INSTALLATION Manual Vehicle Applications: Vehicle description Product Part Number 94-98 5.9L Dodge Cummins 62100 98.5-02 5.9L Dodge Cummins 62101 03-06 5.9L Dodge Cummins 62102 01-06 6.6L GM Duramax 63100 94-03 7.3L Ford Power Stroke 61100 03-07 6.0L Ford Power Stroke 61101 FLUID DAMPER
TROUBLESHOOTING: If you have questions during the installation of this product, please visit www.bullydog.com/product_updates.php. The latest version of these instructions can be found at the same location. Please review the Troubleshooting section on page 25 before calling technical support to cover most common issues.technical support is available by calling 866- bullydog (866-285-5936). TABLE OF CONTENTS INTRODUCTION...pg. 2 BILL OF MATERIAL...pg. 2 tools & procedures...pg. 3 Balancing...pg. 3 Damper Removal...pg. 4 Damper Installation...pg. 4 Installation continued...pg. 5 Warranty & Disclaimer...pg. 6
Introduction: These instructions outline how to install the Bully Dog Fluid Damper. Please note that this install is only for the experienced mechanic. While removing and installing it will be important to have the OEM removal and assembly instructions for a damper handy. This damper installs the same as an OEM damper with the addition of some vehicle specific details noted in this instruction set. Damper install times can range from 2-6 hours depending on mechanical experience and vehicle application. BILL OF MATERIALS Fluid Damper 2
Step 1 Tools & Procedures Proper key if required Anti-seize Compound Do not use hammers or pry bars to install or remove Fluid Damper Sufficient torque wrench (see torque specs on page 2), fan removal tools. Step 2 Balancing Internally and Externally balanced Engines Part Numbers Description 62102 2003-2006 Dodge 5.9L 24v Cummins Internally balanced 62101 1998.5-2002 Dodge 5.9L 24v Cummins Internally balanced 62100 1994-1998 Dodge 5.9L 12v Cummins Internally balanced 63100 2001-2006 GM 6.6L Duramax Externally Balanced 61101 2003-2006 Ford 6.0L Power Stroke Externally balanced 61100 994-2003 Ford 7.3L Power Stroke Externally balanced REPLACING THE DAMPER Fluid Damper counterweights for external balanced engines have been designed to OEM specifications. If the damper being replaced has never been altered, Bully Dog Fluid Damper can be installed with no additional balancing. BALANCING OR MATCH BALANCING Each Bully Dog Fluid Damper component is precision balanced during manufacturing, so NO additional balancing is required. DO NOT ATTEMPT TO BALANCE THE CRANKSHAFT WITH THE BULLY DOG FLUID DAMPER INSTALLED The inertia ring inside is balanced to a close tolerance at the factory and it rotates inside the Bully Dog Fluid Damper. DO NOT DRILL THE DAMPER The inertia ring and silicone fluid are in a hermetically sealed housing. If balancing the crankshaft is required, install the stock damper while balancing. 3
Step 3 Removal Remove fan and shroud as per manufacturer s instructions, draw sketch of belt routing if required and remove the accessory drive belt. Dodge Cummins 5.9 (1992 to early 1998). BEFORE REMOVING THE STOCK DAMPER, rotate the engine so that the magnetic pick up is not on one of the notches in the outside diameter of the stock damper. If you do not have access to the gap spec, use a feeler gage to measure and record the gap between the magnetic pick up and the stock damper. Remove the stock damper Step 4 Fluid Damper Installation On engines that the damper slides or presses onto the crankshaft, carefully remove burrs, scratches, or nicks on the crank snout by filing or polishing the snout so that it is smooth and free of surface irregularities. Remove any sharp keyway corners. The key should fit snugly in the keyway on the crank. A heavy press fit creates high stress on the slot and should be avoided. If you use a hammer for anything other than a light tap, the key is too wide. Replace or modify the key if it is too tight or too loose. Coat the crankshaft snout and damper inside diameter with anti-seize compound or moly grease to prevent galling during installation. Dodge Cummins 5.9 12 Valve (1992 to early 1998) BEFORE INSTALLING THE FLUID DAMPER, loosen the magnetic pick up and move it outward to clear the larger Bully Dog Fluid Damper. Install the damper, torque the bolts to the proper torque, and readjust the magnetic pick up to the previously measured gap or to the manufacturers spec. Dodge Cummins 5.9 (2003-2006) Ford Power Stroke 6.0 (2003-2006) The belt must be routed between the Fluid Damper and the water pump pulley before the Fluid Damper is installed. Install the Fluid Damper and torque the bolt or bolts properly as per the original manufacturers torque or torque to yield requirements. Install the accessory drive belt, fan and shroud as per manufacturer s instructions.
