BDS Suspension Installation Instructions
Contents
1. bolts to 50 ft lbs 60 Attach the clevis end of the upper control arms to the front axle mounts Fig 23 The clevis end will angle in toward the center of the vehicle Fasten the arms to the axle with 10mm x 80mm bolts nuts and 3 8 SAE washers BP 715 Leave hardware loose 014850 Page 13 61 Using a provided zip tie attach the differential breather tube to the driver s side upper control arm 62 Locate and drill a 5 16 hole in the center of the front coil spring axle mounts Fig 24 Use a provided 3 8 self tapping bolt 438 to cut the threads for the bump stop extension 3396 Remove the bolt 63 Remove the front OE rubber bump stops and replace with the provided longer ones 3528 or 3529 Apply a small amount of grease to the bump stop and push it into the mounting cup 64 The front sway bar link axle mounts must be cut off to make room for the extended mounts provided These new mounts will provide proper steering linkage clearance once the vehicle is lifted Starting on the driver s side make a cut mark on the axle link mount that is flush with the top surface of the axle coil mount This mark will be approxi mately 2 5 8 from the top point of the link mount Fig 25A B Page 14 014850 65 Cut the link mount along the cut line with a reciprocating saw or cut off wheel Take care to make the cut as straight and square as possible The top portion that is cut from the driver s side mount will2. Attach the shock to the axle with the OE hardware Torque upper nut until the bushings begin to swell and install the jam nut Torque the lower OE hardware to 25 ft lbs 81 Install the provided disconnect ball studs 01302 in the mounts so that the ball portion points toward the center of the vehicle Fig 33 Install the stud with a 4 lock nut and two 1 2 SAE washers BP 718 one on each side of the mount Torque stud to 60 ft lbs Page 18 014850 82 Install the provided upper u bracket 01325 to the sway bar using the original link mounting hole with a 7 16 x 1 1 2 bolt nut 7 16 SAE and 7 16 USS washers BP 718 Install the bolt up through the u bracket with an SAE washer into the sway bar Fasten with the nut and USS washer Position the bracket so that the thru holes are parallel with the stud on the axle Fig 34 Torque to 50 ft lbs 83 Locate the new provided sway bar disconnect assemblies A100 Lightly grease and install the provided sleeves 45313 in the bushings 84 Attach the sway bar link assembly to the upper u bracket with the provided 3 8 x 2 1 2 bolt nut and 3 8 SAE washers BP 718 running from the inside out Torque bolt to 30 ft lbs Leave the sway bar links disconnected at this time 85 Install the provided new track bar bracket 01398 to the driver s side frame with the original hardware Torque the factory hardware to 60 ft lbs starting with the lower bolts Fig 35
3. 014850 Page 19 86 87 88 89 90 91 92 93 94 95 96 97 98 99 Grease and install the provided track bar bushings M02888RB and sleeve 51792 in the new track bar assembly A161 The exact length will be adjusted at the end of the installation Install the provided grease fitting 516 in the adjustable end of the track bar Install the new track bar assembly to the original steering stabilizer axle mount with a 1 2 x 2 1 2 bolt nut and washers BP 440 so the track bar runs up toward the new frame mount Leave hardware loose The frame end will be attached at the end of the installation Attach the drag link to the pitman arm with the original castellated nut and new provided cotter pin BP 715 Torque nut to 50 ft lbs Do not loosen the nut to install the cotter pin only tighten Steering Stabilizer Installation Q Using OE cylinder Attach the loose end of the cylinder to the new stabilizer bracket on the axle with the OE hardware Run the bolt from the back forward and torque to 60 ft lbs Q Installing new cylinder Install the provided bushings in the new stabilizer cylinder Install the provided sleeve 0 625 x 0 060 x 1 375 in the body end of the cylinder Attach the body end of the stabilizer to the new stabilizer bracket with the original stabilizer hardware Run the bolt from the back forward Torque bolt to 60 ft lbs Attach the opposite end of the cylinder to the drag link with the
