Installation Instruction
Contents
1. so that it doesn t contact anything With the weight of the vehicle on the wheels Tighten the u bolts to 100 120 ft Ibs Raise the front track bar to align it with the new drop bracket If the track bar doesn t line up with the bracket just turn the steering wheel This will shift the axle and make the track bar line up easily If installing the 6 kit attach the track bar in the upper hole on the drop bracket If install the 8 kit attach the track bar to the lower hole If install ing box kit 013004 attach the track bar using the supplied 9 16 grade 10 bolt nut and washers Insert the bolt from the back side forward If installing kit 013005 or 013006 then use the OE bolt to retain the track bar to the drop bracket Torque OE bolt to 369 ft lbs or 9 16 bolt to 130 ft lbs Bounce the front of the vehicle to allow the shackles to swing out to their intended position Torque front spring hanger bolt to 203 ft lbs Spring to shackle and shackle to frame bolts to 185 ft lbs Grease the supplied sway bar bushings and install them in to the supplied anti sway bar links Grease the supplied sleeves and install them in to the bushings Install the sway bar links in place of the OE links Use the two 12mm bolts nuts and washer supplied to at tach the links to the frame mount Use the OE fasten ers to attach the links to sway bar Torque all sway bar bolts to 35 ft lbs Note On 99 amp up models it will be necessary to re2. 013004 5 6 7 amp 9 Installation Instructions Front Box Kit Ford Super Duty amp Excursion SUSPENSION P READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE SAFETY WARNING 4 Post suspension system vehicles may experience BDS Suspension Co recommends this system be drive line vibrations Angles may require tuning installed by a professional technician In addition slider on shaft may require replacement shafts to these instructions professional knowledge of may need to be lengthened or trued and U joints disassembly reassembly procedures and post may need to be replaced installation checks must be known 5 Secure and properly block vehicle prior to PRODUCT SAFETY WARNING installation of BDS Suspension components Certain BDS Suspension products are intended to Always wear safety glasses when using power improve off road performance Modifying your vehicle tools for off road use may result in the vehicle handling 6 If installation is to be performed without a differently than a factory equipped vehicle Extreme hoist BDS Suspension Co recommends rear care must be used to prevent loss of control or alterations first vehicle rollover Failure to drive your modified vehicle 7 Due to payload options and initial ride height safely may result in serious injury or death BDS variances the amount of lift is a base figure Final Suspension Co does not recommend the comb
3. e move the spring eye bolts and remove the factory spring Loosen but do not remove the shackle to frame bolt 6 Use the jack to lower the axle to allow for installa tion of replacement springs CAUTION Be sure not to over extend the brake lines or vent tube Reroute brake line as necessary Install new BDS spring 003609 6 or 003809 8 10 Install factory spring eye bolts and nuts but do not tighten at this time 7 Raise the axle with the jack Be sure to align the leaf spring center pin with the hole in the spring mounting plate Raise the axle until the spring sets flush on the plate Install the supplied u bolts and factory u bolt plate and retain using supplied high nuts and wash ers Tighten u bolts to 60 ft Ibs using an X pattern 8 Install wheels and tires Tighten lug nuts to OE specifi cation 9 Raise the vehicle to remove jack stand and lower the vehicle on to the ground Bounce the vehicle to allow the shackles to swing out to their intended position Torque the spring to frame bolts shackle to spring and shackle to frame bolts to 185 ft lbs Page 4 of 4 10 Tighten the u bolts to 130 150 ft lbs using an X pat tern 11 Loosen the u bolt that holds the lower shock mount in place Rotate the lower shock mount upwards in order to install supplied BDS shocks at this time Tighten the lower shock mount u bolt to 35 ft lbs 12 Install flat brake line relocation bracket to the top of t
