FABTECH FT23230 6 Inch Performance Lift Kit Instruction Manual

INSTALLATION INSTRUCTIONS

2019-2021 DODGE RAM 1500 2WD
6” BASIC & PERFORMANCE SYSTEMS
FTS23230

NOTE: TO ORDER WEARABLE REPLACEMENT COMPONENTS DO NOT USE PART NUMBERS SHOWN ON THIS INSTRUCTION SHEET. GO TO FABTECH WEBSITE AND LOOK UP WEARABLE REPLACEMENT PARTS TO FIND THE PROPER PART NUMBER TO ORDER.

FTS23038 SPACER KIT

2| FT44209BK| 6” SHOCK SPACER
FT44546 – HARDWARE KIT| LOCATION
---|---
6| 8” ZIP TIE|
5| 1/4-20 X 3/4” HEX BOLT|
8| 1/4” SAE WASHER|
3| 1/4-20 NYLOCK NUT|
2| 5/16-18 X 1” SELF-TAPPING BOLT|
6| 3/8-16 C-LOCK NUT|
6| 3/8” SAE WASHER|
26| 7/16” SAE WASHER|
1| 7/16” LOCK WASHER|
15| 7/16-14 C-LOCK NUT|
5| 7/16-14 X 1-1/4” HEX BOLT|
6| 7/16-14 X 1-1/2 HEX BOLT|
2| 9/16” SAE WASHER|
1| 9/16-12 C-LOCK NUT|
1| 9/16-12 X 3” HEX BOLT|
4| 5/8-11 X 5-1/2 HEX BOLT|
8| 5/8” SAE WASHER|
4| 5/8-11 C-LOCK NUT|
8| 1/4-28 GREASE FITTING|
2| CLAMP|
2| THREAD LOCKING COMPOUND|
3| 1/2-13 X 1-1/4 HEX BOLT|
2| 1/2-13 X 2-3/4 HEX BOLT|
22| 1/2 SAE WASHER|
8| 1/2-13 C-LOCK NUT|
2| 1/2-13 X 2-1/4 HEX BOLT|
2| 1/2-13 X 1-1/4 HEX BOLT|
4| 1/2” SAE WASHER|
2| 1/2-13 C-LOCK NUT|
6| 1/2-13 X 1-1/2 HEX BOLT|
11| 1/2” SAE WASHER|
5| 1/2-13 C-LOCK NUT|
1| 7/16” SAE WASHER|
4| M12-1.75 X 70MM HEX BOLT|
8| M12 FLAT WASHER|
4| M12-1.75 C-LOCK NUT|

 TOOL LIST

Required Tools (Not Included)

• Basic Hand Tools
• Floor Jack
• Jack Stands
• Assorted Metric and S.A.E sockets, and Allen wrenches
• Torque Wrench
• Die Grinder w/ Cutoff Wheel or Sawzall

PRE-INSTALLATION NOTES

For technical assistance call: 909-597-7800 or e-mail: [email protected]

READ THIS BEFORE YOU BEGIN INSTALLATION –
Check all parts to the parts list above before beginning installation. If any parts are missing contact Fabtech at 909-597-7800 and a replacement part will be sent to you immediately.
Read all instructions thoroughly from start to finish before beginning the installation. If these instructions are not properly followed severe frame, driveline, and/or suspension damage may occur.
Check your local city and state laws prior to the installation of this system for legality. Do not install if not legal in your area.
Prior to the installation of this suspension system perform a front-end alignment and record. Do not install this system if the vehicle alignment is not within factory specifications. Check for frame and suspension damage prior to installation.
The installation of this suspension system should be performed by two professional mechanics.
This suspension must be installed with Fabtech shock absorbers.
Use the provided thread locking compound on all hardware.
WARNING- Installation of this system will alter the center of gravity of the vehicle and may increase rollover as compared to stock.
Vehicles that receive oversized tires should check ball joints, uni balls, tie rod ends, pitman arm, and idler arm every 25005000 miles for wear and replace as needed.
Verify differential fluid is at the manufactures recommended level prior to kit installation. Installation of the kit will reposition the differential and the fill plug hole may be in a different position. (For example, if the manufacturer recommends 3 quarts of fluid, make sure the diff has 3 quarts of fluid). Check your specific manual for the correct amount of fluid.

