Carli Suspension Front Instructions

Transcription

1 Carli Suspension Front Instructions DODGE X4 SUSPENSION SYSTEM Note: Prior to installation, carefully inspect the vehicle=s steering and drive train components. Be sure to check ball joints, tie rod ends, pan-rod bar, and control arm bushings. Everything must be tight and in good working condition. We recommend installation be done by a trained professional Read instructions carefully before attempting installation Secure and properly block vehicle prior to installation Front end alignment is necessary upon completion of install FRONT INSTALLATION 1. Set emergency brake and block rear wheels, in front and behind tires. 2. Disconnect sway bar end links from sway bar and axle, then remove. 3. Disconnect brake line bolts from axle on both sides. They are located between upper and lower control arms. 4. Remove pan-rod bolt at driver side frame mount. 5. Remove upper shock bolts and washers. 6. Remove three flange nuts holding upper shock mounts to coil bucket (both sides). 7. Remove lower shock bolts and pull shocks from lower mounts. 8. Jack up front of truck and place jack stands under frame behind lower control arms. 9. Remove wheels and tires. 10. Remove inner fender wells. Be sure to disconnect ABS sensor wire from fender well at this time. 11. Remove coil springs. You will reuse OEM isolators. 12. Drill out 3 existing holes in coil bucket to 9/16". 13. Rotate clamp on turbo outlet, located just above coil bucket on passenger side, 180 degrees so smooth part of clamp faces out. Be sure to re tighten! 14. Install supplied stainless high mis-alignment spacers in shock bearings and feed shock reservoir through the bottom and out top of the coil bucket. Reservoir faces towards front of the truck. 15. Now feed Billet Tower over the end of the shock reservoir and up over the top of the shock. 16. Install Stud Ring through 3 holes in bottom of coil bucket and up through Billet Towers. Secure Billet Towers with supplied fasteners and torque to 35ft.lbs. 17. Place OEM isolator on top of supplied coil and install. Be sure to pull shock up, clear of lower coil bucket when installing.

2 Note: For easier installation, separate right side tie rod end from knuckle. Note: For proper coil indexing, rotate coil so the tail does not cover drainage hole in lower coil seat but is about 2" in front. 18. Add drop of Lock Tight to supplied stainless shock bolt. 19. Install upper shock bolt through tower and shock. Torque to 40ft.lbs. Now jack up axle to line up lower shock bolts, add Lock Tight and tighten to OEM specs. 20. For Drill out the lower sway bar end link mount on the axle to 2". The mount is located off the front of the lower coil seat. 21. Assemble the new Stainless End links 1 2" longer than stock. 22. Install Stainless End links onto truck with supplied hardware and tighten. You will connect to sway bar when truck is at ride height. Notice order of spacers and washers, from the outside in goes -bolt, washer, OEM mount, washer, spacer, heim end, spacer, washer, nut. Note: For sway bar must be flipped upside down

3 Note: weld upper limit strap tab to bottom of the L-shaped bracket existing on frame. (Above the upper control arm) 23. For limit strap tab placement on see illustrations. DRIVER SIDE VIEW 24. Attach limit strap to tab and pull tight up to coil bucket edge to find upper hole location and make a small mark. From the mark measure 1 ½ inches up and drill a ½ inch hole. Note: upper mount bolt arrangement far right image. Sequence as follows: bolt, washer, strap, spacer, washer, coil bucket, and nut.

4 25. Reinstall wheels and tires and set truck on ground. 26. Connect sway bar to end links and tighten till rubber bushings start to crush. 27. Connect upper and lower limit strap mounts and tighten. 28. Add Lock Tight to pan rod bolt and reinstall.

5 29. Reservoir mounting: Hold supplied reservoir mounting brackets between reservoir and frame. Be sure to leave a little slack in reservoir hose to allow for movement. Also be sure to mount as high up on the frame as possible. Now mark the two holes to be drilled. Use a 3/16" drill bit and drill out marked holes. Mount reservoir mounts. Use supplied hose clamps to secure reservoirs to mounts. See image below. 30. Reinstall fender wells and secure ABS lines. 31. Make sure to install vent tube from the factory shock tower to the edge of the coil bucket on the driver side. 32. Double check all fasteners and lugs and align.