4. ement hoses if needed can be purchased components When selecting combinations larger from a local parts supplier than OE consider the additional stress you could 3 Perform head light check and adjustment be inducing on the OE and related components 4 Re torque all fasteners after 500 miles Always inspect fasteners and components during routine servicing 102 S Michigan Avenue Coldwater MI 49036 517 279 2135 www bds suspension com rev 4 26 2007 Page 1 of 4 PARTS LIST FOR 013004 013005 013006 Part Qty Description 96318101204 9 16 x 3 1 8 x 10 1 2 Square U bolt 013004 013005 only or 9 16 x 3 1 8 x 11 Radius U bolt 013006 only 963181100H 4 N96FH 8 9 16 High Nut W96S 8 9 16 SAE Flat Washers 083401R 1 Pitman Arm 013004 only or 083403R 1 Pitman Arm 013005 013006 only 01067 1 1 Track Bracket 013004 only or 01057 1 1 Track Bracket 013005 013006 only BP123401 1 Bolt Pack 403 1 Bolt Pack 01019 2 4 Link Kit 01027 1 2 Bump Stop Drop 01067 1 1 Track Bracket 013004 only or 01057 1 1 Track Bracket 013005 013006 only M02016RB 4 Large Shock Eye 65 1 4 3 4 x 134 x 1 650 Dom Sleeve PARTS LIST FOR 013007 amp 013009 Part Qty Description 583581500R 4 5 8 x 3 5 8 x 15 Round U bolt 013007 or 583581200R 4 5 8 x 3 5 8 x 12 Round U bolt 013009 N58FH 8 5 8 High Nut W58S 8 5 8 SAE Flat Washers B381G2 1 3 8 x 1 Bolt SBLA 1 Brake Adapters B382G5 1 3 8 x 2 Bolt LW38 2 3 8 L
5. he pinion using the OE fastener and tighten Attach the OE brake line bracket to the supplied bracket with the supplied 3 8 x 1 bolt nut and washer 13 Install the supplied sleeve between the OE brake line bracket and the frame rail using the supplied 3 8 x 2 bolt nut and washer Tighten to 25 ft lbs If the vehicle is equipped with a carrier bearing install BDS carrier bearing lowering kit at this time Recheck all fasteners for torque Re torque all fasteners after 100 miles Be sure to re torque the U bolts after 100 miles and after 500 miles If rear drive line vibration occurs you must adjust the carrier bearing spacer as well as the rear pinion angle using a degree wedge sold separately This fine tuning of the drive line angle will vary from vehicle to vehicle
6. ined ride height dimensions may vary in accordance use of suspension lifts body lifts or other lifting to original vehicle attitude Always measure the devices attitude prior to beginning installation You should never operate your modified vehicle under the influence of alcohol or drugs Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt 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 PRE INSTALLATION NOTES lines fuel lines fuel tank floor boards and wiring 1 Special literature required OE Service Manual for harness Check steering gear for clearance Test model year of vehicle Refer to manual for proper and inspect brake system disassembly reassembly procedures of OE and 2 Perform steering sweep to ensure front brake related components hoses have adequate slack and do not contact 2 Adhere to recommendations when replacement any rotating mobile or heated members Inspect fasteners retainers and keepers are called out in rear brake hoses at full extension for adequate the OE manual Slack Failure to perform hose check replacement 3 Larger rim and tire combinations may increase may result in component failure Longer leverage on suspension steering and related replac
7. move the OE bracket on top of the frame rail that originally held the top end of the sway bar links Flip the OE bracket over and attach it to the bottom of the frame and retain using OE fasteners Torque to 55 ft Ibs Page 3 of 4 24 Check all fasteners for torque Adjust the drag link to center the steering wheel CAUTION You will want to test the front driveshaft rota tion at full droop You will need to clearance grind the drive shaft for smooth rotation You may need to lengthen the front drive shaft Be sure to test this at full droop before driving the vehicle Be sure to tighten all fasteners after 100 miles Be sure to tighten the spring U bolts again after 500 miles REAR INSTALLATION 013007 amp 013009 1 Raise the rear of the vehicle and install jack stands under the frame Be sure to chock the front wheels Remove the rear tires and wheels 2 Remove the OE shocks 3 Use a large set of pliers to bend the OE brake line bracket out flat where it attaches to the frame Be sure not to kink the brake line Drill out the OE rivet that attaches the bracket to the frame With the rivet removed move the bracket below the frame and allow it to hang loose It will be reattached later after the springs are installed 4 Remove the factory brake line bracket from the top of the pinion on the axle Retain OE fasteners 5 Complete this step one side at a time Place a jack under the axle and remove the factory u bolts R
