2216 (STOCK) / 2224 (3 LOWER) 2WD SPORT SWAY BAR SET 97-UP DODGE DAKOTA INSTALLATION OF HOTCHKIS PERFORMANCE FRONT SWAY BAR

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1 2216 (STOCK) / 2224 (3 LOWER) 2WD SPORT SWAY BAR SET 97-UP DODGE DAKOTA Thank you for your purchase from our line of Dodge Dakota & Durango suspension parts. Please call us at (877) 4NO-ROLL if you have any questions regarding the service and installation of your Hotchkis Performance products. Visit us This installation will require: ¾ Hydraulic jack, jack stands, torque wrench ¾ Rotary grinder or disk sander ¾ The following wrenches or sockets: 15mm, 16mm, 17mm, 3/4" INSTALLATION OF HOTCHKIS PERFORMANCE FRONT SWAY BAR 1) Securely block the rear wheels of the vehicle. Use a jack to raise the front and support with jack stands to the frame. You do not have to remove the front wheels for this installation. 2) Use a 15mm socket or wrench to loosen and remove the nut holding the stock end link to the sway bar. Retain the stock nut, washer, and bushing for re-installation later.

2 3) Use a 15mm wrench or socket to loosen and remove the bolts holding the stock sway bar and bushings in place. Use caution not to drop the sway bar, as these are the only bolts holding the stock sway bar in place. The sway bar should be free for removal from the truck. Twist the bar to free the ends of the bar from the end links. Retain the stock hardware for later use. 4) Use a rotary grinder or sander to sand the corner of the bump stop pad on the frame. You ll want to remove the front edge of the pad as shown on both sides of the vehicle. Remove roughly 1/4" of material for sway bar clearance. BE SURE TO WEAR EYE PROTECTION WHEN GRINDING! 5) Use the grease pack provided to apply a thick coat of grease to the inside of the new sway bar bushings. Place the bushings over the Hotchkis sway bar in roughly the same position as the stock bushings fit. Install the bushings so that the split in the bushing faces forward with the bar installed on the truck. Place the retainer bracket over the bushing.

3 6) Lift the Hotchkis bar into place and use the stock bolts to attach the sway bar brackets to the frame. Do not fully tighten the bracket bolts! Loosely tighten the bolts and rotate the sway bar to check the clearance between the bar and the portion of the bump stop pad you ground off. You should have about 1/4" of clearance between the sway bar and the frame. 7) If no more grinding is necessary, then swing the front sway bar out of the way or remove it. Clean the exposed area of grinding debris and use spray paint to cover the bare metal surface. 8) Re-install the front sway bar and use a 15mm wrench or socket to tighten the bolts holding the bushing retainer brackets in place. Torque the bolts to 35 ft/lbs. 9) Replace the rubber bushings on the end links with the polyurethane end link bushings included with this kit. The small, piloted end, of the lower bushing should point upwards into the hole in the end of the sway bar.

4 10) Rotate the ends of the sway bar over the end links. Place a second polyurethane bushing over the end link with piloted end facing down this time. Replace the washer and nut on the end link and use a 15mm wrench or socket to tighten the nut. The bushings should be tightened until the bushing is roughly the same diameter as the washer. 11) Re-check the hardware for tightness. Cover the zerk fittings with the grease caps provided. Use a jack to remove the jack stands and lower the vehicle. Move on to the rear sway bar install. IMPORTANT: For proper maintenance, the bushings should be greased at least once a year (15,000 miles) or whenever excessive noise occurs. Use non-lithium grease only! Lithium-based grease can wash out with water and should not be used.

5 Please call us at (877) 4NO-ROLL if you have any questions regarding the service and installation of your Hotchkis Performance products. INSTALLATION OF HOTCHKIS PERFORMANCE REAR SWAY BAR 1) Securely block the front wheels of the vehicle. Use a jack to raise the rear end and support with jack stands. As with the front bar, you will not need to remove the wheels for this installation. 2) Vehicles without a stock rear sway bar may move on to step 4. Remove the four nuts holding the end link mounting brackets up to the frame. Leave the stock end links attached to the sway bar and let the assembly droop out of the way. Retain the stud plate and attaching hardware for later re-installation. 3) Remove the four bolts holding the sway bar to the axle. The stock bar should now be free for removal. You will not need this hardware and may discard it. 4) Use the hardware from kit #T1711 to install the frame brackets into the existing holes in the rear of the frame. Use a 16mm socket or wrench for the bolt and a 17mm socket or wrench for the nut. Torque the hardware to 35 ft/lbs. If your vehicle was equipped with a stock sway bar, then you should re-use the stock stud plate and nuts. Torque the hardware to 35 ft/lbs.

