BDS1611FPE 4 Inch Lift With 4 Link For Dodge Ram 2500 4WD Installation Guide

BDS1611FPE 4 Inch Lift With 4 Link For Dodge Ram 2500 4WD

FAQs

Q: What should I do if I have ride height concerns after installing the suspension kit?

A: If you have any concerns about the ride height after installation, please measure and note down the ride heights from the WHEEL AXLE CENTER up to the FENDER LIP at specified locations and contact Technical Support for assistance.

THANK YOU Your truck is about to be fitted with the best suspension system on the market today. That means you will be driving the baddest-looking truck in the neighborhood, and you’ll have the warranty to ensure that it stays that way for years to come. Thank you for choosing BDS Suspension!

BEFORE YOU START

BDS 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.

FOR YOUR SAFETY

Certain BDS Suspension products are intended to improve off-road performance. 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 vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions. Always wear your seat belt.

BEFORE INSTALLATION

Special literature required: OE Service Manual for model/year of the vehicle. Refer to the manual for proper disassembly/reassembly procedures of OE and related components. Adhere to recommendations when replacement fasteners, retainers, and keepers are called out in the OE manual. 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. Post-suspension system vehicles may experience drive line vibrations. Angles may require tuning, the slider on the shaft may require replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced. Secure and properly block vehicle prior to the installation of BDS Suspension components. Always wear safety glasses when using power tools. If installation is to be performed without a hoist, BDS Suspension Co. recommends rear alterations first. 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 the original vehicle attitude. Always measure the attitude prior to beginning installation.

BEFORE YOU DRIVE

Check all fasteners for proper torque. Check to ensure 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 the steering gear for clearance. Test and inspect the brake system. Perform a 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. Perform headlight check and adjustment. Re-torque all fasteners after 500 miles. Always inspect fasteners and components during routine servicing.

• 4″LIFT: 37×13.50 w/ 5.625″ Backspacing on 9″wide wheel 37×12.50 w/ 5″ Backspacing on 9″ wide wheel
• 6″LIFT: 37×13.50 w/ 5.625″ Backspacing on 9″wide wheel 37×12.50 w/ 4.5″ Backspacing on 9″wide wheel

CONTENTS OF YOUR KIT

pre-installation

IMPORTANT

It is required that ride height measurements be taken before and after installation. Measure from the WHEEL AXLE CENTER up to the FENDER LIP of the wheel opening. Do this for all 4 wheels. Record measurements\ below.**

BEFORE

Left Front__ Right Front__ Left Rear__ Right Rear___

AFTER

Left Front__ Right Front__ Left Rear__ Right Rear__ **These ride heights will be required if you have any ride height concerns after installation. Please be prepared to provide these to Technical Support.

INSTALLATION INSTRUCTIONS

PRE-INSTALLATION NOTES: 6.4L Gas models will require exhaust modification to clear the front driveshaft and potentially the passenger’s 4-link bracket. 5.ll Gas models may require modification – but not in all cases. The vehicle can be driven without the front driveshaft to an exhaust shop for modification and reinstalled after modification.

SPECIAL TOOLS

• Pitman arm puller
• 11 /16″ drill (step drill highly recommended) Welder
• Rivet Gun

MEASURE FIRST

Measure and record from the center of the wheel up to the bottom edge of the wheel opening as shown on page 4.

4-LINK INSTALLATION INSTRUCTIONS

1. Park the vehicle on a clean flat and level surface. Block the rear wheels for safety.
2. Disconnect the battery/batteries, welding will be required. Do not weld on the vehicle with the batteries connected.
3. Remove the front trackbar bolt from the frame rail. Retain all hardware. (Fig. 1)
4. Raise the front of the vehicle and support the frame rails with jackstands. Do not support the radius arms, they will be removed during the installation.

TRANSFER CASE INDEXING RING/ CROSS-MEMBER INSTALLATION

TiP When the front driveshaft is disconnected: Before reattaching the front driveshaft, now is a great time to grease the nearly impossible-to-access grease fitting on the front dual Cardan joint. A needle adaptor on a grease gun is required. This fitting is required to be serviced at every oil change interval. Ensure that this maintenance is not skipped!