FOOTNOTES:

• Can not use OEM wheel and tire
• Will not fit factory air suspension vehicles
• Must use aftermarket 20” wheels or larger
• Does not fit vehicles equipped with OEM 22” wheel & heavy duty bearing option
• Does not fit Rebel models
• Does not fit 2019 Ram 1500 classic models
• Does not fit models equipped with 2 piece drive shaft
• Does not fit models equipped with the thermal rear axle.

Recommend Tires and Wheels:
Use 35/12.50R20 tire w/ 20×9 wheels w/ 5” BS w/ minor trimming
Use 37/12.50R20 tire w/ 20×9 wheels w/ 5” BS w/ minor trimming

INSTRUCTIONS

FRONT SUSPENSION

1. Disconnect the negative terminal on the battery. Jack up the front end of the truck and support the frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE! Remove the front tires.

2. Locate the sway bar and sway bar end links. Disconnect the end links from the lower control arms. Then, remove the sway bar from the frame and save the hardware.

3. Working from the driver’s side of the vehicle, disconnect the tie rod end from the steering knuckle by striking the knuckle to dislodge the tie rod end. SEE FIGURE 1

4. Remove the brake line bracket bolt from the frame Coilover perch. Save hardware. SEE FIGURE 2

5. Remove the brake caliper and secure it to the frame. Do not overstretch the brake hose when doing so. DO NOT LET THE BRAKE CALIPER HANG FROM THE BRAKE HOSE. Retain the hardware for reinstallation. Remove the brake rotor and save. Unplug the ABS wire at the plug behind the inner fender well and remove the ABS line clamp where it is attached to the steering knuckle. SEE FIGURES 3-6
   

6. Remove the upper and lower ball joint nuts and save. Using a large hammer, strike the steering knuckle to dislodge the ball joints from the steering knuckle. USE CARE NOT TO DAMAGE THE THREADS ON THE BALL JOINTS. Remove the steering knuckle from the truck. SEE FIGURES 7-9
   

7. Remove the three upper shock assembly bolts from the truck and save. Remove the lower shock bolt and save. Remove the shock assembly from the truck and save. The factory shock assembly will be reused if you are installing the 6” Basic System. If you are installing the 6” Performance System, you can discard the factory shock assembly and hardware. SEE FIGURE 10

8. Remove the factory lower control arm bolts/alignment cams and save. Remove the lower control arm and save.

9. Using a cutoff wheel. Mark and cut the factory brake line bracket on the upper Coilover mount like shown in FIGURES 11-12
   

10. Repeat steps 2-9 on the passenger side.

11. Remove the factory rear cross member from the vehicle and discard it. SEE FIGURE 13

12. Locate the driver-side rear lower control arm mount where the factory rear cross member was previously removed. As shown in the picture below, measure 1” from the factory cam bolt tab and mark a straight vertical line then cut. SEE FIGURE 14.

13. On the same mount, measure 1/2” from the bottom corner and mark a straight horizontal line, and cut. SEE FIGURE 15
    DUE TO VARIANCES IN EACH TRUCK, ADDITIONAL CUTTING / GRINDING MAY BE REQUIRED FOR PROPER FITMENT OF THE CROSSMEMBERS. USE THESE MEASUREMENTS AS A STARTING POINT AND CLEAR THE FRAME POCKETS AS NEEDED FOR PROPER FITMENT OF THE CROSSMEMBERS.

