BDS Suspension Installation Instructions
Contents
1. PS 491 W Garfield Ave Coldwater MI 49036 EAN Phone 517 279 2135 KA vill lt Web live chat www bds suspension com E mail tech bds suspension com Part 122801 122802 Product Transfer Case Indexing Kit Application 03 12 Dodge Ram 2500 3500 Auto 122801 03 12 Dodge Ram 2500 3500 Manual 122802 94 02 Dodge Ram 2500 3500 Auto Manual 122802 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 I2. 933 Match up the threads from the removed studs to ensure proper hardware 3 8 or 10mm depending on model year is seleceted and attach with counter sunk allen bolts with loc tite on threads Ensure the ring goes on square and there are no gaps Tighten to 35 ft lbs Fig 9 17 Thread in the 3 8 set screws into the indexing ring with loc tite on threads Securely tighten to 25 ft lbs 122801 122802 Page 5 18 All Automatic Transmissions or earlier Pre 2010 Manual Transmission models that have a single lipped seal Remove the output seal from the transmission Fig 10 Late 2010 Manual transmission models with a factory double lipped seal do not need the seal extension installed skip to step 21 19 Pick the correct output seal extension from the kit that matches the inside diameter of the transmission Lightly grease the outer surface of the transmission output seal extension and install into the transmission Make sure it is seated flush against the transmission 20 Lightly grease the outside of the seal to aid in installation Install the new transmission output seal into the adaptor Ensure that it is seated flush with the extension Lightly grease the inner lip of the seal Fig 11 21 Reinstall the transfer case It may be necessary to grab the output shaft of the transfer case and rotate it to get it to align with the transmission output shaft Attach the transfer case with new 3 8 flanged nuts Use loc tite
3. remove carrier bearing hardware if equipped Fig la 1b Page 2 122801 122802 5 Support the transmission with an appropriate type of transmission jack Take extra care not to damage the trans mission pan or any lines around the pan 6 Disconnect the transfer case shift linkage for manual transfer cases disconnect the transfer case shift module for auto shift applications Fig 2a 2b 7 Disconnect the breather tube 8 Disconnect the transmission mount from the transmission crossmember 3 nuts Retain nuts Fig 3 9 Remove the mount from the transmission 4 bolts retain bolts Fig 4a 4b 122801 122802 Page 3 10 Remove the 4 bolts that hold the transmission crossmember into position Mark the front side of the crossmember and remove from vehicle Fig 5a 5b Page 4 122801 122802 12 Support the transfer case and remove the 6 nuts that attach the transfer case to the transmission Fig 7a 7b 13 Remove the transfer case from the vehicle 14 Clean the mounting surfaces from any corrosion or oxidation that may be present 15 Remove the studs from the transfer case Thread on up to 3 nuts in order for there to be enough resistance to unthread the studs Fig 8 16 Install the transfer case indexing ring onto the transfer case Note This will only go on one way rotate until the holes line up Certain model years use metric hardware BP 937 earlier years use standard 3 8 hardware BP
4. NSTALLATION NOTES 1 Special literature required OE Service Manual for model year of vehicle Refer to manual for proper disassembly 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 f
5. he seal is included in the kit Kit is designed to be installed with lifts of 6 8 inches If the kit is being installed with a kit other than a BDS Long Travel Kit the front driveshaft spacer may or may not need to be installed Itis the installers responsibility to ensure there is adequate slip engagement in the driveshaft through wheel travel Note Due to variances in OE drivetrains it may not be necessary to install the transfer case indexing ring The indexing ring lowers the front output by approximately 2 5 Measure the clearance from the driveshaft flange down to the top of the crossmember On most applications this will measure about 3 and can use the indexing ring If the measurement is close to 2 5 some minor grinding may be necessary on the crossmember for driveshaft clearance once the indexing ring has been installed If it is less than 2 5 do not install the transfer case indexing ring due to the interference with the crossmember in the indexed position Front driveshaft to crossmember clearance INSTALLATION INSTRUCTIONS l Park vehicle on clean flat and level surface 2 Block the wheels for safety 3 Leave the transmission in neutral for the installation of the transfer case indexing ring 4 Remove the rear driveshaft from the vehicle Mark the driveshaft at the axle so that it can be reinstalled in the same manner it was removed It will take 2 people to hold the weight of the driveshaft it s heavy
6. ly if the kit is being installed with a lift 4 or taller Check the shift linkage for manual shift transfer cases Adjust the linkage as necessary to allow all gear ranges to be selected Recheck all fasteners for proper torque recheck again after 500 miles 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 122801 122802 Page 7
7. on the threads Tighten to 35 ft lbs Fig 12 Page 6 122801 122802 22 Reattach the breather line and electric connection for auto shift 4x4 models Attach the shift linkage for manual shift transfer case models t Tip Before hooking up the front driveshaft now is a great time to grease the nearly impossible to access grease fitting on the front dual cardan joint A needle adaptor on a grease gun is required This fitting is required to be serviced at every oil change interval Ensure that this maintenance is not skipped 23 24 25 26 27 28 Reinstall front driveshaft with driveshaft spacer and new hardware if it is being installed with 6 inches or more of lift If there is less than 6 inches of lift do not use the driveshaft spacer and reuse the factory hardware Use loctite on threads and tighten to 75 ft lbs Bolt pack 932 Fig 13a 13b Note Certain aftermarket kits may not require the driveshaft spacer It is the installers responsibility to ensure that the driveshaft has adequate engagement and install or skip the installation of the included spacer Reinstall the transmission mount with OE hardware tighten to 35 ft lbs Reinstall the transmission crossmember with factory bolts and tighten to 95 ft lbs Reinstall the rear driveshaft with factory hardware use loctite on threads tighten to 75 ft lbs If the vehicle is equipped with a carrier bearing install carrier bearing drop at this time sold separate
8. uel lines fuel tank floor boards and wiring harness Check steering gear for clearance Test and inspect brake system 2 Perform 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 5 18 2013 122801 122802 Page 1 PARTS LIST TRANSFER CASE INDEXING RING Part Qty 02296 1 932 1 02253 1 933 1 937 l NOTES Description Front driveshaft spacer Bolt pack front driveshaft spacer T case indexing ring Bolt pack t case indexing ring Bolt Pack t case metrics 02251 02252 02249 710058 ji Internal trans spacer 2 687 Internal trans spacer 2 560 Internal trans spacer 3 075 122802 Only Transmission output seal If you ever need to buy a replacement transmission output seal The transmission seal you need is from a 48RE transmission This was found in all automatic transmissions behind the 4wd 5 9 Cummins 03 07 Federal Mogul part 710058 It has an outside diameter of 2 563 If you ordered a kit with an R or M code after 9 10 2010 R091010 month day year then t
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