2013 and up Dodge 2500/ Stage Rear Install Instructions

Transcription

1 D2RX Highway 92 - Oskaloosa, IA phone: fax: and up Dodge 2500/ Stage Rear Install Instructions

2 1. Remove the spare tire. 2. Remove the rear bumper. NOTE: The truck box does not need to be removed. The pictures were taken during the design process. 3. Place a jack under each side of the truck frame in front of the rear wheels. Jack the truck up enough so the wheels are just off the ground. Next remove the bolt that holds the leaf spring shackle to the shackle hanger. Set this bolt aside as it will be used in step 8. Next lower the truck down so the shackle is a few inches above the shackle hanger. Use a torch, saw, or plasma cutter to cut the shackles off the frame as shown in the picture below. Make sure to cut the shackles off and DO NOT CUT INTO THE FRAME! NOTE: The leaf springs are removed in the pictures below for design purposes. You will not remove yours springs.

3 4. Now grab your bumper and it is required to trim part of the mounting system. Remove the corner bracket. It will not be reused. Mark each side of the inner bumper mounting structure like the pictures below. Use a cutting wheel to cut off the part that needs to be removed. Be careful not to cut into the bumper. Feel free to remove the entire substructure from the bumper if it makes you feel more comfortable.

4 5. Now that the leaf springs perches are removed locate the upper air bag mounts (part #18205 DS and PS). Remove the 3 factory 14mm bolts from each side of the hitch. Next place the upper bag mounts in place and fasten them to the frame/ hitch assembly with the 14mm x 120 bolts. Torque these to 115 ft/lbs. 6. Locate the 5323 air bags. Locate the air line fitting and tighten into the port. Next slide the bags into the upper air bag mounts and fasten with the 1/2 and 3/4 nuts and lock washers. Torque to 25 ft/lbs. 7. Next locate the swing arm (part #18212). Use the 5/8 x 6 bolts and one flat washer to fasten the swing arm into the upper bag mounts. Make sure to slide the bolts in from the outside in. Just leave the bolt in place for now. Use a 5/8 washer to shim if there is a 3/8 or larger gap on one side of the bushing. You will add washers, limiters (part#18243) and the lock nut in step Slide the swing arm up so the ears on the end line up with the leaf spring shackle. It may be necessary to jack the truck up or lower it to get everything to line up. Once you get the swing arm ears lines up with the shackle hole, connect the with the factory shackle bolt. NOTE: MAKE SURE TO RUN THE BOLTS FROM THE INSIDE OUT SO THE HEAD OF THE BOLT IS ON THE FRAME SIDE. 9. Locate the 1/2x 3 1/2 bolts, flat washers and lock nuts. Insert the bolt through the bottom of the swing arm up through the bottom of the airbag. You may have to wiggle the bottom of the air bag to get everything to align up. Once the bolt is started, torque to 30 ft/lbs. NOTE: DO NOT OVERTIGHTEN OR YOU RISK DAMAGE TO THE AIR BAG. 10. Locate six 5/8 flat washers, the two limiters (part# 18234) and two 5/8 lock nuts. Go back to the 5/8 bolts that fasten the swing arm to the upper bag plates. Place 2 flat washers over each bolt. Next slide the limiters over the bolts. The function of the limiters is the stop the swing arm from over extending when removing a trailer or when lifting the vehicle on a post lift. Once the limiters are installed put on another 5/8 flat washer and lastely the 5/8 lock nut. You will torque this bolt to 150 ft/lbs once the air controls are wired up and the truck is at ride height. NOTE: RIDE HEIGHT IS WHEN THE BOTTOM SWING ARM IS LEVEL WITH THE GROUND, BOTH EMPTY AND LOADED. 11. Locate the over load pads (3500 only) (part# DS and PS). With no load on the leaf springs, use a large clamp to pull the overload spring down. Slide the clamp over the top and tighten. 12. Use the supplied instructions for whichever air control kit you have purchased.

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7 Item No. Part Number Description Qty Driver Side Top Frame Mount Passenger Side Top Frame Mount Dodge Swing Arm (G5) 1 4 F5323 Firestone Air Bag F Limiter Passenger Side Overload Bracket Driver Side Overload Bracket 1 8 Hex bolt M14 x 2.0 x S M14-2.0x120 Hex Cap DIN 931 GR.10.9 Z&Y 6 9 Bolt-1/2-13x3 1/2 GR5 Bolt - 1/2-13 x 3 1/2 HEX CAP GR Bolt-1/2-13x5 GR5 Bolt - 1/2-13 x 5 HEX CAP GR Bolt-5/8-11x6 Bolt - 5/8-11 x Washer - 1/2 SAE MIL-CARB ZINC /16 SAE MIL-CARB WASHER ZINC Washer - 5/8 SAE MIL-CARB ZINC 8 15 Nut,Lock 5/8-11 GRB Zinc Lock Nut - 5/8-11 GRB Zinc 2 16 Nut, Hex-1/2-13GR5 Hex Nut - 1/2-13 GR Nut, Hex Jam-1/2-13GR5 Hex jam nut - 1/2-13 GR Nut, Hex Jam-3/4-10 Hex jam nut - 3/ Regular LW Regular LW 0.5 4