Cab Mount Core Support Cab Mount Except Core Support NOTE The number of cab mounting bolts may vary with the length of the cab b Remove bolt from each cab mount on passen ger side Remove Bolt At These Mounts SB WS Tl LAB is Cab Mount A WARNING Use extreme caution when lifting body from frame To prevent serious personal injury ensure the lifting device is securely placed Keep your hands out from between the body and frame A CAUTION Continually
15. se 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 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 21 Accessories The following accessories are also available Kit 4 6627 Gap Guards _BSiore Depending on the vehicle configuration automatic or manual transmission 2WD or 4WD cab length bed length etc some parts may not be used 2009 Dodge 1500 Kit 60203 Kit Parts List Qty Op MOOrANHX WHANON A OW Ah Nh N RO i b b b b SOTO CO Ny Description Block 3 x 3 spacer Block 3 crush Bolt 1 4
16. se of vehicle with combined lifts may result in unsafe and or unexpected handling characteristics Front bumper tow hooks can NOT be used following the installation of this kit 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 Z 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 av
17. sher 7 16 USS DO NOT TIGHTEN f At each other bed mount install kit bolt 12mm 1 50 x 100mm and kit washer 7 16 USS DO NOT TIGHTEN g Repeat previous steps on driver side of bed h Set bed to cab spacing according to previous measurement 2009 Dodge 1500 Kit 60203 i Remove each kit bolt one at atime and apply a c Install spare tire winch onto kit bracket winch few drops of kit Loctite to threads Install kit with two kit bolts 3 8 x 1 four kit washers 3 bolt with kit washer 7 16 USS Tighten kit 8 USS and two kit nuts 3 8 Nylock bolts to 55 ft Ibs kit Bolts Rear of Vehicle 3 8 x 17 kit Washers 3 8 USS Kit Nuts 3 8 Nylock 1 Spare tire winch a Remove two bolts and spare tire winch from crossmember Guide Spare Tire Kit Bracket Winch d Install ratchet tube onto spare tire winch with retaining clip e Verify ratchet tube is visible through hole in bed and plastic ratchet tube guide Adjust kit bracket spare tire ratchet tube if necessary b Install kit bracket winch and mounting plate onto crossmember with two bolts Position bracket between winch and the frame Ratchet Tube Spare Tire Winch y Kit Bracket Winch f Install spare tire on vehicle See owner s man ual Spare Tire Crossmember 12 2009 Dodge 1500 Kit 60203 g Reattach ground strap to frame with bolt near b
18. should perform all welding 1 Manual transmission shift lever a Scribe a line along side of transmission shift lever below lowest bend Cut lever into two pieces and deburr as necessary d Install two plastic shift tabs plastic ball shim and mounting plate onto shift lever Kit Extension Shim Mounting Plastic Ball Plastic Shift Tabs 16 2009 Dodge 1500 Kit 60203 e Install shift lever onto shift tower with four Torx bolts Torx Bolts Mounting Plate Shift Tower f Install rubber cover onto shift tower Rubber Cover Shift Tower g Install shift lever boot seal onto floor with six bolts Shift Lever Boot Seal h Install center console onto floor with bolts i Screw transmission shift lever onto shift tower lever j Install bolts securing center console to floor Transmission oe Rubber Cup Holder Inserts k Replace rubber cup holder inserts into center console Check transmission shift lever operation Ensure there is complete engagement in all gears Engine Compartment 1 Steering shaft Kit Extension Steering 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 17 2009 Dodge 1500 Kit 60203 a Install kit extension steering in position on 2 If possible install br
19. tallation you a Remove fuse cover encounter something different from what is outlined in the instructions call technical support at 928 636 7080 b Remove airbag fuse 4 Special tools needed Fuse Cover a Welder or access to a professional welding shop b Drill with 1 2 drill bit c Die grinder cut off wheel sawzall or similar tool capable of cutting metal 5 Park vehicle on a clean dry flat level surface and block tires so vehicle cannot roll in either direction Airbag Fuse s 2 2009 Dodge 1500 Kit 60203 Prepare to Install Kit Measurements 1 Measure and record distance between front bumper and fenders Driver Side Passenger Side 2 Measure and record distance between rear bumper and bed Driver Side Passenger Side 3 Measure and record distance between cab and bed Driver Side Passenger Side Front of Vehicle 1 Front bumper a Remove front grill by removing four bolts from top then pulling grill out b Remove push clips and lower splash guard from bumper core support and fan shroud Splash Guardr Front Bumper c Remove bumper trim by removing one bolt at each corner Under inner fender cover Slide cover forward to remove Front Bumper Trim Peace Remove Bolt Front Trim Bolts d Remove grill support by removing two bolts from each side e Disconnect fog light harness at driver side of front bumper and pull connector off of front bum
20. to prevent accidental movement 2009 Dodge 1500 Kit 60203 b Mark intermediate shaft in relation to rack and Underside of Vehicle pinion as shown 1 Wire harnesses and brake lines Intermediate A veal Shaft amp a Remove bolis and brake line brackets from at driver side frame rail Brake Lines Alignment Mark Bolt Rack a Pinion Remove bolt and intermediate shaft from rack and pinion Slide intermediate shaft up to sepa rate from rack and pinion C Intermediate shaft may not separate from rack and pin ion until cab is lifted 3 Remove brake sensor harness from passenger and driver fender wells b Remove bolt and ground strap from driver side Driver Side frame rail Ground Strap Wire Harness s S S 2 h h Connectors Sar 4 NSB 2204 b nTE 0 DTT F d JIT 7 bil YD Hud Passenger Side 2009 Dodge 1500 Kit 60203 c Remove harness from driver side body mount bracket Harness Body Mount Bracket NOTE The following procedures applies ONLY to automatic transmissions d Automatic transmission models Remove transmission shifter cable from clip on driver side brake line Trans Shifter Cable Clip Brake Line lt lt FRONT e Automatic transmission models Remove transmission wire harness from frame mount clip Trans Harness Clip di Front gt 2 Parking brake cable a
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