TM Dayton Parts, LLC P. O. Box 5795 Harrisburg, PA 17110-0795 Helper Springs Installation Instructions INS-138 1. 2. 3. 4. 5. Read instructions carefully and completely before installation of kit. Chock front wheels and raise rear of vehicle. Support rear axle with jack stands or other suitable device, remove rear tires and wheels. Remove U-bolts and top plate discard the U-bolts. This kit may require drilling holes in the truck frame for proper bracket mounting. To insure proper bracket location, templates are provided. Tape or hold templates in place, mark holes to be drilled with a center punch. Drill holes using a sharp 15/32" (.468) diameter bit. If the vehicle has rear inner wheelhouse linners which extend below the frame rail they must be removed to facilitate drilling of the frame rail. Proceedures for their removal are outlined in the Ram Truck Service Manual, (Dodge publication #81-370-5108), pages 23-13 to 23-15. IMPORTANT: Lubricate the drill bit with cutting oil while drilling to prevent overheating of frame and prolong bit life. 6. Right Side of Vehicle Passenger Side (See Figure 1 below) 6a. Front of Axle Use factory locator hole (approx. 9/16" dia.) to position template #4 on frame, keeping hole pattern as level as possible. Center punch and drill three 15/32" (.468) dia. holes. Remember to use cutting oil while drilling. Remove upper shock absorber mounting bracket by loosening the four bolts indicated. Replace shock bracket after helper bracket has been installed and properly adjusted. Center Punch & Drill Three (3) Holes 15/32" (.468") Dia. Center Punch & Drill Three (3) Holes 15/32" (.468") Dia. 9/16" Locator Hole 9/16" Locator Hole Figure 1 Rear of Axle Axle Centerline Vehicle Right Side (Passenger) FRONT Shock Absorber Bracket Mounting Bolts (4) 6b. Use factory locator hole (approx. 9/16" dia.) to position template #2 on frame, keeping hole pattern as level as possible. Center punch and drill three 15/32" (.468) dia. holes. Remember to use cutting oil while drilling. Continued
2 Dayton Parts, LLC Installation Instructions INS-138 (Continued) 7. Left Side of Vehicle Driver Side (See Figure 2 below) Front of Axle 7a. Use factory locator hole (approx. 9/16" dia.) to position template #1 on frame, keeping hole pattern as level as possible. Center punch and drill three 15/32" (.468) dia. holes. Remember to use cutting oil while drilling. Center Punch & Drill Three (3) Holes 15/32" (.468") Dia. Center Punch & Drill Three (3) Holes 15/32" (.468") Dia. 9/16" Locator Hole CAUTION: FUEL TANK 9/16" Locator Hole Two (2) 11/32" Holes (Some models have emergency brake cable bolted to the frame in this location) Figure 2 Axle Centerline Vehicle Left Side (Driver) FRONT CAUTION: Protect fuel tank with wood block or drain and remove fuel tank when drilling left side front bracket holes.(see Figure 3 below) Rear of Axle 7b. Use factory locator hole (approx. 9/16" dia.) to position template #3 on frame, keeping hole pattern as level as possible. Center punch and drill three 15/32" (.468) dia. holes. Remember to use cutting oil while drilling. Frame Fuel Tank Wood Block Figure 3 CAUTION: Protect fuel tank with wood block or drain and remove fuel tank when drilling left side front bracket holes Continued
Installation Instructions INS-138 Dayton Parts, LLC 3 (Continued) 8. Place spacer block provided, on top of main spring, be sure center bolt is seated in the center hole of the block. 9. Place helper spring on top of spacer block. Be sure center bolt head is seated in the center hole of the block. springs are marked front or rear, check orientation. Note: Some 10. 11. 12. 13. Place top plate on helper spring. (See Figure 6 on next page) Install new U-bolts (finger tight only). Check alignment of helper and main. Tighten U-bolts per the following procedure. (See Figure 4 below) 1 4 U-Bolt Rod Dia. at Thread 7/16 1/2 9/16 5/8 Torque Chart Final Torque (ft-lbs.) 45-60 65-80 90-105 120-150 3 2 Step 1 Step 2: Step 3: Snug U-bolts in the order shown to about the final torque. Finish tightening U-bolts to final torque values shown in the chart above. Tighten in order shown. Check U-bolt torque after 100 miles. Figure 4 14. 15. 16. Install wear pads in the one piece adjustable brackets. Using the 7/16" x 1" long bolts,nuts and washers provided, install the brackets with one bolt in the center slot (finger tight). Set adjustment to the highest possible position. Lower the truck and adjust brackets for 1-1 1/2 inches clearance between the helper spring and wear pad. (See Figure 5 below) 1 to 1 1/2 Figure 5 Continued