4. 32 Support the front axle with a hydraulic jack 33 Remove shocks retain lower shock hardware 34 Remove OE sway bar end links and discard Fig 14 014850 Page 9 35 Disconnect the steering stabilizer from the axle and retain hardware If replacing remove the steering stabilizer from the drag link by removing the nut and dislodging the tapered stud with a pickle fork Fig 15 _ A ay alas de gt es ew 7 ii hil itd e i te oan i REA z ir 36 Disconnect the track bar from the axle Fig 16 Disconnect the OE track bar frame bracket from the driver s side Remove the four bolts nuts and remove the bracket and track bar from the vehicle Save the frame mount hardware Page 10 014850 37 38 39 40 41 42 43 44 45 46 47 Disconnect drag link from pitman arm retain hardware Use a pickle fork to dislodge the drag link from the pitman arm Mark the relationship between the pitman arm and the steering box sector shaft Remove the pitman arm mounting nut and washer Retain hardware Using the appropriate pitman arm puller remove the OE pitman arm and install the new provided drop pitman arm 084601R using the alignment marks to ensure it is indexed properly Fasten with the OE nut and washer and torque to 185 ft lbs Remove brake line retaining clips Remove fasteners holding brake line anchors to frame on driver s and passenger s side Disconnect passenger s sid
5. 4 from center of eye to center of eye 54 Thread the provided jam nut followed by the provided assembled flex end 01374 onto the upper control arm 01373 Install the provided grease fittings in the flex ends Fig 20 Adjust the length of the control arm so that it is 28 3 8 from center of eye to center of clevis Slide bolt through clevis end to get this measurement 55 Install the adjustable end of the lower control arms into the new lower control arm pockets in the crossmember Fig 21 Loosely fasten the arms with 9 16 x 4 1 2 bolts nuts and 9 16 SAE washers BP 715 Note Apply a small amount of grease to the faces of the bushings to aid in installation of the control arms Page 12 014850 56 Loosen but do not remove all the OE upper and lower control arm mounting bolts 57 With the front axle properly supported remove the lower control arms from the frame and the axle Retain the axle mount hardware 58 Install the new lower control arms in the axle mounts and loosely fasten with the OE hardware 59 Install the new upper control arms into the new upper control arm pockets in the crossmember Fig 22 Fasten the arms with 7 16 x 3 1 2 bolts and 7 16 SAE washers BP 715 into the welded nut on the crossmember Use Loctite on the bolt threads Note In some cases it may be necessary to loosen the exhaust to gain clearance for installing the passenger s side control arm bolt Torque the 7 16
6. Page 5 15 16 17 18 19 20 21 A Thread a 10mm x 40mm bolt and 3 8 oversized washer BP 715 in the front hole on each side of the crossmember just a couple of turns to help square it to the frame and snug the 10mm x 30mm bolt so the crossmember is setting tight to the bottom of the frame Remove the front 10mm x 40mm bolt and washer Locate the provided crossmember side support plates 01371 01372 These parts are driver s and passenger s side specific Identify the correct side by matching the large relieve in the brackets to the existing bolt holding the crossmember The relief in the bracket will clear the bolt head Attach the side support plate so that they sandwich the crossmember between themselves and the frame Fig 7 Attach the brackets with 10mm x 40mm bolts and 3 8 oversized washers BP 715 in the forward most and rearward most holes in the side plates crossmember Ensure that the side plates are flush against the side of the frame and snug hardware With the side plates in position mark the center of the two side mounting holes to be drilled The rear hole is larger than the front hole With the side support mounting holes marked remove the two outer 10mm bolts and remove the side supports from the vehicle Drill a 7 16 hole at the front mark for the side plate Only drill through the first layer of the frame Do not drill all the way through the frame Drill a 7 16 hol
7. 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 fuel lines fuel tank floor boards and wiring harness Check steering
8. 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 2 2013 014850 Page 1 PARTS LIST FRONT Qty in for 124654 only Part 034852 O84601R 01370 715 01371 01372 01377 01378 22 01373 01374 36270 01375 01383 01468 36274 3523RB 61 60107 A161 01398 MO2888RB 51792 516 Page 2 014850 2 1 1 1 2 2 4 2 2 2 4 2 2 6 k Q D D DIDNIN RN ONNNNDNDN BRP eR Bee KF DH Qty Description Coil Springs Pitman Arm Long Arm Crossmember Bolt Pack 9 16 12 x 4 1 2 bolt 9 16 12 prevailing torque nut 9 16 SAE flat washer 7 16 SAE flat washer 7 16 14 x 3 1 2 bolt 10mm 1 50 x 80mm bolt 10mm 1 50 x 40mm bolt 10mm 1 50 x 30mm bolt 10mm 1 50 prevailing torque nut 3 8 heavy duty oversized flat washer 3 8 USS flat washer 3 8 16 x 1 1 2 self tapping bolt 7 16 14 x 4 1 2 bolt 7 16 prevailing torque nut 7 16 14 x 1 1 4 bolt 12 x 3 4 self drilling hex head Screw W
