BOX KIT # 63000 4WD 81-96 FORD F150 BRONCO 4 OR 6 SERIES II RADIUS ARM SYSTEM INTRODUCTION Installation requires two professional mechanics. Be sure the vehicle is in excellent working condition-repair or replace all worn parts. Read instructions several times prior to beginning installation. Check to make sure you have all needed parts and know where to install them. Read each step completely. NOTES: Front coil springs, rear kit(s) or rear leaf springs, and shock absorbers are purchased separately and are also required for proper installation of this system. ( ) denotes foot pound torque readings after each appropriate fastener. Prior to attaching components, be sure mating surfaces are free of grit, grease, under coating, etc. After installation is complete, the vehicle will require a front end alignment. IMPORTANT Prior to disassembly, identify each part and place the appropriate mounting hardware with it. Contact your Dick Cepek Race Series Suspension dealer if any components are missing before beginning any work on the vehicle. PARTS LIST (p/n DCS 63000 Radius Arm Box Kit) Quantity Description Item Number Illus./Fig. # 1 Extended Tubular Radius Arm driver side DCS 03400 1,2,C 1 Extended Tubular Radius Arm passenger side DCS 03401 1,2,C 1 Radius Arm Mounting Bracket driver side DCS 03402 1,2,6 1 Radius Arm Mounting Bracket passenger side DCS 03403 1,2,6 1 Hardware Kit Radius Arm containing: DCS 03410 6 12 ½ (13) x 1-1/2 grade 8 bolt 12 ½ (13) steel lock nut 24 ½ SAE flat washers 1 thread lock tube 2 mil. 2 Dick Cepek SPUD Spacer DCS 03415 6 ALSO RECCOMENDED FOR INSTALLATION OF THIS SUSPENSION SYSTEM: PARTS LIST (p/n DCS 73000 FRONT BOX KIT) Description Item Number Illus./Fig. # Quantity 1 Front Axle Pivot Bracket driver side DCS 03404 1, 2, B 1 Front Axle Pivot Bracket passenger side DCS 03405 1, 2, A 1 Back-up Support Plate passenger side DCS 03406 1, 2, 3 1
1 Hardware Kit Bumpstops containing: DCS 03411 5 2 5/16 (18) x 1- ½ grade 8 bolt 2 5/16 (18) steel lock nut 4 5/16 SAE flat washer 2 Bumpstop Extension DCS 03408 5 1 Hardware Kit Axle Pivot (driver side) containing: DCS 03415 B 7 ½ (13) x 1- ½ grade 8 bolt 6 ½ steel lock nuts 15 ½ SAE flat washers 1 DCS #03414 Axle Pivot Bracket Sleeve (9/16 x 1.80 ) 1 9/16 (12) x 3 grade 8 bolt 1 9/16 (12) steel lock nut 2 9/16 flat washer 1 thread lock compound 1 Hardware Kit Axle Pivot (passenger side) DCS 03409 A containing: 4 ½ (13) x 1- ½ grade 8 bolt 4 ½ (13) steel lock nut 8 ½ SAE flat washers 4 7/16 (14) X 1- ½ grade 8 bolt 4 7/16 (14) steel lock nuts 8 7/16 SAE flat washers 1 Drop Pitman Arm (bulk in bag) See separate instructions. DCS 33001A ALSO NEEDED FOR ISTALLTION OF THIS SUSPENSION SYSTEM: Dick Cepek Front Coil Kit ** (Illustrations 1, 2, D) Dick Cepek Rear Block or Add-A-Leaf Kit ** (See separate instructions.) Dick Cepek D.O.T. Approved Extended Brake Hose Kit ** (See separate instructions.) Dick Cepek Race Series Shock Absorbers**(Illustrations 1, 2, D) **see product application guide for specific part numbers required per vehicle type. TORQUE SPECIFICATIONS 1. 3/8 bolts 28-32 ft. lbs. 2. 7/16 bolts 30-35 ft. lbs. 3. ½ bolts 65-80 ft. lbs. 4. 9/16 bolts 75-90 ft. lbs INSTALLATION FRONT PREPARATION AND REMOVAL OF FACOTRY BRACKERTY: 2
1. Block rear wheels. Raise front end of vehicle approximately 12 with two floor jacks under each axle half and place hack stand under frame rails. Ease down the jacks leaving a slight load on the coil springs. Chock rear tires to prevent vehicle from rolling. Remove front tires. Remove the brake calipers and set them on top of the coil towers. RIVET REMOVAL: 2. Rivet removal: Center punch rivet head. Drill a ¼ pilot hole in the center of the rivet approximately ¼ deep. Drill out rivet head using a 7/16 bit (be careful not to drill into the frame). Drill out rivet. RADIUS ARM BRACKET REMOVAL AND INSTALLATION: NOTES: 3. Remove the rivets holding the radius arm bracket to the frame (repeat per rivet removal in step 2). 