Installation Instructions Truckin Suspension 4.5” Lift Kit 1999
Contents
1. lik EKih as SUSPENSION COM Installation I nstructions Truckin Suspension 4 5 Lift Kit 1999 Newer DODGE DAKOTA DURANGO Rack and Pinion I mportant Read all instructions before attempting any work on the vehicle DO NOT DISSASSEMBLE ANY PART OF VEHICLE PRIOR TO COMPARING THE DELIVERED PARTS AND THE INCLUDED PARTS LIST REPORT ANY DISCREPENCIES IMMEIDATELY TO 800 775 7150 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering Tabs are no longer on 6 5 kit Parts E and F are now integrated into one piece Truckin Suspension 4 5 Suspension Lift Kit 1999 Newer DODGE DAKOTA DURANGO Rack and Pinion Page 2 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering important Read all instructions before attempting any work on the vehicle DO NOT DISSASSEMBLE ANY PART OF VEHICLE PRIOR TO COMPARING THE DELIVERED PARTS AND THE INCLUDED PARTS LIST REPORT ANY DISCREPENCIES IMMEIDATELY TO 800 775 7150 Disclaimer Notice nstalling this suspension system on any vehicle implies that you are in agreement with the following terms and conditions with respect to that vehicle the vehicle owner and any or all occupants of said vehicle at any time e Truckin Suspension is not responsible and cannot be held responsible for any conditions of said vehicle including but not limited to the following 1 Any and all adverse behavior premature failure or breakage caused by oversized tires and wheels im2. 4 3 4 OD x 9 16 ID x 1 1 2 sway bar bushing sleeves 2 Pancake bump stops 2 Big soft cushion bump stops 1 Set of sway front sway bar bushings with hardware Daystar KU05014BK 2 Front sway bar 1 aluminum 1 Hanger hardware kit 6 7 16 14 x 1 1 4 Grade 8 hex bolt 8 7 16 washers 4 7 16 crimp nuts 4 3 8 16 x 2 1 4 Grade 8 hex bolt 4 3 8 16 nyloc nuts 8 3 8 washers 2 1 2 13 x 1 3 4 Grade 8 hex bolt 14 1 2 13 x 1 1 2 Grade 8 hex bolt 10 1 2 13 x 2 3 4 Grade 8 hex bolt 4 1 2 13 x 4 1 2 Grade 8 hex bolt 2 1 2 13 x 1 3 4 bolt tabs 64 1 2 washers 32 1 2 13 crimp nuts 4 5 8 11 x 4 Grade 8 hex bolt 8 5 8 washers 4 5 8 11 nyloc nuts Not Included 2 1930LL REAR SHOCKS 4 5 RETAIN STOCK FRONT SHOCKS Page 6 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering Installing Front Kit 1 2 10 11 12 Disconnect Battery Remove upper shock nuts and bushings Remove wheels when vehicle is properly lifted from the ground and secure with jack stands Release tension from torsion bars and remove lower a arm has dowel pin keeping torsion bars in tap dowel pin Remove brake calipers and tie up off front of frame Don t allow brakes to hang from brake lines Remove sway bar from under lower control arms Remove CV axles spindles and upper and lower control arms Unbolt front driveline from front differential and tie up to frame Rem
3. frame and the drop down bracket until the holes are lined up Install front lower a arm cross member rack and pinion drop part D between front lower a arm drop brackets part C as seen in illustration using 7 16 x 1 bolts washers and crimp nuts 4 bolts are for the front and 2 are for the middle rear bolt holes Page 8 18 19 20 21 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering ee Using the 2 aluminum sway bar blocks part L and the new sway bar bushings and 3 8 x2 bolts washers and lock nuts install sway bar to rear of front lower a arm drop down brackets parts C the aluminum blocks are drilled to go over the 2 rear 7 16 bolts you installed in step 17 Install rack and pinion factory fluid lines may need to be slightly tweaked using supplied 5 8 bolts washers and crimp nuts 2 5 8 bolts are for rack and pinion and the other 2 are for the factory location to bolt rack pinion drop part D Install steering extension at the end of the steering column Leave the stock u joint on the rack Be sure not to turn the steering wheel as you may damage the clock spring Install all front differential drop down brackets parts J K as they appear in the illustration and front differential using x2 3 4 bolts washers and crimp nuts Page 9 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering 22 Install rear lower a arm drop down cross member part H install pan