9. 6 USS flat washer 10 16 x 5 8 self drilling screw Bump Stop 1987 1996 Only Bump Stop 1997 2001 Only Front Brake Line Brake Line Clip Brake Line L Bracket Crush Washer Zip Tie Description Rear Brake Line Brake Line Clip Zip Tie XJ Rear Shackle Rear Shock Mount Shock Stud Kit 5 16 x 1 Self Tapping Bolt 2 Tapered Block 0 750 x 0 095 x 3 140 Sleeve 0 750 x 0 095 x 2 750 Sleeve XJ Spring Bushing small eye XJ Spring Bushing large eye XJ Shackle Bushing Straight Grease Zerk U bolts High Nuts and Washers GLOSSARY OF TERMS OE Original Equipment SAE washer Small OD tight fit to bolt of same size USS washer Larger OD then SAE loose fit on bolt of same size ft lbs Foot Pounds standard torque units INSTALLATION INSTRUCTIONS Note This suspension system is design for use with 4 0 L 6 cylinder engine automatic transmission equipped vehicles only With this setup the transmission crossmembers will be positioned approximately 14 from the back of the OE lower control arm pocket This dimension can be checked to ensure the proper fitment of this suspension system on your vehicle 014850 Page 3 FRONT INSTALLATION l Ce eS y 6 8 Measure and record the distance from the center of the wheel to the bottom of the fender opening LF RF RR LR Park the vehicle on a clean level surface and block the rear wheels for safety Safely raise the front of the vehicle and support with jac
10. D EA Gage 491 W Garfield Ave Coldwater MI 49036 Phone 517 279 2135 Web live chat www bds suspension com Uh i K SUSPENSION E mail tech bds suspension com Part 014850 Product 8 5 Long Arm Suspension System Application 1987 2001 Jeep Cherokee XJ 4 0L 16 quto trans 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 INSTALLATION NOTES 1 Special literature required OE Service Manual
11. be used as a template for the passenger s side Also making a square cut here will help with setting up the welding process later on 66 With the driver s side link mount removed use the cut portion as a template by aligning the hole and the profile of the cut piece with the passenger s side mount Mark the cut line on the passenger s mount Fig 26 Note A 1 2 bolt can be inserted in the mounting holes of the ends to aid in aligning them 67 Cut the passenger s side link on the cut line in the same fashion as the driver s side 68 With the link mounts cut go through and remove any corrosion oil etc from the remaining portion of the OE link mounts as well as on the top of the OE stabilizer mounting bracket pass side The surfaces must be corrosion oil free to promote quality welds Important Installation Note A certified welder should perform all welding operations This step can be skipped until the vehicle is complete and can be carefully driven to a local welding shop if need be Always keep a fire extinguisher near by when welding Discon nect both the positive and negative battery cables before welding 69 Position a provided new link mount 01360 on the cut surface of the original driver s side mount The front edge of the new mount should be flush with the front cut edge of the old mount The inside surface of the link mount should also be flush parallel with the inside surface of the original mount Tack we
12. e at the rear mark for the side plate Drill outside and inside layers of the frame Drill straight in the frame as square as possible to the bottom surface of the frame CAUTION BE CERTAIN that all the fuel lines brake lines etc are clear from the area being drilled Page 6 014850 22 With the rear thru hole drilled to 7 16 go back with a 5 8 drill or a uni bit works well too and drill just the outside layer of the frame You will now have a 7 16 and a 5 8 hole in the outside of the frame and a single 7 16 hole on the inside Fig 8 23 Install the side supports back into position with the same hardware as before Lightly snug the hardware Install the provided nut tab 01377 01378 in the slotted hole in the frame in front of the side support Fig 9 back to the 7 16 hole drilled earlier the nut tabs are driver s and passenger s side specific to match the angle of the slot Loosely fasten the side support with a 7 16 x 1 1 4 bolt and 3 8 USS washer BP 715 into the nut tab Note Holding the nut tab with vise grip pliers eases installation 24 Insert the provided 5 8 x 3 5 8 frame crush sleeve 22 1 in the 5 8 hole just drilled in the frame Fig 10 Do not push it all the way in at this time 014850 Page 7 25 Install a 3 8 USS washer on a 7 16 x 4 1 2 bolt BP 715 and insert it into the frame crush sleeve Push the bolt and sleeve all the way into the frame so that