8. ock Washer 45313 1 1 5 8 x 109 x 1 375 Sleeve 4KB W96 2 4 Lift Block 013007 only INSTALLATION INSTRUCTIONS Helpful Hint The following installation may go easier if you remove the front bumper before you begin The bum per is attached by four bolts The removal will require two people This is not necessary for installation but will make removal of the front spring eye bolts easier 1 _Unhook the track bar at the top end where it attaches to the frame bracket Retain fasteners for later use 2 Raise the front of the vehicle and support with jack stands Be sure to chock the rear tires Remove the wheel and OE shock 3 With a large set of pliers bend the OE brake line mounting tab on the frame out to 45 degrees Remove the bracket from the frame and retain the OE fastener Fig 1 Page 2 of 4 4 Remove the anti sway bar end links Fig 2 Remove the cotter pin and castle nut from the drag link at the pitman arm Use a tie rod puller to separate the tie rod end from the pitman arm 5 Remove the three bolts that retain the factory track bar bracket to the frame Set the bracket off to the side and retain the factory fasteners for later use Fig 3 6 Remove the nut and washer from the steering shaft that retain the pitman arm Remove the pitman arm using a pitman arm puller Complete the following instructions one side at a time 10 11 12 13 Place a hydraulic jack under the front a
9. rd the front Install the factory spring eye bolts in to the springs and install nuts but do not tighten at this time Raise the front axle with the jack Align the leaf spring center pins in the holes in the axle spring pads Raise the axle until the springs are seated flat on the spring pads Install the supplied front u bolts over the springs and through the stock original u bolt plates Retain the u bolts using the supplied high nuts and washers Tighten bolts but do not torque at this time With the front axle at full droop move the brake line mounting bracket The bracket should rest about 2 down from it s original position and about 3 forward Reroute brake line as needed Use the bracket as a template and drill a new hole in the frame Attach the bracket to the frame using the OE fastener that you remove earlier Attach the drag link to the pitman arm and retain using the factory nut Torque to 60 ft Ibs and then tighten until the cotter pin hole line up DO NOT LOOSEN THE NUT TO LINE UP THE COTTER PIN Install a new cotter pin Install the front BDS shocks at this time If you are installing a dual shock system do so at this time Install the front tire wheel assembly and tighten to OE specification Torque specifications can be found in the owner s manual Raise the vehicle to remove the jack stands and lower the vehicle on to the ground CAUTION When lower ing the vehicle be sure to watch the hanging track bar
10. xle Remove the u bolts that hold the leaf spring to the axle Slowly lower the jack allowing the axle to separate from the leaf spring CAUTION Be sure not to over extend the brake lines or vent tube Remove the shackle and solid mount spring eye bolts Note These bolts are coated with loctite from the factory You will need to remove the radiator con denser mounts one side at a time in order to remove the front spring eye bolts Loosen the shackle to frame bolt Do not remove just loosen Remove the stock leaf spring and repeat for the op posite side Install the supplied drop pitman arm to the steering shaft and retain with the factory fasteners Torque to 200 ft lbs Install the supplied track bar bracket in the factory lo cation Attach using the three OE fasteners and torque to 130 ft lbs Fig 4 Remove the factory bump stops from the frame Install the bump stop drop brackets between the OE bump stops and the frame Use the supplied 3 8 bolts nuts and washers to retain the drop bracket to the frame and use the OE fasteners to attach the bump stop to the drop bracket Torque to 30 ft lbs Fig 5 Lower the front axle using the hydraulic jack to aid in leaf spring installation CAUTION Be sure not to over extend the brake line or vent tube 14 15 16 18 19 20 21 22 23 Install the supplied front leaf springs 003602 6 or 003802 8 The double wrapped eye goes towa
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