14. Repeat steps 15-16 on the front side of the driver’s rear pocket. SEE FIGURES 19-20
    

15. Repeat steps 15-17 on the passenger side rear control arm pocket.

16. Locate FT44477 (front cross member) and install it into the front lower control arm pockets using the supplied 5/8” x 5 ½” bolts, nuts, and washers. Leave loose at this time. SEE FIGURE 18

17. Locate FT44478 (rear crossmember) and install it into the frame pockets using the 5/8” x 5 ½” bolts, nuts, and washers. Leave loose at this time. SEE FIGURE 19

18. Install the factory lower control arms to the Fabtech cross members using the original alignment cam bolts. Leave loose at this time. Torque the upper cross-member bolt to 210 ft-lbs. SEE FIGURE 20
    FOLLOW STEPS 19-20 FOR BASIC KIT ONLY. IF INSTALLING THE PERFORMANCE SYSTEM WITH DIRT LOGIC 2.5 COILOVERS, INSTALL THE COILOVER SO IT IS OFFSET AWAY FROM THE AXLE.

19. Locate the previously removed shock assembly and attach FT44209BK spacer to the top of the shock assembly using the stock hardware. Torque to 35 ft-lbs. You will need to mount the spacer so that it aligns properly with the coilover. SEE FIGURE 21

20. Install the complete shock assembly into the truck attaching the three upper bolts first using the supplied 7/16” C-lock and flat washers, leave loose. Torque upper hardware to 83 ft. lbs. SEE FIGURE 22 Repeat on passenger side.

21. Locate the factory knuckles and remove the hub bearing and heat shield from both of them. Save hardware. SEE FIGURES 23-24
    

22. Locate FT44467D & FT44467P, and install the hub bearing and heat shield onto each of them in the same manner as they were installed on the factory knuckles. SEE FIGURE 25

23. Install the new knuckle by installing it to the lower ball joint first. Then attach the upper control arm ball joint. Torque the upper and lower ball joint nuts to 47 ft-lbs. SEE FIGURE 26

24. Install ABS line to the back of the knuckle using the supplied adel clamp, and ¼” x 3/4” hardware. Reinstall the sensor to the hub using the factory bolt. SEE FIGURES 27-28 Torque to 10 ft-lbs.
    

25. Repeat steps 22-24 on the passenger side.

26. Using FT44472 (Driver brake line bracket) as a guide place onto the frame like shown in FIGURE 29 and mark the hole to drill. Drill to 5/16” SEE FIGURE 30
    

27. Install the new brakeline bracket using the supplied 5/16 x 1” self-tapping bolt. Then, install the brakeline to the new bracket using the supplied 1/4” hardware. Torque to 10 t-lbs SEE FIGURE 31 Use the supplied zip ties to attach the ABS line to the hydraulic brake lines. Repeat on the passenger side using FT44473 (Pass brake line bracket)

28. Install FT44486 (driver sway bar drop bracket) & FT44487 (pass sway bar drop bracket) to the frame using the factory hardware. Torque to 78 ft-lbs. Then, install the factory sway bar to the new brackets using the supplied 7/16 x 1-1/4” hardware. Torque to 78 ft-lbs SEE FIGURE 32

29. Reinstall the sway bar end links to the lower control arms using the factory hardware. SEE FIGURE 32

30. Remove the factory tie rod end and install FT44288 (Tie rod end) in its place. Then, install to the knuckle. SEE FIGURES 34-35
    REAR SUSPENSION

31. Disconnect the rear brake line from the frame. Save hardware. SEE FIGURE 36

32. Remove the inner fender wells and save all hardware.

33. Remove the factory sway bar end links and discard. Then Disconnect the track bar from the axle side. Save hardware.

34. With the axle supported. Remove the factory shocks, coil springs, and upper link arms. Save hardware.

35. Locate FT44188BK (driver) & FT44189BK (pass) Rear Bumpstop Brackets and the supplied 7/16”x 1-1/2” hardware. Place the bump stop extension mounts onto the existing pads on the top of the differential. Mark and drill the rear hole to 7/16” and open up the front factory holes to 7/16”. Using the 7/16” bolts, washers and C-lock
    nuts and FT44045 ((nut tab) driver-side only), secure the mount to the factory bump stop pad. Torque to 70 ft-lbs. SEE FIGURES 37-39 Repeat on passenger side.
    

