BDS Suspension Installation Instructions
Contents
1. PS 491 W Garfield Ave Coldwater MI 49036 EAN Phone 517 279 2135 KA n lt Web live chat www bds suspension com E mail tech bds suspension com Part 022410 Product 4 Suspension System Application 2002 2005 Dodge Ram 1500 4wd READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE SAFETY WARNING sps 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 d2. 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 3 3 2014 022410 Page 1 PARTS LIST Part 02230 02231 44016 02270 02271 3527RB 112 113 516 02289 02290 02274 02268 MO2060RB 02269 02276 911114 01240 01234 01236 01237 01238 654 Page 2 022410 Qty Pd Dom Nh Nh Nm bun bobbin n NNN A mwmw Nw 617 Description Steering Knuckle drv Steering Knuckle pass Tie Rod Ends 18mm 02 05 Front Crossmember HC 778 Rear Crossmember HC Bushing Sleeve Large dia washers Grease zerk straight Torsion Bar Bracket drv Torsion Bar Bracket pass Torsion Bar Brkt Spacer Front Bump Stop Bracket Bump Stops Blue Crossmember Brace Differential Skid Plate Sway Bar Link Extension 779 Front Driveshaft Spacer Differential Brkt pass Differential Brkt drv Differential Brkt pass Differential Brkt Bolt Pack 10mm 1 50 x 65mm bolt loctite So ee ae Oe ee NNNNA AH ND Bolt Pack Differential Drop 1 2 13 x 2 3 4 bolt 1 2 13
3. ball joint nut and remove the knuckle from the lower control arm Retain the ball joint nuts Remove the three bolts mounting the hub bearing assembly to the OE steering knuckle Retain the mounting bolts Remove the hub assembly and dust shield from the knuckle Note It may be necessary to press the hub out of the knuckle as a result of excessive corrosion on some vehicles Install the hubs and factory dust shield on the corresponding new knuckles 01230 01231 and fasten with the stock mounting bolts Index the hub so that the ABS line runs out the front side of the knuckle toward the steering arm Use Loctite on the bolt threads and torque to 125 ft lbs Remove the lower control arms from the frame Retain hardware Make indexing marks on the front drive shaft and differential input flange for realignment later Fig 5 Remove the four bolts and disconnect the drive shaft from the differential Discard mounting bolts Locate the exhaust crossover pipe If the crossover pipe runs under the front driveshaft it must be modified Fig 6 The pipe can either be completely removed or cut to clear the driveshaft at this time The other option is to wire up the front drive shaft if traveling a very short distance to the exhaust shop Note Vehicles equipped with a crossover pipe that runs near the transfer case will not require an exhaust modification Have the exhaust modifications completed by a quality exhaust shop when the installation of this sus
4. block so that the short end of the block is toward the front of the vehicle Fasten the spring block and axle together with the provided u bolts high nuts and washers Snug u bolts The final u bolt torque is performed with the vehicle on the ground Repeat installation on the driver s side of the vehicle Install the new BDS shocks with the OE hardware Install the wheels Lower the vehicle to the ground and bounce the vehicle to settle the suspension Torque the u bolts to 100 120 ft lbs If installing new rear springs torque spring bolts to 95 ft lbs Check all hardware for proper torque Check all hardware 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 Page 18 022410
5. x 2 1 2 bolt 1 2 13 prevailing torque nut 1 2 SAE flat washer 12mm 1 75 x 30mm bolt Bolt pack Main hardware 5 8 11 x 5 1 2 bolt 5 8 11 x 8 bolt 5 8 11 prevailing torque nut 5 8 SAE flat washer 1 2 13 x 3 Button head bolt 1 2 13 prevailing torque nut 1 2 13 x 1 1 4 bolt 1 2 13 x 1 3 4 bolt 1 2 SAE washer 1 2 13 flanged nut Bolt pack Front Driveshaft misc 12mnv 1 75 x 45mm bolt 12mm flat washer 3 8 16 x 1 1 4 SHCS 3 8 SAE Flat washer 5 16 18 x 1 1 4 self tapping bolt loctite INSTALLATION INSTRUCTIONS PRE INSTALLATION NOTES A special tool is required to load unload the torsion bars The Dodge service manual lists tool 8686 This tool differs slightly from the C clamp style tool used on most other IFS vehicles A special tool is required to remove the factory rear lower control arm bushings from the frame This tool is available through Dodge or SPX Miller Special Tools 8682 SPX Miller Special Tool 1 800 801 5420 The factory service manual specifically states that striking the knuckle to loosen the ball joints or tie rod ends is prohibited Striking the aluminum knuckle can damage it A special puller tool 8677 or equivalent ball joint tool is recommended to be used to separate these components from the knuckle On some vehicles an exhaust modification will be required to clear the front driveshaft in its new lower position T 60 and T 55 impact quality torx sockets are necessar