• 5. 6″ kits will require the installation of a transmission indexing ring and replacement crossmember. This installation is typically not required on 4″ kits, however, in rare circumstances, it may be necessary. 6″ gas models reference the 122616 instruction sheet. Diesel 6 bolt transfer case models reference 122623 instructions. Diesel 8 bolt transfer case models reference 122813 instructions.
• 6. 4″ kits only: Install the provided front driveshaft spacer (02296) between the transfer case output flange and the front driveshaft. Fasten with the provided 7/16″x 2-1/4″ 12-point bolts (Bolt Pack 932). Apply thread locker to the threads and torque hardware to 75 ft-lbs. The front driveshaft spacer is supplied in box kit #012414 for 4″ kits and with the t-case indexing kit (#122613 or #122813) for 6″ kits.

SUSPENSION DISASSEMBLY

7. Support the front axle with a hydraulic jack.

• Remove the factory wheels, remove the retaining clips that hold the rotor on, and may interfere with aftermarket wheels.
• Remove the transmission skid plate (if equipped), and retain the hardware.
• Break the jam nuts loose on the adjusting collar of the drag link. (Fig. 2)
• Disconnect the tie rod from the pitman arm, do not damage the tie rod boot. Mark the orientation of the pitman arm and remove the pitman arm from the sector shaft. (Fig. 3)
• Disconnect the sway bar links from the sway bar. Retain all hardware. (Fig. 4)
• Disconnect the brake line bracket from the top of the radius arm mount on the axle, retain the bolt, discard the bracket. (Fig. 5)
• Disconnect the front driveshaft from the axle, and retain the 4 bolts.
• Disconnect the factory shock from the lower shock mount. (Fig. 6) Lower the front axle and remove the factory coil springs.
• Raise the front axle and reattach the factory shocks with the factory bolt. It is not necessary to put the nut tab back on. The shocks will be there to keep the axle secure. Keep a jack under the axle for extra support.

4-LINK BRACKET INSTALLATION

• Mark the cam at the axle. Remove the passenger’s side radius arm. Retain all hardware. It will be necessary to remove the shock bolt and move the shock out of the way to get the upper hardware out. Reinsert the lower shock bolt when the arm is removed. This is a safety measure to keep the axle from moving an excessive amount.
• On the passenger’s side only. Measure and mark as shown (Fig. 7a,b). This material will need to be removed for clearance to the 4-link drop bracket. On the rear, the inside edge of the cut will be flush with the transmission crossmember and the outside edge will be flush with the radius arm mounting plate. Measure up 3/8″ and remove this material for clearance. Similar to the rear, trim up the front side of the crossmember as shown by measuring up a quarter inch.
• Remove the nuts from the transmission crossmember, if not already done in the transfer case index installation. Place the 4-link bracket up to the frame rail. Insert¾” bolt to locate the bracket. Mark the center of the slot on the bottom of the frame rail, mark the center of the top, rear hole on the side of the frame rail. (Fig. 8)
• Remove the bracket and drill the 2 centers to 11 /16”. Prep the area on the side of the frame rail for welding. Place the weld-in bung into the hole and weld the bung into place. (Fig. 9)
• Insert the rivet nut into the bottom of the frame rail. Use the hardware (#799) to set the rivet nut into place as shown (Fig. 1 0a). See the end of the instruction sheet for detailed rivet nut installation instructions.
• (6.4L Only) Normally running the front upper bolt on the 4-link bracket from the inside outward (Fig 1 Ob) will allow this piece of exhaust to clear the bracket. To do so the exhaust piece containing the Cat needs to be removed. Reinstall the exhaust once the bracket is installed in step 23. Exhaust modification is still required to clear the front driveshaft.
• Place the machined sleeve into the existing frame rail hole. Reinstall the bracket with hardware (#788) and sleeve as shown. There will bea spacer sleeve that goes between the bracket and frame. Due to variations in the factory brackets, shims are included to go between the bracket and transmission crossmember to take up the slack. Drop the shims in from the top. There are (2) 1/8″ shims and (2) 1/16* shims included. Shims may need to be stacked. (Fig. 11a-h)
• Grease and install bushing and sleeves into the lower control arm. Thread the grease fitting into the arm.
• With a jack still under the axle, disconnect the radius arm from the driver’s side frame bracket. Install the new upper and lower control arm on the passenger’s side. The upper arm will get 9/16″ x 4″ hardware, the lower will get 3/4″ x 5″ hardware. The factory hardware is usedat the axle. It is recommended to knock the nut tabs from the factory nuts to allow for quick torque of the hardware with the shocks in place later in the installation. Place a large socket over the nut and press off the tab in a vice. Note: The lower arm is curved inward for tire clearance. Both the upper and lower arms will have the part #s stamped on them and the part #’s will face toward the center of the vehicle. (Fig 12)
• Tighten hardware as follows: 1/2″ 65 ft-ibs, 5/8″ through the frame bolt 110 ft-ibs, 3/4° through the factory radius arm mount: 180 ft-lbs. Do NOT tighten the control arm hardware at this time, final torque will be done with the weight of the vehicle on the ground.
• Repeat the bracket and arm installation procedure on the driver’s side. The driver’s side will require the transmission crossmember bolt that is closest to the frame rail to be run from front to rear for upper arm clearance. Tip The trimming for clearance on the frame bracket is not required on the driver’s side.
• Rotate the cam to the position marked at the beginning of the installation. Snug all hardware, do not tighten at this time.