4. Installation of Radius Arm Brackets: The radius arm bracket will need to be relocated using the new Cepek brackets (#03402-driver side and #03403-passenger side). Relocate exactly 15 rearward from the original rear mounting location of the factory radius arm bracket (measure from rear hole on bottom of original frame bracket to the front hole on the bottom on the new Cepek frame attaching bracket). Carefully locate the brackets exactly 15 behind from the original factory radius arm bracket location hole. A. It may be helpful to attach new bracket with radius arm in position, using a C- clamp, in order to make exact placement prior to drilling holes. B. On 1994-1996 F-series Pickups and Broncos, there is a small plate holding the gas lines in place where they leave the frame inward towards the engine (the plate is located about a foot behind the drivers side radius arm rear mount on the inside of the frame rail). The rear mounting bolt will have to be trimmed flush with the outside of the frame rail. This leave enough of the bolt to locate in the rear hole. The front mounting bolt should be left installed to this gas ling holding plate. C. One some short bed, standard cab vehicles, it may be necessary to drill through the frame crossmember when attaching the new Cepek radius arm bracket. 5. After location of the mounting brackets, mark the holes using a transfer punch or a center punch, and carefully drill the mounting holes using a ½ drill bit (see figure 2). Be sure that there is nothing on the other side of the frame prior to drilling. Use a wire brush to remove any undercoating. The bracket must have a clean surface to be installed on. It may be necessary to re-route vacuum lines on certain models if they interfere with new mounting brackets or bolts. RADIUS ARM REMOVAL AND INSTALLATION: 6. Remove original radius arms from front beams by removing the stud at the top of the beams and the bolt from the bottom. Install the Dick Cepek radius arm (p/n DCS #03400-driver side & #03492 passenger side). 3
7. If you have the short style radius arm bushings, install the SPUD spacers (p/n DCS #034415). It is recommended to replace the bushings with new O.E.M. rubber bushings or Dick Cepek Race Series Polyurethane Bushings at this time. 8. Make sure all the radius arm bushings and spacers are installed correctly (see figure 6). Apply locking compound and torque the radius arm nuts 80-120 ft. lbs. Torque axle pivot bolts to 75-90 ft. lbs. Re-check torque on all the bolts you have installed including axle pivot brackets and radius arm brackets. 9. Cycle steering all of the way to the right and to the left inspecting steering, suspension and driveline systems for proper operation, tightness and adequate clearance. If brake hose fittings are touched, recheck lines for leaks. Be sure all hoses/wiring are of adequate length. Repeat this inspection with the suspension unloaded and hanging. FINAL PROCEDURES 1) With the front tires pointing straight ahead, the steering wheel crossbars will be misaligned. The center the steering wheel position is achieved. To center the steering wheel, loosen the two clamp bolts on the drag link adjustment sleeve and rotate the sleeve until the desired steering wheel position is achieved. Then tighten the clamp bolts. 2) Cycle steering all of the way to the right and to the lift inspecting steering, suspension and driveline systems for proper operation, tightness and adequate clearance. If brake hose fitting are touched, recheck lines for leaks. Be sure all hoses/wiring are of adequate length. Repeat this inspection with the suspension unloaded and hanging. 3) INSTALL WARNING DECAL (metallic sticker) TO THE INSIDE OF THE DRIVER SIDE DOOR JAM NEXT TO THE V.I.N. PLATE. 4) HANG MIRROR TAG WITH WARNING AND WARRANTY REGISTRATION CARD FROM REAR VIEW MIRROR! 5) Readjust headlights to proper setting. 6) Check the vehicle for proper alignment. 4
CAUTION AND WARNING INFORMATION Installation of these parts will modify the height of the vehicle and may raise the center of gravity. Altered height modification and off-road operation may increase your vehicle s susceptibility to roll over conditions and may cause serious injury or death. Many states regulate the height modification to each vehicle. Check the laws in your state for exact specifications Height modifications may effect the reaction, ride, and handling and wear factor of your vehicle s components. Height modifications may require other adjustments to the vehicle. A professional mechanic should install all Dick Cepek Race Series suspension components. All vehicles must be aligned within 100 miles after installation of these parts. Always use extreme caution when operating your vehicle in conditions, which may cause loss of balance or control. Avoid sharp turns and abrupt maneuvers, which may cause a vehicle to roll over or have an accident. Always wear a seat belt. Never drink uses drugs and drive! DRIVE RESPONSIBLY!! 5