Performance Automotive Group Dodge HEMI 2500/3500 2010-2012 Body Lift Installation Instructions

The Dodge HEMI 2500/3500 2010-2012 Body Lift is a kit that will raise the body of your vehicle 3 inches. This will give your truck a more aggressive look and increase ground clearance. The kit includes all necessary hardware and instructions for installation.

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3651 N Highway 89 • Chino Valley, AZ 86323

(928) 636-7080 • www.p-a-g.net

DODGE RAM 2500/3500 (4WD)

HEMI ENGINE ONLY

(INCLUDING MEGA CAB)

(EXCLUDING POWER WAGON)

3” BODY LIFT

INSTALLATION INSTRUCTIONS

2010-2012 KIT# 60223

MANUAL TRANS. MODELS REQUIRE:

KIT# SE9627

MANUAL TRANSFER CASE MODELS REQUIRE:

SE9629

WARNING

Installation of a Performance Automotive Group body lift kit will change the vehicle’s center of gravity and handling characteristics both on- and off-road. You must drive the vehicle safely! Extreme care must be taken to prevent vehicle rollover or loss of control, which could result in serious injury or death. Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fastened.

WARNING

Before you install this kit, read and understand all instructions, warnings, cautions, and notes in this instruction sheet and in the vehicle owner’s manual.

CAUTION

Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components. We recommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation. Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components install this kit.

WARNING

DO NOT combine suspension, body, or other lift devices. Use of vehicle with combined lifts may result in unsafe and/or unexpected handling characteristics.

WARNING

This kit should only be installed on a vehicle that is in good working condition. Before you install the kit, thoroughly inspect the vehicle for corrosion or deformation of the sheet metal around the factory body mounts. If the vehicle is suspected to have been in a collision or misused, do not install this kit. Off-road use of your vehicle with this kit installed may increase the stress applied to the factory body mounts. We do not recommend that any vehicle with a body lift kit installed be involved in any extreme off-road maneuvers such as jumping. Failure to observe this warning may result in serious personal injury and/or severe damage to your vehicle.

WARNING

Many states and municipalities have laws restricting bumper heights and vehicle lifts. Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law.

WARNING

The installation of larger tires may reduce the effectiveness of the braking system.

WARNING

Always wear eye protection when operating power tools.

WARNING

Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.

WARNING

Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental deployment during installation of the kit, the Supplemental Restraint System (SRS, or airbag) must remain deactivated. Do not allow anyone near the airbag during installation. Refer to the factory service manual or owner's manual for the recommended procedure to disable the SRS. After you install the kit, reactivate the

SRS before driving the vehicle.

NOTE

Performance Automotive Group recommends using the Loctite® supplied in the kit on the threads of all kit nuts and bolts unless specified otherwise in these instructions.

1 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Before Starting Installation

NOTE

Kit parts are prefaced by the word kit and appear in

bold print.

1. Carefully read all warnings and instructions completely before beginning.

2. Verify all parts have been received in this kit by checking the parts list at the end of this document.

Engine Compartment

1. Disconnect both battery cables to both batteries.

Disconnect negative cables first, then positive cables.

Negative

Cable

NOTE

If parts are missing from kit, please be prepared to provide the following information:

1. Name of purchase location

2. Bar Code on side of box

3. Date above bar code

4. Date inside box cover

5. Inspector # from inside box cover

3. Only install this kit on the vehicle for which it is

specified. If anytime during the installation you encounter something different from what is outlined in the instructions, call technical support at (928)

636-7080.

2. Airbag Fuse

NOTE

Positive

Cable

The location of the airbag fuse may vary; check the owner's manual. a. Remove fuse cover.

b. Remove airbag fuse(s).

4. Special tools needed: a. Welder or access to a professional welding shop.

b. Die grinder or similar tool capable of cutting metal.

Drill and drill bits

5. Park vehicle on a clean, dry, flat, level surface and block tires so vehicle cannot roll in either direction.

Fuse Cover

2 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Prepare to Install Kit

Measurements

1. Measure and record distance between front bumper and fenders.

Driver Side ________ Passenger Side ________

2. Measure and record distance between rear bumper and bed.

Driver Side ________ Passenger Side ________

3. Measure and record distance between cab and bed.

Driver Side ________ Passenger Side ________

Front of Vehicle

1. Front grill a. Remove clips from front air shield and remove air shield from grill.

b. Remove four bolts from grill and remove grill from core support.

Remove Clips from Air Shield

Remove Grill

Front

Bumper a. Disconnect fog light harness at driver side of front bumper and pull connector off of front bumper, if equipped.

Fog Light

Connector

Fog Light

Front

Bumper b. Remove four nuts from two double bolt fasteners.

Factory Nuts

Front

Bumper

Front c.

Remove all four push clips and air shield attached to bumper before removal. d. Remove two double bolt fasteners and front bumper from vehicle.