BUMP STOP INSTALLATION:

• Remove the factory bump stops, it is easiest to hit them from the side with a hammer to pop them out. (Fig. 13a)
• Grease the new replacement bump stops and raise the axle to press the bump stops into position. These will be a tight fit. It is easiest to lift the axle with a jack to compress the bump stops into position. (Fig. 13b)

TRACK BAR BRACKET INSTALLATION

• Install the trackbar bracket with a factory bolt through the original trackbar hole.
• Clearance the factory hole on the frame crossmember where the trackbar bracket meets to 9/16:
• The upper slot in the trackbar bracket will align with the hole in the factory trackbar bracket. These holes have variations in their position, and minor grinding of the factory hole may be required. Clear the hole so ½”hardware will fit through it. (Fig. 14)
• Fish the bolt tab through the frame rail with the included bolt wire and attach it to the trackbar bracket with ½” USS washer and regular nut. Apply thread locker to the bolt threads. (Fig. 14)
• Attach the upper hole with ½*x 1-3/4 (#789) bolt with 1/4″ spacer (01499) washer as shown. (Fig. 15)
• Insert the factory 18mm bolt back through it original hole and the new bracket. (Fig 15)
• Tighten ½” trackbar hardware to 65 ft-lbs. Tighten 18mm factory bolt to 250 ft-Ibs.
• Support the front axle and remove the factory shocks. Retain the lower hardware, discard shocks, and upper hardware.
• 4″ Lifts Only: Lower the axle and install the new coils with the factory isolator. The coils are side-specific. They are marked “PASS.” for the passenger side and nothing for the driver side
• 6″ Lifts Only: Lower the axle and install the new coils with the factory isolator. The Driver’s side coil will be installed with the isolator tab in thefactory hole. The Passenger’s side isolator will need to be rotated just over 45 degrees. Cut and place the template up to the factory mount, mark the hole center, and drill to 1/2″. The upper isolator on the passenger’s side is shown in the new hole. (Fig 16a, 16b, 16c, 16d) ONLY on the passenger’s side.
• Grease and install bushings and sleeves into the shocks. Install new shocks with cup washers, bushings, and ½” nut at the top mount. Tighten the nut until the bushings begin to swell.
• Attach the lower shock with factory hardware. Tighten hardware to 65 ft-Ibs.