6. al frame mount with two x 2 3 4 bolts nuts and 1 2 SAE washers BP 617 Leave hardware loose Fig 14 31 Install the two front driver s side differential drop brackets so that the bracket with the small offset 01236 is toward the outside of the vehicle offsetting out and the one with the bigger offset 01237 is on the inside offsetting in The brackets should taper down in height as they go toward the rear of the vehicle Fasten the brackets to the frame with two 2 x 2 1 2 bolts nuts and 1 2 SAE washers BP 617 Leave hardware loose 32 Install the driver s side rear differential drop bracket 01238 to the frame with three 12mm x 30mm bolts and 4 SAE washers BP 617 into the existing welded nuts on the frame The bracket will offset toward the outside of the vehicle with the gusset to the front Leave hardware loose 33 Using a jack and an assistant to aid in balancing raise the differential up to the new brackets 34 Attach the differential to the driver s side front and rear brackets Fig 15 with 4 x 2 1 2 bolts nuts and washers BP 617 Attach the passenger s side to the differential with 1 2 x 2 3 4 bolts nuts and 1 2 SAE washers BP 617 Leave all differential hardware loose 022410 Page 9 35 Torque all 14 differential mounting bolts Torque the 4 hardware to 65 ft lbs and the 12mm hardware to 50 ft lbs 36 Attach the breather hose and wiring to
7. crossmember with 5 8 x 8 bolts nuts and 5 8 SAE washers installed from front to back Fig 22a b 022410 Page 13 i gt 13 Large l Washer 48 With the lower control arms installed torque the crossmember hardware as follows Front crossmember upper OE bolts 125 ft lbs Rear crossmember 1 2 button head hardware 65 ft lbs Leave control arms loose 49 Torque the differential skid plate hardware to 65 ft lbs 50 Install the provided drive shaft spacer on the differential input flange Attach the front driveshaft to the differential by aligning the marks made earlier Fasten the driveshaft and spacer to the differential flange with 12mm x 45mm bolts and 12mm washers BP 779 Use loctite on the bolt threads and torque to 55 ft lbs Fig 23 Page 14 022410 ol 52 53 54 59 56 Install the new driver s side steering knuckle to the driver s side lower control arm ball joint and loosely attach with the original nut Install the driver s side CV axle in the hub and loosely fasten with the original axle nut Swing the knuckle CV assembly up while aligning the axle with the differential output shaft Loosely attach the knuckle to the upper control arm ball joint with the original nut Push the CV axle all the way onto the differential output to seat the internal retaining clip Torque the upper ball joint nut to 55 ft lbs and the lower ball joint nut to 60 ft lbs Torque the axle nut to 185 ft lbs R
8. ed earlier If necessary adjust the torsion bars to achieve 4 of lift over the original measurements The front height measurement should not exceed 27 If your vehicle is equipped with aftermarket fenderflares check the z height Measure and record the distance from the center of the lower control arm bolt to the ground and from the center of the lower shock bolt to the ground The difference between the two should be nealy zero 1 2 arm is level This will ensure proper front end alignment and good ride quality The ride height can be adjusted in the front to get the desired rake since these trucks came from the factory with a stance 1 1 2 3 1 2 tail high Optional rear blocks can also be ordered to adjust rear stance REAR INSTALLATION 69 70 71 72 73 Block the front wheels for safety Raise the rear of the vehicle and support the frame with jack stands Remove the wheels Support the axle with a hydraulic jack Remove the OE shocks Retain the mounting hardware Remove the parking brake cable retaining ring from the driver s side frame rail Fig 28 Remove the ring from the cables 022410 Page 17 Block Installation T4 75 76 TT 78 79 80 8l 82 83 Remove the passenger s side u bolts Lower the axle from the leaf spring enough to install the provided 2 lift block Note Take care not to over extend any wires or hoses Make adjustments where necessary Install the 2
