COGNITO 7153 Caster Adjustable Radius Arm Kit Instruction Manual

: June 15, 2024
: COGNITO

Table of Contents

COGNITO 7153 Caster Adjustable Radius Arm Kit
Product Usage Instructions
PARTS LISTS
INTRODUCTION
TECHNICAL INFORMATION
INSTALLATION
WARRANTY AND SAFETY
Contact
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COGNITO 7153 Caster Adjustable Radius Arm Kit

COGNITO-7153-Caster-Adjustable-Radius-Arm-Kit-
product

Product Usage Instructions

Step 1: Precautions and Safety Measures

Before beginning the installation, please read the entire instruction sheet. Improper installation may lead to safety risks and damage to the vehicle.

Always wear safety glasses when using power tools.
Take appropriate precautions when working under a vehicle.

Step 2: Technical Information

Check the parts and hardware packages against the parts list to ensure that your kit is complete. Each lift kit and options to lift kits are packaged separately. Therefore, familiarize yourself with specific set of instructions before beginning. Follow the original equipment (OE) specifications when replacing or re-installing OE fasteners, retainers, and hardware specified in the OEM manual.

FAQ (Frequently Asked Questions)

Q: Can I install this product myself?
- A: Proper installation of these components requires a qualified mechanic. It is recommended to seek professional assistance for installation.
Q: Is a lift required for installation?
- A: Yes, a lift is required to perform the installation of these products. Ensure that the vehicle is properly supported before attempting installation to avoid serious injury.
Q: What should I do if my kit is missing parts?
- A: Check the parts list and compare it to the contents of your kit. If any parts are missing, please contact customer support for assistance.

PARTS LISTS

INSTALL INSTRUCTIONS

COGNITO Caster Adjustable Radius Arm Kit
SKU: 120-90408

PARTS LIST FOR SKU: 120-90408

QTY.| PART #| DESCRIPTION
1| 8522| FSD Radius Arm Driver
1| 8523| FSD Radius Arm Passenger
1| 8524| Radius Arm Clevis and Rod End Passenger
1| 8525| Radius Arm Clevis and Rod End Driver
1| HP9164| FSD Radius Arm Pivot Bushing Kit
2| HP9202| FSD Radius Arm Hardware

HP9164 – FSD Radius Arm Pivot Bushing Kit

2509.1

HP9202 – FSD Radius Arm Hardware

QTY.| PART #| DESCRIPTION
4| 6198| FSD Radius Arm Misalignment Spacer
4| H-15267| 9/16”-12 x 3.50 Lg. Cap Screw
4| H-33088| 9/16” SAE Flat Washer
2| H-37270| 9/16”-12 Lock Nut

WARNING: Please read this entire instruction sheet before beginning installation. Proper installation of these components requires a qualified mechanic. Always wear safety glasses when using power tools, and take appropriate precautions when working under a vehicle. If these instructions are not properly followed you may jeopardize your, and your passenger’s safety, and severe frame, suspension or tire damage may also result from improper installation.

INTRODUCTION

Cognito caster adjustable radius arms are an off-road styled, boxed sheet metal design that is a direct replacement for OEM radius arms. The modified axle mounting geometry provides an adjustable caster range thus resulting in excellent ground clearance over OEM arms with drop brackets. This radius arm kit can also be used with Cognito 6” and 8” lifts with a short radius arm drop bracket that provides excellent ground clearance for proper off-road use and style. Caster adjustment is necessary when adding larger tires that warrant caster angle and cross caster adjustments for proper street drivability. The solution from Cognito is a fine adjustment that is easy to make on the truck without having to disassemble any components. The adjustment is on the lower axle mount rather than the upper to prevent the front axle and tires from being pulled rearward during adjustment, which can cause large tires to rub the fender wells or front of the cab.

REQUIREMENTS

Installation requires a qualified mechanic
A lift is required to perform the installation of these products and always ensure the vehicle is properly supported before attempting installation or serious injury may occur.
Read instructions carefully and study the pictures before attempting installation.

TECHNICAL INFORMATION

Check the parts and hardware packages against the parts list to assure that your kit is complete
Each lift kit, and options to lift kits, are packaged separately. Therefore installation procedures are covered in separate instructions. Familiarize yourself with each specific set of instructions before beginning.
Follow the OE specifications when replacing or re-installing OE fasteners, retainers, and hardware specified in the OEM manual

