D1200 Installation - pg. 2
INSTALLATION INSTRUCTIONS
Park vehicle on clean, flat and level surface. Block the rear wheels for safety.
1.
Measure the ride height of the vehicle and record.
2.
Raise the front of the vehicle with a hydraulic jack. Support the frame rails with
3.
jackstands.
Measure the length of the torsion bar adjuster bolts (top of the adjuster bolt head
4.
to adjuster)
Remove the adjuster bolts, keep driver's and pass side bolts separate.
5.
Use the appropriate torsion bar removal tool to remove the threaded adjuster as-
6.
sembly. Release the pressure from torsion bar with the unloading tool.
Caution:
There is an extreme amount of energy stored in the torsion bars. Use extreme
care with the proper tools to avoid serious injury or death.
Pull the torsion bars rearward out of the lower control arms to allow the keys to
7.
be removed. It may be necessary to use an air hammer on the factory keys to get
them free from the end of the bars.
Apply a small amount of grease to the hex on each end of the torsion bar. Install
8.
the new torsion keys.
Install the torsion bar adjuster assembly with torsion bar tool.
9.
Set the overall length of the exposed thread and bolt head to the original mea-
10.
surement. The minimum recommended exposed length is 3/4". This may need
to be adjusted if heavy accessories are added to the front of the vehicle.
Lower the front end to the ground, bounce the front end to settle the suspension
11.
and roll the vehicle forward and back several feet to allow the vehicle to set at
the final ride height.
Check the final ride height measurement. This should not be more than 25". If
12.
it is greater than this, the adjusters need to be lowered. Excessive ride height
will reduce ride quality and increase wear on suspension, steering and drive axle
components.
A front end alignment must now be performed.
13.
Torsion Key
Torsion Bar
Adjuster Bolt
Kit Contents
Qty
Part
2
Dodge Torsion Keys
Important—measure
before starting!
Measure from the center of the
wheel up to the bottom edge of the
wheel opening
LF__________ RF__________
LR__________ RR__________
Important—measure
before starting!
Measure from the exposed length
of the torsion bar adjusters before
starting:
Drv_________ Pass__________
Caution: There is an extreme
amount of energy stored in the tor-
sion bars. Use extreme care with
the proper tools to avoid serious
injury or death.