13. e just inside of the leaf spring u bolt Fig 40 Leave enough room between the u bolt and the bracket to weld about 1 2 3 4 Note The driver s side mounts to the back side of the axle and the passenger s side to the front 014850 Page 23 ACER oh Toes b i Iig See H 4 t al rs t 7 ra 29 Position the new shock mounts so the flat shock mount surface is parallel to the centerline of the shock Fig 41 This will ensure that the shock bushing will run square in the shock eye at ride height Tack the brackets into position 30 With the brackets in position go back and fully weld them to the axle tube Allow the brackets axle to cool and paint all exposed metal to prevent corrosion 31 Install the provided shock stud P00932 on the bracket with the provided hardware Torque nut to 55 ft lbs 32 Install the shock on the new stud and fasten with the provided hardware Fig 42 Torque hardware to 40 ft lbs Page 24 014850 POST INSTALLATION 1 Bleed brakes starting with the wheel furthest away from master cylinder 2 Go back through and grease all new greasable components control arms track bar shackles These components should be serviced regularly and after off road use Double check all fasteners for proper torque 4 Check all moving parts for clearance Complete a full radius turning check to ensure that no interference occurs Adjust front wheel toe in and center steering wheel 6 Recon
14. e rubber brake line from metal hard line Disconnect brake line from caliper and discard crush washers retain the OE banjo bolt Ensure old washer is removed from caliper and brake line mounting area Install new upper brakeline bracket BO6103C with OE bolt Mount hard line into new bracket before installing new stainless steel line Install BDS front brake line 22510 by attaching upper portion first Tighten securely Fig 17 Install lower portion with provided new crush washers and original banjo bolt Note One washer is required on EACH side of the fitting Brake line must face up after installation Torque bolt to 20 ft lbs Fig 18 014850 Page 11 48 Repeat brake line installation for driver s side 49 If equipped remove the lower coil spring retainer clips from the axle Fig 19 Retain clips and bolts 50 Lower the front axle and remove the front coil springs from the vehicle 51 Grease and install the provided bushings 8523RB and sleeves 61 1 in the lower control arm 01375 and adjustable lower control arm ends 01468 Note If using flex end style lower control arms follow same instructions as the standard ends The flex ends came pre assembled 52 Install the provided 90 degree grease fittings 60107 in the lower control arms and control arm ends 53 Thread the provided jam nut followed by the adjustable end onto the lower control arm Adjust the length of the control arm so that it is 32 3
15. et toward the rear 3 and mark on the top of the bracket Fig 31 Make a line along the top of the bracket parallel to the front face at the 3 marked distance This will be a reference line for installing the new stabilizer mount support gusset 014850 Page 17 74 Position the new provided stabilizer mount 01354 on the top of the original mount so that the hole is to the driver s side and the front surface is aligned to the line marked on the top of the OE bracket Fig 32 The will butt up to the passenger s side link mount that was just installed 75 Check that the stabilizer mount is perpendicular to the top of the OE mount and position against the link mount and tack weld in place Double check the position and finish weld the mount to the OE bracket and the link mount 76 With all welding complete allow the brackets to cool and then paint any raw metal to prevent corrosion 77 When the paint is dry on the new link mounts install the new BDS coils 034852 with the provided lower bump stop 3396 inside the spring Rotate the spring until the end is seated correctly in the axle mount 78 If equipped install the OE coil retainer clips with the original bolts Torque to 25 ft lbs 79 Attach the bump stop extension with the provided 3 8 x 3 1 2 bolt and 3 8 USS washer BP 438 Torque to approximately 30 ft lbs 80 Install the new BDS shocks in the vehicle with the provided upper stem bushings washers nuts