9. epeat knuckle CV installation on passenger s side Remove the factory outter tie rod end Attach the new tie rod ends to the new steering knuckles with the new nut Torque to 45 ft lbs Install the sway bar link extensions onto the factory sway bar links tighten securely Install factory cup washers and rubber bushings onto sway bar links Attach to sway bar with new 10mm bolt BP 654 with loc tite on threads Tighten until the bushings begin to swell Do NOT overtighten Passenger s side brake line Remove the bolt retaining the line bracket to the frame Fig 24 Carefully reform the hard line so that the mounting bracket can be lowered approximately 3 remove the hard line from the retaining clip on the inside of the frame rail Measure back 1 2 from the lower existing hole in the frame and drill a 17 64 hole Fig 25 Attach the brake line to the new hole with the provided 5 16 x 1 1 4 self tapping bolt BP 779 Ensure that the hard line is properly routed 022410 Page 15 57 Driver s side brake line Remove the bolt retaining the line bracket to the frame Fig 26 Support the hard leader with pliers and carefully bend the line down approximately 30 Fig 27 Mark and drill the new mounting location on the frame with a 17 64 drill Fasten the bracket with the provided 5 16 x 1 1 4 self tapping bolt BP 779 Page 16 022410 58 59 60 6l 62 63 64 65 66 67 68 In
10. ipped 11 Disconnect the tie rod ends from the steering knuckles Fig 2 Remove and retain the mounting nuts Use the appropriate puller to separate the tie rod end from the steering knuckle Take care not to damage the tie rod end 12 If equipped disconnect the ABS brake line at the frame Remove it from any retaining clips 13 Remove the brake caliper anchor bracket bolts Fig 3 and pull the caliper free from the steering knuckle and rotor Hang the caliper securely out of the way Retain caliper mounting hardware Remove the brake rotor from the hub Note Do not allow the brake caliper to hang from the brake hose 14 Remove the hub axle nut Retain nut 15 Loosen but do not remove the lower control arm bolts 16 Disconnect the CV axles from the differential by carefully prying CV out at the differential to disengage the internal retaining clip Fig 4 Pry the shaft out just enough to release the clip and leave the axle on the differential at this time Page 4 022410 17 18 19 20 21 22 23 Remove the upper and lower ball joint nuts Reinstall the nuts a few turns by hand Separate the upper and lower ball joints from the steering knuckle using the appropriate puller Take care not to damage the ball joint Remove the upper ball joint nut and allow the knuckle CV axle and lower control arm to swing down while sliding the CV axle off of the differential Remove the CV axle from hub Remove the lower
11. is used on the bumpstop Fig 18 Note Bumpstop included in the kit has a lower profile than shown in the picture below F ai s 7 p E ae Oe z aT P a ee fe r j a my F ae Aka Es 1 be Ba a 4 whi ay EF el ree s i a el Ba m K ha Fae THI T J see i a fa y i Jp Paa s J s i i SEE L Ge es 44 Mark the control arm as shown This area must be removed from the control arm for CV boot clearance The area to be removed is wedge shaped Draw a triangle to connect the points and remove material with a grinder Coat with paint after material is removed Fig 19a b 022410 Page 11 45 Remove corrosion inside the lower control arm where the bolt head originally rested Install the spacer as shown Fig 20a b Page 12 022410 46 Install the torsion relocation brackets on the arm as shown Rotate the arm so that the flat bracket rests on the control arm Mark the hole center and drill to Attach with x 1 3 4 bolt with washer on the head of the bolt and a serrated flanged nut on the inside of the control arm Use loctite on the threads and tighten to 65 ft lbs Fig 21 47 Install the lower control arms in the front and rear crossmembers Attach the control arms to the front crossmember with 5 8 x 5 1 2 bolts nuts and 5 8 SAE washers BP 778 installed from front to back Install the spacer washer as shown attach the arms to the rear
12. isassembly 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
13. pension system is complete 022410 Page 5 24 Remove the four bolts mounting the OE rear crossmember to the frame rails and remove the crossmember from the vehicle Fig 7 Discard the crossmember and the hardware 25 Disconnect the vent hose and wiring if equipped from the differential Fig 8 Page 6 022410 26 Using a jack support the differential Loosen and remove the two forward most differential mounting bolts on the driver s side Fig 9 Loosen but do not remove the three rear driver s side bolts Fig 10 and the two passenger s side bolts Fig 11 27 With the differential securely supported remove the remaining bolts and lower the differential from the vehicle 022410 Page 7 28 Using the appropriate puller tool press out the OE rear lower control arm bushings from the frame Refer to individual puller tool instructions for proper operating procedures Another option is to cut the OE bushing flush with the backside of the frame This is needed for clearance of the torsion bar relocation brackets Fig 12 29 The lower control arm bump stop cups must be removed from the frame Using a saw zall or cutoff wheel cut the weld beads holding the bump stop cups to the frame Fig 13 A B Remove the cups and be sure that the surface is ground flush Paint any bare metal to prevent rust Page 8 022410 30 Install the provided passenger s side differential drop bracket 01234 to the origin