4. LUDED PARTS LIST REPORT ANY DISCREPENCIES IMMEIDATELY TO 800 775 7150 Failure to read entire instruction packet before beginning disassembly will likely result in additional downtime spent acquiring tools special equipment and skilled mechanical know how We strongly recommend installation be done by a professional mechanic in a shop with a suitable vehicle hoist If attempting this installation as a do it yourselfer please review this packet carefully BEFORE attempting any work on the vehicle A well equipped shop can perform this installation in approximately 12 hours This packet uses standard nomenclature when referring to each side of the vehicle LEFT side means DRIVER S side while RIGHT side means PASSENGER side Page 4 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering Required Tools and Equipment Make sure all of these tools and equipment are readily available BEFORE beginning work on the vehicle Good quality safety glasses and ear protection Professional Quality Floor Jack or vehicle hoist Tall Jack Stands 4 4 drive Socket set and ratchets with metric standard and deep sockets 3 8 drive Socket set and ratchets with metric standard and deep sockets Hex Sockets recommended OR Allen wrench hex key set Compressor w impact wrench and air ratchet recommended Air hammer with flat pointed chisel and shovel tip chisel bits Pickle fork type tie rod separator and ball joint separator Torsion ba
5. cake bumpstops to top of rear cross member and soft cushion bumpstops to lower part of cross member 23 Install all factory front suspension to factory torque specifications now you can TIGHTEN all Suspension Page 10 24 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering To install new torsion bar cross member part N you will need to draw a straight line from center of old cross member to bottom of frame center cross member drop down brackets parts M and drill 2 holes up into lower frame rails install drop down brackets and new torsion bar cross member using 2 x 1 bolts washers and crimp nuts Page 11 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering INSTALLING REAR KIT The Durango kit will use an axle relocater Flip Kit and no hangers 1 Remove clips from old brake line bracket located on inside of frame 2 Remove factory shocks and sway bar end links DO NOT UNDO WITHOUT REAR END BEING SUPPORTED 3 For 4 lift only remove the rear hangers 4 Bolt on new hangers with 7 16 inch bolts supplied in kit 5 Remove rear shackle invert and flip then reinstall with factory hardware to new rear spring hanger 6 Mount new e brake bracket to frame with supplied hardware You must drill 1 2 inch hole in frame 7 Loosen but to not remove U bolts holding rear springs to the axle Retighten This is to relieve any bind in the leaf springs 8 Install sway bar extensi
6. kit installed on your vehicle you are implying that you agree to the above terms and conditions Please do not install this system if you do not agree Page 3 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering Kit Hardware Torque Specifications Remember that actual torque may vary if lubricant is used or extension bars are used with the torque wrench Torque all re used O E factory hardware to original vehicle torque specifications according to factory service manual If in doubt concerning the torque specification of ANY fastener always consult the factory service manual Always consult factory service manual for sequence and torque specification of any O E parts being reassembled such as ball joint nuts and steering tie rod ends For hardware supplied with this kit use the following list as a guide for fastener torque Bolt Size eT ee ee 70 Ft Ibs 100 Ft lbs F B 10 FteIbs mportant Maintenance I nformation It is the end user s responsibility to have all fasteners checked for proper torque after the first 200 miles then every 3000 miles Have a qualified professional mechanic or alignment specialist inspect the steering Suspension and driveline components immediately after installation and at regular intervals thereafter important Please read all instructions before attempting any work on the vehicle DO NOT DISSASSEMBLE ANY PART OF VEHICLE PRIOR TO COMPARING THE DELIVERED PARTS AND THE INC
7. ons with factory hardware Page 12 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering 9 Install new shocks 10 Install wheels and place vehicle on the ground Torque lower control arm pivot bolts with the vehicle resting on the ground CHECK ALL FLEXIBLE BRAKE LINES making sure they are clear of moving parts when the suspension cycles up and down Make preliminary adjustments to camber and toe in as needed to get front wheels visually straight Recheck all fasteners and components again to make sure everything is tight REMEMBER TO TORQUE THE LUG NUTS Reconnect battery 11 Test drive vehicle at speed and listen for noises Drive vehicle in different conditions while turning in drive and reverse to check tire clearance and trim plastic bumper valance if necessary Engage 4WD in low and high Have a QUALIFIED ALIGNMENT SPECIALTY SHOP reset the front end alignment to correct specification DO NOT drive vehicle more than 15 miles before having the alignment checked by a qualified shop Re torque wheels after 200 miles and recheck all lift kit hardware after 3000 miles Page 13