Frame

Double Bolt

Fasteners

Front

Bumper

3. Transmission cooler models

2. Front bumper

3 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

a. Remove four OEM bolts from transmission cooler and lower radiator.

Transmission

Cooler

Radiator b. Remove fan shroud wire harness to AUX fan.

Remove two bolts from fan shroud and prepare to remove fan shroud with engine fan.

(Note: Only if equiped with AUX fan.) .

Radiator

Fan Shroud

Bolts

Bolts b. Carefully lower transmission cooler from radiator locking tabs.

Temporarily support transmission cooler with kit

tie (zip).

4. Engine Compartment Airbox a. Remove wiring harness, intake hose, clamps and airbox vent hose from airbox and engine.

Intake

Hose

Hose Clamps

Wiring

Harness

Airbox Cover

Fan Clutch

Harness c.

Locate factory lower fan shroud insert shield and remove lower fan shroud insert shield.

Lower Fan

Shroud Insert

Shield d. Using proper tool; remove engine fan from water pump. (Note: Removing engine fan at this time will allow for easier reinstallation in later steps.)

Engine

Engine Fan

5. Radiator Fan Shroud a. Remove upper radiator hose from fan shroud

Upper

Radiator

Hose

Clip

Fan Shroud e. Remove all push clips and air shield from lower f.

fan shroud before removing shroud assembly.

Remove fan shroud, AUX fan and engine fan as assembly from engine compartment.

Engine Fan

Fan Shroud

4 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

WARNING

DO NOT perform the following procedure until the engine is completely cool. Coolant may be extremely hot and could cause serious personal injury.

6. Steering Shaft

7. Remove brake sensor wire harness from passenger and driver fender wells.

Driver Side

WARNING

Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental deployment during installation of the lift kit, the Supplemental Restraint System (SRS, or airbag) must remain deactivated. Do not allow anyone near the airbag during installation. Refer to the factory service manual or owner's manual for the recommended procedure to disable the SRS. After kit installation, the SRS must be reactivated before driving the vehicle.

CAUTION

If the following step is not performed, the airbag clockspring could be damaged. Do not turn the steering wheel while the steering shaft is disconnected.

a. Strap steering wheel to prevent accidental movement.

Wire Harness

Connectors

Passenger

Side

8. Remove two push clips and block heater cord from passenger side frame, if equipped.

b. Mark lower steering shaft in relation to upper steering shaft as shown.

Upper

Steering Shaft

Bolt

Alignment

Mark

Lower

Steering Shaft

Frame

Push Clips

Block

Heater Cord c.

Remove bolt and slide upper steering shaft up to separate from lower steering shaft.

Underside of Vehicle

1. Remove bolts and brake line bracket from driver side frame.

Brake Lines

Bracket

Bolts

Front

2010-2012 Dodge HEMI 2500/3500 - Kit 60223

2. Remove bolt and ground strap from driver side frame.

5. Remove harness from driver side body mount bracket.

Ground

Strap

Bolt

Frame

Harness Clip

Body Mount

Bracket

3. Remove nut and ground strap from stud on lower driver side firewall.

Firewall

Ground

Strap

Nut

Front

4. Remove push clip and wire harness from brackets on back of driver side engine.

NOTE

The following procedures applies ONLY to automatic transmissions.

6. Automatic transmission models: Remove transmission shifter cable from clip on frame.

Trans Shifter

Cable

Clip

Frame

Push Clip

Driver

Side

7. Parking brake cable

a. Pull slack into parking brake cable. If necessary, attach locking pliers onto parking brake cable to allow slack.

Locking

Pliers

Brackets

Parking

Brake Cable

Wire

Harness

Front

6 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

b. Use expanding pliers and disconnect parking brake cable from junction.

Junction b. Remove trunnion and shift rod from 4WD shift lever and transfer case input lever.

Transfer Case

Shift Lever

Cable c.

Remove front parking brake cable from driver side parking brake cable mount.

8. Fuel filler

Transfer Case

Input Lever

Trunnion

WARNING

Use extreme caution when working near fuel line(s) and fuel tank(s). Clean up spilled fuel immediately. Any spark could cause an explosion or fire resulting in serious personal injury and/or property damage.

a. Remove fuel cap from fuel filler.

b. Remove three bolts and fuel filler from body.

Fuel Cap

Shift Rod

Inside of Vehicle

1. Some Models: Manual transmission and transfer case shift levers a. Shift transmission into neutral and transfer case into 2H.

b. Remove two caps, two nuts, and transmission and transfer case shift knobs.

Bolts

Nut

Shift Knob

NOTE

The following procedures apply only to vehicles with manual transfer cases.

9. Manual transfer case a. Shift transfer case shift lever into 2H position.

Shift

Lever

7 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Remove transfer case shift lever boot from center console.