14. stall the brake rotor and caliper on the knuckle hub Torque the OE caliper bolts to 130 ft lbs If equipped connect the ABS wire at the frame Place a jack under the lower control arm and raise the arm until the distance from the center of the hub to the edge of the fender is 6 more than measured in the pre installation measurements typically about 28 Torque the lower control arm hardware to 125 ft lbs Note Failure to complete this step will result in premature lower control arm bushing wear as well as poor ride quality Install the new front shocks Attach the shocks to the lower control arm with the OE hardware and to the frame with the provided new hardware Torque the lower bolt to 95 ft lbs and the upper hardware until the bushings begin to swell Reinstall and load the torsion bars Adjust length of adjusting bolts to that recorded at the beginning of the installation Reinstall front wheels Torque to OE specifications see owner s manual Grease rear lower control arm bushings Lower the vehicle to the ground and bounce the front to settle the suspension Check all fasteners for proper torque Recheck all fasteners after 500 miles and at regularly scheduled maintenance intervals Roughly align the front wheels by adjusting the toe to 1 16 1 8 toe in Lock off the jam nuts on the tie rod ends A complete front end alignment is required Recheck the final lift height and compare to the pre installation measurements record
15. the differential 37 Install the new front crossmember 02270 in the OE front lower control arm pockets and loosely fasten with the OE lower control arm hardware Note The offset in the crossmember goes to the front bolts run from front to rear If installing optional dual steering stabilizers the tips must be cut off the bolts for additional clearance 38 Grease and install new bushings and sleeve into the rear crossmember Install grease zerks into crossmember and tighten securely 39 Install the new rear crossmember 02271 The crossmember is attached with 12 x 3 button head bolts Do not put a washer on the head of the bolt Run the bolt from REAR to FRONT and attach with SAE washer and Prevailing Torque Nut It may be necessary to slightly clearance the holes in the frame for the larger than factory bolts do not tighten at this time Fig 16 40 Install the new differential skid plate to the crossmembers with x 1 1 4 bolts and SAE washers BP 618 41 Install the passenger s side skid plate with 1 2 x 1 1 4 bolts and SAE washers Fig 17 Page 10 022410 42 Install the provided hexagon shaped urethane bump stops to the new bump stop extensions 02268 43 Attach the bump stop extension to the frame with 3 8 x 1 1 4 socket head cap bolts and 3 8 SAE washers down through the original bump stop frame mount Use loctite on the threads Use a rag to protect the powdercoat if a wrench
16. y for the installation of this kit PRE INSTALLATION MEASUREMENTS Measure from the center of the wheel up to the bottom edge of the wheel opening FRONT INSTALLATION 1 Park the vehicle on a clean flat surface and block the rear wheels for safety 2 Raise the front of the vehicle and support with jack stands under the frame rails 3 Remove the wheels 4 Measure and record the length of the exposed thread on the torsion bar adjusting bolts for later reference Fig 1 5 Remove the torsion bar adjuster bolt and retainer block CAUTION The torsion bars are under extreme pressure Use the correct unloading tool to remove the pressure on the torsion bars before attempting to remove the assembly Be sure to follow the OE manual and the torsion bar unloading tool literature as to how to unload the torsion bars properly 6 Mark the unloaded torsion bars to indicate passenger s and driver s side Mark both of the torsion bars to indicate the front verses the rear for later installation Mark the rear of the bars relative to the adjusting arms to indicate indexing 7 Pull the torsion bars back out of the lower control arms and remove them from the vehicle 8 Remove the OE shocks Retain the lower mounting hardware Discard the shock and the upper mounting hardware 022410 Page 3 9 Disconnect the sway bar links from the sway bar Retain all bushings cup washers and nuts 10 Remove and discard the OE front skid plate if equ
Download Pdf Manuals
Related Search