8. ove front differential Unbolt rack and pinion and remove FRONT SUSPENSION SHOULD BE COMPLETELY REMOVED BEFORE GOING TO THE NEXT STEP Using a plasma cutter or sawzall cut and remove droop bump stop from both drivers and passengers side of frame Also remove the top inner 1 2 in of metal where the lower a arm mount meets the frame to clear the upper a arms when installed with the new drop down brackets j 08 p A r Page 7 13 14 15 16 17 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering Using a grinder clean area so frame is smooth Spray with paint or sealant to prevent rust DO NOT TIGHTEN ANY OF THE LIFT KIT UNLESS NOTED UNTIL YOU HAVE ALL FACTORY SUSPENSION HUNG ADJ USTMENT WILL BE NEEDED BEFORE TIGHTENING Hang upper a arm drop down brackets along with integrate shock relocaters using 2 2 x1 1 bolts washers and crimp nuts drill 2 holes into inner side of rear a arm pockets and use x1 bolts washers and crimp nuts to attach a arm drop bracket ear to inner side of rear a arm pocket and TIGHTEN Hang front lower a arm drop brackets part C and drill 4 hole upwards through front frame cross member insert bolt tabs into front cross member and down through drop brackets put 1 2 washer and crimp nuts on bolt tab and tighten If the space between the new lower a arm mounting points is not equal to the stock distance then you will need to add washers between the
9. proper installation failure to follow instructions or any general negligence caused by installer or owner of said vehicle 2 Any breakage or premature failure caused by racing or driver negligence 3 ANY incident determined to be caused by an increase height in said vehicle s center of gravity 4 ANY incident determined to be caused by improper installation 5 ANY incident determined to be caused by a failure of materials e Truckin Suspension is to be held harmless by the installer of this lift kit owner of said vehicle ANY occupants of said vehicle and any parties related directly or indirectly to said vehicle or owner of said vehicle Truckin Suspension is to be held harmless by all parties mentioned during the course of any and all circumstances or incidence resulting from the installation of this lift kit e Truckin Suspension offers this kit strictly as a visual improvement of said vehicle over the factory aesthetics The fact that the suspension system works and functions well is incidental and it is not the intention of Truckin Suspension that said vehicle be modified for use on public highways Sanctioned by the Department of Transportation or any state or local governing body Vehicle owner accepts sole responsibility for ensuring that said vehicle is not in violation of local state or federal laws or vehicle code Please check local vehicle laws and regulations before modifying your vehicle By I nstalling This Kit or having this
10. r unloading tool recommended OR 2 jaw gear puller Transmission J ack recommended Plasma Torch recommended OR Sawzall with metal cutting blades MIG or equivalent wire feed welder with 75 25 Argon or better 4 grinder recommended or chisels and files drill motor and drill index 2 and 34 drill bits required Dead blow hammer recommended OR suitable ball peen hammer Soft face hammer Screwdrivers Pliers and Channel Locks Side cutter type cutting pliers Pointed Heel bars recommended OR pry bars Cotter pin assortment Tie wire and or plastic zip ties DO NOT attempt installation unless you have everything on this list or suitable substitutes for the recommended tools Page 5 Suspension Lift Kit 99 Newer Dakota with Rack and Pinion Steering Parts List 2 Upper control arm drop down brackets left and right 1 Rear lower control arm cross member 2 Front lower control arm drop brackets 1 Front lower control arm cross member rack and pinion drop 1 Driver side differential drop bracket 1 Passenger side differential drop bracket 1 Center differential drop bracket 1 Steering idler bracket Welded 34 heims 2 Torsion bar cross member drop down brackets 1 Torsion bar cross member 2 Rear sway bar end links 2 Rear Hangers NOT FOR DURANGO 1 Flip Kit for Durango 1 E brake relocate bracket Hardware List Pre Installed 8 Rear sway bar bushings
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