16. exposed metal to prevent corrosion REAR INSTALLATION i 2 3 Block the front wheels Safely raise the rear of the vehicle and support with jack stands for safety Remove wheels Place a floor jack under the rear axle for support and remove the rear shocks Retain the upper mounting hardware Note The upper shock mount bolts are prone to corrosion Take care in removing the bolts as they can break easily Use plenty of quality penatrating oil on the threads prior to disassembly Remove sway bar mounts from the body Remove the two bolts mounting the parking brake bracket from the driver s side frame Fig 37 Allow it to hang free 014850 Page 21 10 11 12 13 14 Measure back 3 1 2 from each of the two bracket mounting holes and mark Drill a 1 4 hole at each mark This will be the new mounting location for the bracket It will be reattached at the end of the installation with the new provided 5 16 x 1 self tapping bolts Remove retaining clip holding brakeline to driver s side frame Disconnect rubber brake line from hard line at retaining clip location Disconnect hardlines from brake line junction block on axle Unbolt brake line junction block from axle Retain bolts Install new BDS rear brake line 22512 in place Torque to 25 ft lbs Reattach axle breather Install new retaining clip Locate the factory lower shock mounts on the axle These must be removed from the axle tube completely to make roo
17. ire Clamp Mountable nylon cable tie 1 8 x 1 1 4 cotter pin Side Support Plate drv Side Support Plate pass Nut Tab drv Nut Tab pass Crush Sleeve Upper Control Arm Upper Control Arm End assembled 1 Jam Nut Lower Control Arm Lower Control Arm Flex End assembled Lower Control Arm End 1 1 4 Jam Nut Lower Control Arm Bushing 0 875 x 0 156 x 2 620 Grease Zerk Front Track Bar Assembly Track Bar Bracket Track Bar Bushing Track Bar Sleeve Grease Fitting 440 01360 01361 01354 3396 438 A100 01302 45313 01325 718 3529 3528 22510 5188 BO6103C CCW 03 050 099000 REAR Part 22512 5188 099000 01312 01475 POO932 B561G2 2KB W96 51 52 M02402RB M02403RB 3533RB 516 1 1 1 4 1 1 2 2 1 2 1 2 2 2 2 1 2 4 2 2 2 4 2 2 2 2 2 2 2 2 2 2 4 3 ty RNOUARRBRANNNNNNHPH HAD Bolt Pack Track Bar 1 2 13 x 2 1 2 bolt 1 2 13 prevailing torque nut 1 2 SAE flat washer 12mm 1 75 x 80mm bolt 12mm 1 75 prevailing torque nut Sway Bar Link Mount Sway Bar Link Mount Gusset Weld on Stabilizer Bracket Front Bump Stop Spacer Bolt Pack Bump Stops Sway Bar Link Assembly Disconnect Stud 0 625 x 0 109 x 1 375 Sleeve Sway Bar Link Bracket Bolt Pack 1 2 20 prevailing torque nut 1 2 SAE flat washer 1 2 20 jam nut 3 8 16 x 2 1 2 bolt 3 8 16 prevailing torque nut 3 8 SAE flat washer 7 16 14 x 1 1 2 bolt 7 16 14 prevailing torque nu 7 16 SAE flat washer 7 1
18. k stands under the frame rails Remove the front wheels Locate the plastic retaining clip on the inside of the driver s side uni body frame rail Fig 1 This clip will be holding 4 lines hoses Remove the lines hoses from the clip and remove the clip from the body The two steel lines fuel and brake will be reattached with the provided clips and self drilling screws Disconnecting the front drive shaft from the differential will make this easier but is not necessary The remaining plastic lines will be fastened to the new crossmember after it is installed Locate the hole in the frame where the original plastic retaining clip was installed Install the brake hard line to the frame with the provided clip and self drilling screw just ahead 1 2 max of the existing hole in the frame Fig 2 Position the line up against the floor with the clip mounting tab pointing down Carefully reform the brake line as needed Tighten screw securely Attach the fuel line in the same manner as the brake line Position the clip directly below the brake line clip with the mounting tab pointing up Fig 2 This will make the fuel line run low close to the uni body pinch weld Note These line locations provide clearance for the new upper control arm mounting bolt Page 4 014850 9 Remove the four transmission mount nuts from the transmission crossmember Fig 3 Retain hardware 10 With a hydraulic jack lift the transfer case transmission a
19. ld the new link mount in place Fig 27A B Double check to see that the new mount is square with the original Note It is recommended to grind a bevel in the edge of the new link mount outside where it meets the original mount to promote good weld penetration of both pieces of material 014850 Page 15 70 Repeat the link setup procedure on the passenger s side of the vehicle Fig 28 With both pieces tacked in place check the relationship between the two mounts to see that they are the same Measure the inside distance between the tops of the links and the bottoms of the links to see that they are the same approximately 38 1 2 71 With the links positioned correctly locate the provided formed side gussets 01361 Position the gussets so that they are parallel to the front surface of the original link mount and flush to the outside surface of the new link mount Fig 29 Once they are in the desired position tack weld the gussets in place Page 16 014850 72 With the link mount parts correctly in place finish weld the components to the axle Weld all around the point where the original mount meets the new mounts as well as the full length of the gusset where it meets the new and original link mounts Fig 30 Note Weld the back side of the gusset for best weld penetration and aesthetics 73 Locate the top of the original stabilizer mount on the passenger s side of the axle Measure from the front edge of the brack