6 5) Use the grease pack provided to apply a thick coat of grease to the sides of the dog-bone end links. Fit the greased end links into the brackets installed on the frame. Use the 2-3/4 long bolt from hardware kit #T1712 to secure the top of the end link to the bracket as shown. Loosely apply the nut to the bolt so that the end link may still move freely. 6) Use the grease pack to apply a thick coat of grease to the insides of the sway bar bushings. Install the bushing onto the sway bar near the outside bends in the sway bar. The bushings should be installed so that the split in the bushing is facing the front of the truck with the bar fully installed. Slide the bushing retainer brackets over the bushing. 7) Vehicles with a stock rear sway bar mounting brackets welded on the axle may skip this step! Slide the u-bolts over the axle roughly 1 from the shock mounting brackets on the axle (reference the finished install photo). The open end of the u-bolt will be facing upwards at a degree rearward angle when fully installed. Slide the sway bar axle-mounting bracket over the ends of the u-bolts. You can use a piece of tape to hold the u-bolt temporarily in place.

7 8) Insert the Hotchkis sway bar into the vehicle. Hook the driver s side end of the sway bar around the shock on that side. For vehicles without the stock sway bar mounts: Use the included Anti-Seize from the u-bolt kit #T1722 to apply a small amount to the ends of the u-bolts. Slide the bushing retainer brackets over the ends of the u-bolts so that the bushing rests against the axle bracket. Slide the small washers over the ends of the u-bolts. Start the nylock nuts onto the ends of the u-bolts, but do not fully tighten them yet. For vehicles equipped with the factory sway bar mounts: You will not be using the u-bolts and axle brackets. Place the bushings and brackets against the welded mounting bracket on the axle. Use some of the bolts from hardware kit #T1711 to mount the bushing retainer brackets to the axle. Leave the bolts slightly loose to allow the sway bar to rotate freely.

8 9) Rotate the sway bar up to the suspended end links installed in step 5. Use the 3 long bolt from hardware kit #T1712 to connect the end link to the sway bar. Place the larger diameter washer on the outside of the assembly. This washer is used to contain the bushing face. Install the bolt from the outside of the truck through the larger washer. Slide the smaller washer over the end of the bolt and start the nylock nut onto the end of the bolt. Do not tighten the hardware yet. 10) Make certain the axle is at ride height or it s normal position when the vehicle weight is applied to it. Trucks that have the factory axle brackets only require that you tighten the bolts down. Use a 16mm wrench or socket to tighten the bolts. Torque the bolts to 35 ft/lbs. Trucks using the u-bolts and the Hotchkis axle bracket require that you rotate the u-bolts and brackets slightly so that the brackets are at a degree angle towards the rear of the truck. Slide the brackets and bushings out as far towards the outside as you can, as this well help prevent the bar from walking sideways during use. Use a 16mm socket or wrench to tighten the nylock nut on the u- bolt. Tighten the nuts evenly to keep the u-bolt even around the axle. Torque the nuts to 35 ft/lbs.

9 11) Use a 3/4" socket or wrench to tighten up the bolts holding the end links in place. Torque the hardware to 30 ft/lbs. Make certain that the sway bar can still move. If the bolts are too tight the sway bar will not function properly causing the suspension to bind. 12) Re-check all hardware for tightness. Cover the zerk fittings with the grease caps provided. Use a jack to remove the jack stands and lower the vehicle. You are finished with the installation! IMPORTANT: For proper maintenance, the bushings should be greased at least once a year (15,000 miles) or whenever excessive noise occurs. Use non-lithium grease only! Lithium-based grease can wash out with water and should not be used. SEE NEXT PAGE FOR PARTS LIST

10 97-Up Dakota Sport Sway Bar Set, Parts List P/N 2216 (Stock height) / 2224 (3 lowered) Hotchkis P/N Item Description Quantity Per Kit Front Sway Bar, 97+ 2WD Dakota & Durango G End Link Bushing, Truck Universal Sway Bar Bracket, Greaseable, Small Rear Sway Bar, 97+ 2WD Dakota & Durango 1 5 T2211 Axle Mounting Kit (Includes 2 Brackets per kit) G 1" Greasable Sway Bar Bushing, Small 2 7 T2221 Rear Frame Bracket Kit (Includes 2 Brackets per kit) " Dog Bone Kit (Includes 2 end links per kit) /2" Heavy Duty Greaseable Sway Bar Bushing Heavy Duty Bushing Bracket, Greaseable 2 Hardware Included in Kit T M10-1.5X25CS 10mm x 25mm Hex Head Bolt 4 12 M10SAEWASH 10mm SAE Flat Washer NYLOCK 10mm Nylock Nut 4 Hardware Included in Kit T /2-20 X 3" 1/2" X 3" Hex Head Bolt /2-20X2.75" 1/2" X 2.75" Hex Head Bolt /16USS FW 7/16" USS Flat Washer /2AN 1/2" AN Flat Washer /2-20 NUT 1/2" Nylock Nut 4 Hardware Included in Kit T T1722 3" U-bolt /16AN 7/16" AN Flat Washer /16NYLOCK 7/16" Nylock Nut 4 22 ND907A1 1/8oz Tube, Anti-Seize 1 Items Not Shown Grease Pack Puffy Black/ Chrome "Sport Tuned Suspension" Sticker 1 25 n/a Instruction Set 1