STEERING MODIFICATION

• Disassemble the drag link. Trim the tab from the tie rod end flush with the end of the threads (Fig 16a, 16b). Trim the end of the tab on the drag link to 1-1/4* long. (Fig. 17A-C).
• Reassemble the drag link, and adjust so that there is approximately ¾”~7/8″ of thread exposed past the jam nuts and that the tie rod end faces up. (Fig. 18A)
• Install the new pitman arm, use the alignment mark made earlier. The included pitman’s arm can be installed in 2 different positions. Ensure that thepitman arm is installed in the most counterclockwise position (towards the driver side) as shown in (Fig. 18B). Loctite factory nut and install with lock washer tighten the nut to 225 ft-lbs.
• 4″ Kits Only: Reattach the sway bar links to the sway bar, and tighten to 55 ft-Ibs.
• 6″ Kits Only: Install sway bar drop brackets with factory hardware at the frame. The flat side of the bracket will face ‘out’ and the bracketswill offset the sway bar slightly forward. Attach sway bar to drop brackets with 3/8* hardware, tighten all hardware to 35 ft-Ibs. (Bolt Pack #422) (Fig 19a, 19b). Reattach the sway bar links to the sway bar, torque to 55 ft-Ibs.
• Attach drag link to pitman arm with factory nut. Tighten to 65 ft-Ibs. (Fig. 20)
• Attach brake line relocation brackets to the top side of the axle with the factory bolt and 5/16″ self-threading bolt into the original locating tab hole. The brake lines will need to have the fittings loosened so they can be rotated and pointed up. Attach the brake line to the bracket with retaining clip. The brackets will need to be offset in towards the ‘inside’ of the vehicle to give more clearance to the larger body of the shock. It will be necessary to slightly reform the hard line. (Fig. 21)
•  Place the transmission skid plate (if equipped) up to the factory mounting location. Mark the area that interferes with the 4-link brackets and remove this section from the skid plate, approximately 2″ inward and 1″ rearward. Reinstall with factory hardware, tighten to 35 ft-Ibs The skid plate will not work with the replacement transmission crossmember.
• Reattach the front driveshaft to the front axle with factory hardware and thread locker. Tighten to 75 ft-Ibs.
• Install wheels and tighten lug nuts to factory specifications. Lower the vehicle to the ground. Tighten 4-link hardware as follows: 18mm stock hardware at axle to 180 ft-lbs. 3/4″ Lower hardware at 4-link bracket: 180 ft-Ibs. 9/16* Upper arm hardware: 95 ft Ibs. Turn the steering wheel to not the tracker to align with the bracket Install now 18mm holt with cams and tighten to 250 4-lbc (4790%
•  Turn the steering wheel to get the trackbar to align with the bracket. Install new 18mm bolt with cams and tighten to 250 ft-Ibs (#789). Adjust the cam so that the bolt is closest to the passenger’s side for 6° kit (Fig 22b), and closest to the driver’s side for the 4″ kit (Fig 21a). It is possible to adjust the cam towards the center of the slot more to compensate for axle position by rotating the cam 90 degrees, (Fia 22A. 22B
• If any brake fluid was lost during the installation (rotating the brake fitting), the brakes must be bled, do so at this time.
• If any brake fluid was lost during the installation (rotating the brake fitting), the brakes must be bled, do so at this time. The badge can now be riveted onto the 4-link brackets using the provided 1/8* rivets. Any residue on the badge can be cleaned up using alcohol or brake cleaner before installation. With the badge not installed, it can be painted to whatever color you desire, or left raw as a stainless steel badge.

REAR INSTALLATION FOR 3500 TRUCKS WITH LEAF SPRINGS

2500 TRUCKS SEE SEPARATE INSTRUCTION SHEET

• Raise the rear of the vehicle, and block the front wheels for safety. Support the frame rails with jack stands.
• Disconnect the e-brake cable and reroute the line to give adequate slack in the cable at full droop, reattach once routed for extra slack. (Fig. a, 23b) Reattach once rerouted.
• Remove the factory shocks, and retain all mounting hardware.
• Disconnect the brake line brackets from the top of the axle to allow maximum droop without overextending the brake lines.
• Support the rear axle with a hydraulic jack. Remove the U-bolts and plates from one side of the vehicle only. Loosen the u-bolts, but do not remove the opposite side.

REPLACEMENT LEAF SPRING ONLY:

• Lower the axle and remove the stock leaf spring with a shackle. Transfer the shackle over to the new leaf spring and reinstall the entire assembly. Do NOT tighten any of the 3 bolts that attach to the spring or shackle at this time, make sure the shackle bolt is orientated correctly (inside – out). (Fig 24a, 24b)
• Install new u-bolts and install the nuts, snug but do not tighten at this time.
• Repeat spring and u-bolt installation on the opposite side of the vehicle.
• Tighten u-bolts snugly at this time, do not torque until the vehicle is on the ground.

REAR BLOCK KIT ONLY:

• Lower tine center of the factory let late may he require I vet the pie I eins fig the pin is designed be a press fit Minor clearancing / chamfering of the factory leaf plate may be required to get the pin to slide in. (Fig 25)
• Install a new lift block with new u-bolts and install the nuts, but do not tighten at this time.
• Repeat block and u-bolt installation on the opposite side of the vehicle.
• Tighten u-bolts snugly at this time, do not torque until the vehicle is on the ground.

LEAF SPRING OR BLOCK:

• Grease bushings and sleeves, and install them into both ends of the shocks. Install new shocks with factory hardware. Tighten to 65 ft-lbs. If installing optional Fox shocks, the body will be located at the frame mount.
• 4* kits: Reattach the factory rear brake line bracket to the top of the axle with factory hardware. Tighten to 20 ft-Ibs.
• 6 kits: Install L’ shaped bracket to the top of the axle with factory hardware. Carefully reform the factory hard lines for adequate routing.
• Reinstall wheels, and torque to specification. Lower vehicle to the ground and torque u-bolts to 100 ft-Ibs.
• Replacement Leaf Spring Only: Tighten the leaf spring and shackle hardware. Front mount: 250 ft-ibs Rear Spring to Shackle: 150 ft-lbs Shackle to Frame: 150 ft-ibs.