step 4 continued: Engine Bolt Torque specifications 2003-2006 Dodge 5.9L 24v Cummins 30 ft-lbs plus an additional 60º 1998.5-2002 Dodge 5.9L 24v Cummins 30 ft-lbs plus an additional 60º 1994-1998 Dodge 5.9L 12v Cummins 30 ft-lbs plus an additional 60º 2001-2006 GM 6.6L Duramax 74 ft-lbs plus an additional 90º 2003-2006 Ford 6.0L Power Stroke 50 ft-lbs plus and additional 90º 994-2003 Ford 7.3L Power Stroke 212 ft-lbs WARNING: FAILURE TO USE PROPERLY TORQUED BOLTS WILL VOID WARRANTY AND COULD RESULT IN DAMPER, KEY, OR CRANK DAMAGE. 5
warranty & disclaimer REMEMBER, THIS IS A PERFORMANCE PRODUCT, USE AT YOUR OWN RISK. This product is not intended to be used to break the law. Do not use this product until you have carefully read the following agreement. This agreement sets forth the terms and conditions for the use of this product. The installation of this product indicates that the buyer has read and understands this agreement and accepts the terms and conditions. Never exceed recommended vehicle or tire top speed ratings. DISCLAIMER OF LIABILITY Bully Dog Technologies, LLC. Its distributors, jobbers, and dealers (hereafter Seller) shall be in no way responsible for the product s proper use and service. THE BUYER HERBY WAIVES ALL LIABILITY CLAIMS. The Buyer acknowledges that he is not relying on the Sellers skill or judgment to select or furnish goods suitable for any particular purpose and that there are no liabilities which extend beyond the description on the face hereof, and the Buyers hereby waivers all remedies or liabilities expressed or implied, arising by law or otherwise, (including without any obligation of the Seller with respect fitness, merchantability and consequential damages) or whether or not occasioned by the Seller s negligence. The Seller disclaims any warranty and expressly disclaims any liability for personal injury or damages. The Buyer acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this agreement and the Buyer agrees to indemnify the Seller and to hold the Seller harmless from any claim related to the item of the equipment purchased. Under no circumstances will the Seller be liable for any damages or expenses by reason of use or sale of any such equipment. The Seller assumes no liability regarding the improper installation or misapplication of its products. It is the installer s responsibility to check for proper installation and if in doubt contact the manufacturer. The Buyer is solely responsible for all warranty issues from the manufacturer. LIMITATION OF WARRANTY BULLY DOG TECHNOLOGIES, LLC. (Hereafter Seller ) gives Limited Warranty as to description, quality, merchantability, and fitness for any particular purpose, productiveness, or any other matter of Seller s product sold herewith. The Seller shall be in no way responsible for the products proper use and service and the Buyer hereby waives all rights other than those expressly written herein. This warranty shall not be extended, altered or varied except be a written instrument signed by Seller and Buyer. The Warranty is Limited to one (1) year from the date of sale and limited solely to the parts contained within the products kit. All products that are in question of Warranty must be returned prepaid to the Seller and must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by BULLY DOG TECHNOLOGIES, LLC. Under no circumstances will the Seller be liable for any labor charged or travel time incurred in diagnosis for defects, removal, or reinstallation of this product or any other contingent expenses. Under no circumstances will the Seller be liable for any damage or expenses incurred by reason of the use or sale of any such equipment. IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT: THE BUYER MAY PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE TO THE PLACE OF PURCHASE WITHIN TEN (10) DAYS FROM DATE OF PURCHASE FOR A FULL REFUND. THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS. 6
Bully Dog Technologies, LLC is a team built on integrity that is dedicated to leading the vehicle UNLEASH THE POWER WITH BULLY DOG PERFORMANCE PRODUCTS Downloaders Intake Systems Custom OutLook Pod Exhaust Systems See More at: bullydog.com Doc.# BD60001 v1.0.0 For a full listing of Diagnostic Trouble Codes go to: www.bullydog.com/dtc.php For Free Technical Support Call: 866-bullydog (866-285-5936)