36. Install FT44474 & FT44475 (Driver & Pass Rear coil spacers) into the existing holes using the supplied 3/8” nuts and washers. Torque to 49 ft-lbs. SEE FIGURES 4041

37. Locate FT44163BK (Rear Upper Link), FT44164BK (Rear Lower Links), Press the FT1038 Bushings and FT77 Sleeves from FT90111 (Bushing kit) into each end. Then
    install the supplied zerk fittings.

38. Install the new FT44163BK (Upper Link Arms) into the factory rear axle mounts with the factory hardware. Then attach the arm to the frame mounts also with the factory
    hardware. Torque to 160 ft.-lbs. SEE FIGURE 42

39. Remove the factory lower links and save hardware. Install the new FT44464BK (Lower link arms) using the factory hardware. Torque to 160 ft-lbs. SEE FIGURE 43

40. Install FT44474 (Track bar bracket) into the factory track bar axle bracket using the factory bolt. Mark and drill the side hole to 7/16”. Reinstall the bracket using factory bolt, supplied 7/16 x 1-1/4” hardware and FT44045 (Nut tab). Torque 7/16” hardware to 70 ft-lbs and the factory bolt to 160 ft-lbs. SEE FIGURES 44-45
    

41. Install the factory coils using the factory coil isolator. SEE FIGURE 46-47

42. Install the factory track bar to the new bracket using the supplied 9/16 X 3” hardware. Torque to 153 ft-lbs SEE FIGURE 48

43. Using a 31/64” drill bit, drill out the factory sway bar mount hole on the frame. SEE FIGURES 49-50
    

44.  Install the FT1004 (Bushings) & FT404739 (sleeves) in the FT1599-2-4 (sway bar endlinks). Then install the end links to the frame and sway bar using the supplied M12 X 70mm hardware. Torque to 93 ft-lbs SEE FIGURE 51

45. 2020 MODELS ONLY: Disconnect the factory brake line from the frame. Install FT44543 (Brake line bracket) to the frame using the factory hardware. Then, install the factory brake line rod bracket to the FT44543 (Bracket) using the supplied 1/4” x 3/4” hardware. Torque hardware to 8 ftlbs. SEE FIGURE 52

46. Install the rear shocks FTS7348 (Performance), FTS6353 (Stealth), or FTS811442 (Dirt Logic) using the factory hardware at the lower mount and the supplied stem pack for the upper mount. SEE FIGURES 53-54

47. Re-install the rear fender wells.

48. Install tires and wheels and torque lug nuts to the wheel manufacturer’s specifications. Turn front tires left to right and check for appropriate tire clearance.
    Note – Some oversized tires may require trimming of the front bumper & valance.

49. Check front-end alignment and set it to factory specifications. Readjust headlights.

50. Recheck all bolts for proper torque.

51. Recheck brake hoses, ABS wires, and suspension parts for proper tire clearance while turning tires fully left to right.

52. Check the fluid in the front and rear differential and fill if needed with factory specification differential oil.
    Note – some differentials may expel fluid after filling and driving. This can be normal in resetting the fluid level with the new position of the differential/s.

53. Install Driver Warning Decal. Complete product registration card and mail to Fabtech in order to receive future safety and technical bulletins on this suspension.

Vehicles that will receive oversized tires should check ball joints, uni balls, and all steering components every 2500-5000 miles for wear and replacement as required.

RE-TORQUE ALL NUTS, BOLTS, AND LUGS
AFTER 50 MILES AND PERIODICALLY
THEREAFTER.
For technical assistance call: 909-597-7800