POST-INSTALLATION

• Adjust the steering wheel to center with the collar on the drag link. Securely lock off the jam nuts once the wheel is straight. Do not drive the vehicle with the steering wheel off-center or adverse traction control problems may arise.
• herself earned Hugh storing so miles rates on the as richest many A at net must now be eliferned ABS wies.
• These trucks can have a vibration from the factory under load and at extremely low RPMs (less than 1200 RPMs), the vibration can become more apparent after lifting the rear of the truck. There is an optional rear driveshaft spacer kit available (Part# 122007). This will increase rear driveshaft spline engagement and has been found to reduce vibration in rare instances where vibration is present.
• Carrier bearing drop is available separately and is not included in the kit. Order separately if required.

RIVET NUT INSTALLATION INSTRUCTIONS

RIVET NUT SIZING

1. Verify the correct size rivet nut for the application based on the thickness of the material where the rivet nut is to be installed using the following chart.

HOLE PREPARATION

• Drill the hole to an appropriate size for rivet nut installation. 1/2″ Rivnuts require an 11/16″ hole and 3/8″ Rivnuts require a 17/32″ drill. It is critical that this hole is drilled to the correct size. Remove any burrs that could keep the rivet nut from seating flat against either side of the hole surface.
• Tip if the core dill size is not available, it is possible to dill the hole to an available smaller size and slowly grind it out to until the rivet nut fits tight.

WALL MOUNTING

RIVET NUT INSTALLATION TOOL ASSEMBLY

• For a 3/8″ rivet nut, place the provided 3/8″ SAE flat washer on the 3/8″ x 1-1/2″ bolt, followed by a 7/16″ hex nut and then a 3/8″ serrated washer. (Fig. 1) Thread this tool assembly into the rivet nut.

• For a 1/2″ rivet nut, place the provided 1/2″SAE washer on a 1/2″ x 2″ bolt followed by a 9/16* high nut and 1/2″ serrated edge lock washer. Thread this tool assembly into the rivet nut as shown. (Fig. 27)

• Place the installation tool with the rivet nut threaded on the end into the appropriately sized hole.

• For a 3/8″ rivet nut, hold the nut closest to the rivet nut still with a 5/8″ wrench and tighten the 3/8″ bolt with a 9/16 wrench to set the rivet nut. Be sure to hold the rivet nut flush to the surface and square to the hole as it is tightened. (Fig. 2)
  Tip Iravailable, an impact gun is recommended for tightening the bolt to ensure the rivet nut remains square to the hole and to ease holding the nut from spinning.

• For a 1/2″ rivet nut, hold the nut closest to the rivet nut still with a 7/8″ wrench and tighten the 1/2″ bolt with a 3/4″ wrench to set the rive nut. Be sure to hold the rivet nut flush to the surface and square to the hole as it is tightened. (Fig. 28)

TORQUE SPECIFICATIONS

• 8. 3/8″ rivet nuts will approach 40 ft. Ibs for maximum grip strength. Do not exceed 45 ft-Ibs when setting the rivet nut.
• 1/2″ rivet nuts will approach 90 ft Ibs for maximum grip strength. Do not exceed 100 ft-Ibs when setting the rivet nut.

Tip Note: fusing the recommended impact gun, use caution to not exceed the recommended torque specifications.

RIVET NUT TOOL REMOVAL

•  Once the center bolt is tightened, keep holding the nut from spinning with the wrench and loosen the center bolt to remove the installation tool.

Caution I is very important to hold the nut as the bolt is loosened because the grip of the star washer will try spin the rivet nut and ruin the installation.

• Verify proper installation by checking for consistent rivet nut deformation to see if the threads are square and centered to the rivet nut. (Fig. 29)

WE WANT TO SEE YOUR RIDE!

Grab photos of your BDS-equipped truck in action and send them in for a chance to be featured. Send it to our Bad Ass Rides customer gallery at bds- suspension.com/bar and post them on the BDS Fan Page on Facebook at facebook.com/BDSSuspensions. Don’t forget about your BDS swag! BDS offers t-shirts, hoodies, decals, and more available on the BDS website or through your local BDS distributor.

Thank you for choosing BDS Suspension.

For questions, technical support, and warranty Sue contacting to mention dire product please contact your distributor/installer

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