INSTALLATION

Locate the following parts (Figure 1).
- (1) – Super Duty Radius Arm Driver (Part # 8522)
- (1) – Super Duty Radius Arm Passenger (Part # 8523)
- (4) – Poly Bushing (Part # POLY-BUSHING-2509.1)
- (2) – Pivot Crush Sleeve (Part # 5617)
Install (2) poly bushings per radius arm from each side (Figure 2). A light lubricant, WD-40, may be used to install but do not grease the outside of the bushing. Once the bushings are installed in radius arms, then grease the inside bore of each bushing (Figure 3).
Install the crush sleeve by using a press or rubber mallet (Figure 4). Once installed, the crush sleeve should be flush with the bushing faces on both sides of the radius arm (Figure 5).
Locate the following components.
- (1) – Radius Arm Clevis and Rod End Passenger (Part # 8525)
- (2) – FSD Radius Arm Misalignment Spacer (Part # 6198)
- (1) – 9/16″-12 x 3.50 Lg. Cap Screw
- (2) – 9/16” SAE Flat Washer
- (1) – 9/16” Lock Nut
Insert the spacers into the rod end from each side as shown (Figure 7). Install the rod end into the radius arm pivot pocket and assemble using the supplied hardware. The cap screw should be inserted from the outside of the vehicle towards the center with one washer per side of the pivot pocket as shown (Figure 8). Do not tighten at this time.
Before starting step 5, chock the tires and raise the vehicle or support front axle housing at a position so the front tires are just touching the ground (Figure 9). Remove the passenger side OE radius arm by removing the three M18 bolts (A, B, C).
Install the Cognito radius arm by inserting the upper front axle mount into radius arm front pivot pocket (Figure 10). Assemble using the OE M18 bolt previously removed, but do not tighten at this time.
If installing a Cognito 4” Drop Down Bracket Kit (Part # 120-70088), refer to Install Sheet, 7167 before proceeding. Install the rear of the radius arm by inserting the bushings into the frame or drop bracket pivot pocket (Figure 11). Assemble using the OE M18 bolt previously removed, but do not tighten at this time.
Prior to mounting the radius arm clevis, make sure the rod end and adjuster sleeve are threaded all the way into the clevis (Figure 12). Adjust the radius arm clevis length by rotating the adjuster nut until the clevis is aligned with the lower front axle mount (Figure 12). When adjusting, make sure the distance between end of radius arm and rod end does not exceed 1 1/2 in. (Figure 13).
Assemble using the OE M18 bolt previously removed, and tighten all three OE M18 bolts to the OE torque specification (Figure 14). Clamp the adjuster nut by tightening both 3/8-16 socket head cap screws to 35 ft.-lbs. and (1) 9/16-12” x 3.50 Lg. cap screw to 135 ft.-lbs. (Figure 15).
Repeat steps (4 – 10) for the installation of the driver side components listed below:
- (1) – Super Duty Radius Arm Driver (Part # 8522)
- (1) – Radius Arm Clevis and Rod End Passenger (Part # 8525)
- (2) – FSD Radius Arm Spacer (Part # 6198)
- (1) – 9/16″-12 x 3-1/2″ Lg. Cap Screw
- (2) – 9/16” SAE Flat Washer
- (1) – 9/16”-12 Lock Nut

WARRANTY AND SAFETY

WARRANTY / RETURN POLICY / SAFETY

Cognito Limited Lifetime Warranty

Cognito Motorsports, Inc. hereinafter “Cognito,” warrants to the original retail purchaser, that its suspension products are free from workmanship and material defects for as long as the purchaser owns the vehicle on which the product(s) were originally installed. This warranty will be void if any modifications are made to the components, including alterations to the surface finish, i.e.; painting, powder coating, plating, and/or welding, or if they are improperly installed. Cognito truck suspension products are not designed nor intended to be installed on “competition” vehicles used in race applications, stunt or for exhibition purposes that are outside of the intended operating conditions specified by the manufacturer. Racing and competition are defined as any contests between two or more vehicles; or vehicles competing individually on off road circuits in timed events (whether or not such contests are for an award or prize).

This warranty does not include coverage for police, taxi, government or commercial vehicles, and the warranty does not cover Cognito products sold outside of the USA. Cognito’s obligations under this warranty are specified and applied at its sole discretion, and warranty coverage is limited to repair or replacement of the defective product(s). Any and all costs of removal, installation or reinstallation; freight charges, incidental or consequential damages associated with the covered products are expressly excluded from this warranty.

The following items are exempt from Cognito limited warranty coverage: bushings, bump stops, tie-rod ends (Heim joints) and limiting straps. These parts are “consumables” and designed to wear as a normal part of their duty cycle, therefore they are not considered defective when worn. The aforementioned products are warrantied separately against defects in workmanship, for 60 days from the date of purchase. As a condition of warranty validation, respective Cognito suspension components must be installed as a complete system (not combined with non-Cognito hardware or ancillary parts).

Any substitutions or omission of required components will void the warranty. Some minor cosmetic wear and imperfections may occur to parts during shipping, which is not covered under this warranty. This limited warranty does not apply to any components that have been subjected to collision damage, negligence, alteration, abuse, or misuse, and coverage does not extend to products manufactured by third-party companies. Cognito reserves the right to supersede, discontinue, or change the design, finish, part number and/or application of its parts when deemed necessary, without notice.

Return Policy

Product returns will not be accepted without prior written approval from an authorized Cognito representative. All products being returned must be shipped via trackable, prepaid freight. Returned products are subject to a 25% percent restocking fee. The eligible return period for products purchased directly from Cognito is 30 days from the verified date when the product(s) were originally received by the purchaser.

Product Safety Advisory

The installation of Cognito steering and suspension components will modify your vehicle’s original factory equipment and geometry, which may cause it to handle differently than a stock (unaltered) vehicle. Installation of these components is not intended to strengthen nor reinforce the vehicle’s frame, nor are they designed to increase rollover protection. It is necessary to periodically inspect all suspension and drive train components for proper attachment, torque specifications, operation, and for any potential unusual wear or damage. Installation of these parts will modify the height of the vehicle and may raise the center of gravity.

Modifying vehicle height combined with off road operation may increase your vehicle’s susceptibility to rollover conditions, which may cause serious injury or death. Many states regulate allowable vehicle height modifications, and it is your responsibility to know and comply with the legal requirements specified by the laws where you reside. Modifications to your vehicle’s ride height may also affect the ride quality, driver input response, trackability and handling, and wear to your vehicle’s suspension components and tires.