20. links and fold them up against the sway bar Clip the provided lanyard clip assembly around the sway bar end link and find the best position for mounting the lanyard This position will vary from vehicle to vehicle Use your best judgment Use the provided self drilling screws to mount the lanyard to the body frame Page 20 014850 100 With the lanyards installed reconnect the sway bar links to the axle The lanyards can be reattached to themselves so that they remain out of the way of moving parts when not in use Front Lower Control Arm Pockets Note This suspension system does not require the removal of the OE lower control arm pockets Under normal driving conditions and l 2 offroad use the new lower control arms will not contact the OE lower control arm pockets However heavy impacts such as jumping can potentially cause contact between the arms and the pockets Also if the front bump stops are not installed per these instructions contact can occur under compression Use your best judgment on whether the pockets should be removed or not These pockets are no longer needed once this install is complete Some individuals will remove the pockets purely for appearance purposes Mark a cut line on the two lower control arm pockets that follow the contour of the frame Fig 36 Using a recipro cating saw or cut off wheel remove the pocket from the frame Take care not to cut into the frame Grind the cut edges smooth Paint all
21. m for the new high clearance shock mounts Carefully cut the brackets off of the axle tube Fig 38 Take care not to cut into the axle tube Grind axle surface smooth The new mounts will be installed at the end of the installation 15 Apply a small amount of grease to bushings 8533RB and install bushings sleeves 52 and grease zerks into the 16 new shackles 01312 Grease and install bushings into leaf spring eyes M02402RB amp M0O2403RB then install sleeves 52 amp 51 Note The longer sleeves 51 go in the large spring eye bushings Page 22 014850 17 With the rear differential supported remove the passenger side spring mounting bolts u bolts shackle and springs Save leaf spring and shackle mounting bolts for later installation Note Once all of the u bolts are removed the sway bar can be disconnected from the frame and removed from the vehicle It will not be reused 18 Locate the bumper bolt that is protruding into the shackle pocket Fig 39 This bolt will contact the new larger 19 shackle through suspension travel The bolt can either be cut off flush with the welded nut on the body or removed Install the new spring and shackle in the OE locations with the original hardware Leave the spring and shackle bolts loose at this time The shackle grease fittings should be toward the front of the vehicle Note The system is designed to be use with a slip yoke eliminator kit and new CV style dri
22. nect the positive and negative battery cables 7 Align headlights 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 014850 Page 25
23. new provided stud and hardware Torque stud the large stud nut to 55 ft lbs and the small nut to 40 ft lbs Use zip ties to fasten brake lines clear of any rotating or heated components Install wheels Remove the jack stands and lower the vehicle to the ground Bounce the front of the vehicle to settle the suspension Visually check to see that the front axle is centered under the vehicle Turn the steering wheel back and forth to help center Adjust the track bar until the proper length is set so the track bar end will mount into the new frame bracket Fasten in the mount with a 12mm x 80mm bolt nut and 1 2 SAE washers Torque hardware to 65 ft lbs Check that the track bar end is square in the frame mount and lock off the jam nut securely Torque the track bar axle mount hardware to 69 ft lbs Lock off upper and lower control arm jam nuts securely Ensure the flex ends are square to the pockets before tightening Torque the lower control arm bolts to 95 ft lbs Torque the upper control arm bolts at the axle to 40 ft lbs Ensure the vehicle setting level on the ground Pull the spring collar up of the disconnect ends and attach them to the ball studs on the axle Make sure the disconnect end stud is square with the ball stud and tighten the jam nut against the disconnect end These disconnects allow for 1 2 adjustment 1 2 longer from full bottomed out Check the jam nuts to be sure they are securely locked off Disconnect both end