Product Warranty and Warnings

Fabtech provides a Limited Lifetime Warranty to the original retail purchaser who owns the vehicle, on which the product was originally installed, for defects in workmanship and materials.
The Limited Lifetime Warranty excludes the following Fabtech items; bushings, bump stops, ball joints, tie rod ends, limiting straps, cross shafts, Heim joints, and driveshafts. These parts are subject to wear and are not considered defective when worn. They are warranted for 60 days from the date of purchase for defects in workmanship.
Dirt Logic and Performance Coilover take-apart shocks are considered serviceable shocks with a one-year warranty on leakage only. Service seal kits are available separately for future maintenance. All other shocks are covered under our Limited Lifetime Warranty.
Fabtech does not warrant any product for finish, alterations, modifications, and/or installation contrary to Fabtech’s instructions. Alterations to the finish of the parts including but not limited to painting, powder coating, plating, and/or welding will void all warranties. Some finish damage may occur to parts during shipping, which is considered normal and is not covered under warranty.
Fabtech products are not designed nor intended to be installed on vehicles used in race applications or for racing purposes or for similar activities. (A “RACE” is defined as any contest between two or more vehicles, or any contest of one or more vehicles against the clock, whether or not such contest is for a prize). This warranty does not include coverage for police or taxi vehicles, race vehicles, or vehicles used for government or commercial purposes. Also excluded from this warranty are sales outside of the United States of America.
Installation of most suspension products will raise the center of gravity of the vehicle and will cause the vehicle to handle differently than stock. It may increase the vehicle’s susceptibility to a rollover, on-road and off-road, at all speeds. Extreme care should be taken to operate the vehicle safely at all times to prevent rollover or loss of control resulting in serious injury or death. Fabtech front-end Desert Guards may impair the deployment or operation of vehicles equipped with supplemental restraining systems/air bag systems and should not be installed if the vehicle is equipped as so.
Fabtech makes every effort to ensure the suspension product compatibility with all vehicles listed on the website, but due to unknown auto manufacturer’s production changes and/or inconstancies by the auto manufacturer, Fabtech cannot be responsible for 100% compatibility, including the fitment of tire and wheel sizes listed. The Tire and Wheel sizes listed on Fabtech’s website are only a guideline for street driving with noted fender trimming. Fabtech is not responsible for damages to the vehicle’s body or tires. Fabtech is not responsible for premature wear of factory components due to the installation of oversized tires and wheels.
Fabtech’s obligation under this warranty is limited to the repair or replacement, at Fabtech option, of the defective product only. All costs of removal, installation or re-installation, freight charges, and incidental or consequential damages are expressly excluded from this warranty. Fabtech is not responsible for damages and/or warranty of other vehicle parts related or non-related to the installed Fabtech product. This warranty is expressly in lieu of all other warranties expressed or implied. This warranty shall not apply to any product that has been subject to accident, negligence, alteration, abuse, or misuse as determined by Fabtech. Fabtech suspension components must be installed as a complete system including shocks as shown on our website. All warranties will become void if Fabtech parts are combined and/or substituted with other aftermarket suspension products. Combination and/or substitution of other aftermarket suspension parts may cause premature wear and/or product failure resulting in an accident causing injury or death. Fabtech does not warrant products not manufactured by Fabtech. Depending on the condition of the factory suspension components retained after the installation of a Fabtech suspension, not all vehicles may have the same ride stance front to rear as described on the website. The blue color of suspension components shown in all Fabtech photographs is for display purposes only. Majority of all Fabtech components will be black specifically where noted with part numbers ending in BK.
Installation of Fabtech product may void the vehicle’s factory warranty; it is the consumer’s responsibility to check with their local vehicle’s dealer for warranty disposition before the installation of the product. Some state laws may prohibit modification of suspension to a vehicle in whole or in part. It is the responsibility of the installer and consumer to consult local laws prior to the installation of any Fabtech suspension product to comply with such written laws.
It is the responsibility of the distributor and/or the retailer to review all warranties and warnings of Fabtech products with the consumer prior to purchase.
Fabtech reserves the right to super cede, discontinue, and change the design, finish, part number, and/or application of parts when deemed necessary without written notice. Fabtech is not responsible for misprints or typographical errors within the website or price sheet. For the most recent Product Warranty and Warnings visit our website www.fabtechmotorsports.com

Instruction Sheet Part# – FT23230i
10/28/21

References

• Fabtech® - Suspension Lift Kits & Truck Accessories

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