4 Dayton Parts, LLC Installation Instructions INS-138 (Continued) 17. Install the remaining 7/16" x 1" bolts, nuts and washers and tighten. frame rail. (See Figure 6 below) Note: Nuts must be installed to the inside of the Bracket Top Plate Helper Spring Spacer Block Heavy Flatwasher Lockwasher Nut Main Spring Bolt Flatwasher Figure 6 18. Proper bracket adjustment is essential to maintaining ride quality and avoiding spring slap when unloaded. Do not adjust bracket so that it touches the helper spring at a no load condition. This will cause harsh ride and may overstress brackets when fully loaded. 19. 20. 21. 22. Check for adjustment clearance between helper springs and such items as fuel fill pipes and exhaust hangers. Remember to re-attach shock mount bracket removed in Step 6a. Reinstall inner wheelhouse liners if they where removed in Step 5. Check U-bolt torque and remember to torque U-bolts after 100 miles. 23. 24. Helper kits are not designed to raise the GVW of a vehicle, they are designed to help the truck to carry its design payload in a safer and more stable manner. Other suspension enhancements that will help control those heavy loads are front and rear anti-sway bars with urethane bushings ask your dealer for more information. WARRANTY The manufacturer warrants that it will at its option, repair or replace product which is returned to the manufacturer within twelve (12) months after its first retail sale because of a claimed defect and which, upon examination by the manufacturer, is found to have failed in normal use because of a defect in material or workmanship. The foregoing warranty is the sole warranty of seller in connection with the sale of any product by it and is given in lieu of all other warranties, expressed or implied, including, but not limited to, any warranty of merchantability or any warrant of fitness of use. LIMITATION OF LIABILITY The manufacturer shall not be liable for any consequential damages arising out of the use of or any defect in any product. HOW TO OBTAIN SERVICE Return product to your distributor for processing of warranty claims. DO NOT return product directly to the manufacturer.
INS-138A Revision A TEMPLATE # 1 LEFT SIDE FRONT EXISTING 9/16" LOCATOR HOLE EXISTING HOLES, SOME MODELS HAVE EMERGENCY BRAKE CABLE HANGER MOUNTED IN THESE HOLES IMPORTANT: Instructions for drilling holes in truck frame follow guide lines established by the truck equipment industry. Manufacturer cannot be held liable for failure to closely follow these guide lines. This template locates the helper bracket in a position similar to the O.E.M. bracket. 96-04-12
INS-138B Revision A TEMPLATE # 2 RIGHT SIDE REAR EXISTING 9/16" LOCATOR HOLE TEMPLATE #3 LEFT SIDE REAR EXISTING 9/16" LOCATOR HOLE IMPORTANT: Instructions for drilling holes in truck frame follow guide lines established by the truck equipment industry. Manufacturer cannot be held liable for failure to closely follow these guide lines. This template locates the helper bracket in a position similar to the O.E.M. bracket. 96-04-12
INS-138C Revision A TEMPLATE # 4 RIGHT SIDE FRONT SHOCK BRACKET MOUNTING BOLTS EXISTING 9/16" LOCATOR HOLE IMPORTANT: Instructions for drilling holes in truck frame follow guide lines established by the truck equipment industry. Manufacturer cannot be held liable for failure to closely follow these guide lines. This template locates the helper bracket in a position similar to the O.E.M. bracket. 96-04-12