24. ssembly just enough to relieve pressure from the trans mission crossmember 11 Remove the nuts bolts retaining the crossmember to the frame and remove the crossmember from the vehicle Fig 4 Note If equipped with a factory installed transfer case skid plate remove that as well Fig 5 It will not be reused 12 Some models may use a combination of threaded studs nuts and bolts to fasten the OE crossmember Fig 4 If this is the case the threaded studs must be removed The studs can be removed by either clamping vise grips on it using the double nut method or tack welding a nut to the stud and using a wrench to remove it 13 Locate the third threaded hole in the uni body rails just ahead of the two that were used to mount the OE crossmember Fig 4 Ensure that the threads are clean of dirt and rust 1Omm 1 5 These holes will be used to mount the new crossmember in conjunction with the original two holes per side 14 With the help of an assistant place the crossmember 01370 up to the uni body and align the front threaded hole in the body with the front mounting hole in the crossmember Loosely attach the crossmember to the frame with a 10mm x 30mm bolt and 3 8 USS washer BP 715 in the second hole from the front of the crossmember on each side of the vehicle Fig 6 Note Make sure that the remaining loose plastic lines on the driver s side are to the inside of the upper control arm mount on the new crossmember 014850
25. the sleeve is against the inside surface of the frame and the bolt is sticking out of the inside 7 16 hole Fasten the bolt on the inside of the frame with a 3 8 USS washer and 7 16 nut from bolt pack 715 Fig 11 Leave hardware loose Ensure that the bolt does not hit the fuel or brake lines Reform these lines as necessary 26 Locate the second hole from the rear of the crossmember Fig 12 on both sides Using the crossmember hole as a guide mark and drill the hole to 5 16 Page 8 014850 27 28 29 30 3l Apply Loctite to the threads of a 3 8 x 1 1 2 self tapping bolt and 3 8 oversized washer BP 715 and install in each of the drilled holes in the bottom of the frame one on each side Torque bolt to 30 ft lbs Remove each of the 10mm bolts one at a time and apply Loctite to the threads Reinstall the bolts and torque to 40 ft lbs With all of the main crossmember bolts tight go back and torque the four 7 16 side plate bolts to 50 ft lbs Lower the transmission mount onto the crossmember by aligning the studs in the slots Fasten the mount to the crossmember with the OE nuts and torque to 25 ft lbs Go back and check the clearance of all the lines running down the driver s side of the frame Attach the plastic lines to the crossmember with the mount style wire tie BP 715 by pushing the wire tie into the 4 hole in the upper control arm mount and securing the lines Fig 13
26. ve shaft The shims installed on the leaf 20 21 22 23 24 29 26 27 28 springs are set to provide the appropriate drive line angles for most slip yoke CV driveshaft setups If additional different shims are required they can be purchased separately from BDS Position the provided 2 tapered block between the axle and leaf spring by align the center pins holes The short end of the taper should go toward the front of the vehicle Install the new provided u bolts and hardware Snug hardware Notes Do not torque to specification until vehicle is on the ground In some cases it might be necessary to slightly clearance the holes in the OE spring plate to allow the u bolts to install smoothly Repeat for driver s side Install the new provided shocks to the upper shocks mounts with the original hardware Torque to 20 ft lbs Leave the lower portion of the shock hanging at this time Reattach the parking brake bracket to the driver s side frame using the provided 5 16 x 1 self tapping bolts in the newly drilled holes Torque bolts to approximately 15 ft lbs Install wheels Remove jack stands and lower vehicle to the ground Bounce vehicle to normalize rear suspension The shackles will now be in their intended position Torque shackle and leaf spring bolts to 95 ft lbs Torque u bolts to 75 90 ft lbs Locate the new lower shock mount brackets 01475 The new mounts should be positioned on the lower half of the axl
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