Transfer Case

Shift Lever f.

Remove six bolts and shift lever boot seal from floor.

Shift Lever

Boot Seal

Transfer Case

Shift Lever

Boot

Bolts d. Remove cup holder inserts, three screws, and center console from floor.

Screws g. Remove rubber cover from shift tower.

Rubber

Cover

Shift Tower

Center

Console e. Unscrew transmission shift lever from shift tower.

h. Remove four Torx bolts from shift tower mounting plate.

Torx Bolts

Mounting

Plate

Transmission

Shift Lever

Shift tower

Shift

Tower i.

Remove shift lever from shift tower.

Shift Lever

Mounting

Plate

Shift Tower

8 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

2. Some Models: Manual transmission and transfer case shift levers a. Shift transmission into neutral and transfer case into 2H.

b. Remove two caps, two nuts, and transmission and transfer case shift knobs.

Nut e. Remove manual transmission shift lever boot from shifter console.

Shift Lever

Boot

Shifter

Console

Shift Knob

Shift

Lever c.

Remove transfer case shift lever boot from center console.

Transfer Case

Shift Lever

Screws f.

Remove two screws and slide shifter console from vehicle.

g. Remove six bolts and shift lever boot seal from floor and shift lever.

Shift Lever

Boot Seal

Transfer Case

Shift Lever

Boot

Bolts d. Remove cup holder inserts, three screws, and center console from floor.

Screws h. Remove two nuts and manual transmission shift lever from shift tower.

Shift Lever

Nuts

Center

Console

Shift Tower

Rear of Vehicle

1. Rear bumper

9 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

a. Disconnect wire harnesses from rear bumper.

Wire Harness

Connectors d. Remove four bolts from bumper and frame.

Frame

Bolts

Bumper

Bracket

Front

2. Spare tire winch a. Lower spare tire onto ground and remove (see owner’s manual for procedure).

Spare Tire b. Remove two screws and license plate.

Screw Holes c.

Remove two bolts from center of bumper.

Remove Bolts b. Remove retaining clip and ratchet tube from spare tire winch mechanism.

Ratchet

Tube

Retaining

Clip

Tire Winch

Mechanism

10 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Remove plastic ratchet tube guide from crossmember.

b. Remove bolt and lower bushing from each cab mount on passenger side.

Bolt Lower Bushing

Remove Bolt

From These Mounts

Ratchet

Tube

Plastic

Guide

Crossmember

‘04-’05 Models: Cab Mount

Install Kit

Cab

1. Prepare to lift cab from frame a. Loosen, but DO NOT REMOVE, cab mounting bolts on driver side.

Loosen Bolt

Cab Mount

(Core Support)

‘06 Models: Cab Mount

Captive Washer

Bolt

WARNING

Use extreme caution when lifting body from frame. To prevent serious personal injury, ensure the lifting device is securely placed. Keep your hands out from between the body and frame.

CAUTION

Continually check hoses, wires, lines, etc. to be sure that everything is flexing properly and not binding, or damage to the vehicle could result. Be especially careful of the a/c hoses at the fire wall, the belt pulley, and at the core support. Ensure brake lines stretch while lifting. Bending the lines to gain ample slack may be necessary. Be extremely careful not to kink the lines.

Cab Mount

(Except Core Support)

NOTE

The number of cab mounting bolts may vary with the length of the cab.

11 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

2. Cab passenger side a. Remove captive washer from each cab mounting bolt.

e. Front Cab Mounts: Install kit bolt (12mm x

180mm) into each cab mount. DO NOT

TIGHTEN.

Kit Block

Captive

Washer

Bolt

Upper

Bushing

Kit Bolt

(12mm x

180mm) f.

Rear Hydro Cab Mount: Install lower bushing and kit bolt (12mm x 220mm) into each rear cab mount. DO NOT TIGHTEN.

NOTE

The OE cab mounting bolt captive washers will be used in the installation of this kit. DO NOT discard captive washers.

b. Position hydraulic jack and wood block under passenger side of cab (under the body seam).

Slowly lift cab just enough to install kit block on top of factory upper bushing.

Lower

Bushing

Kit Bolt

(12mm x

220mm)

WARNING

The kit blocks must be installed in addition to the factory upper and lower bushings. Installing the kit blocks without the factory upper and lower bushings could result in damage to the vehicle or serious personal injury.

Install kit block onto metal cups and upper bushings of each cab mount.

Kit Block

Metal Cup

3. Cab driver side a. Repeat previous steps to driver side of cab.

b. Set cab-to-bed spacing according to previous measurement.

Upper

Bushing d. Lower passenger side cab onto kit blocks.

12 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Remove each kit bolt, one at a time, and apply small amount of kit Loctite® onto threads.

Install kit bolt, and captive washer. TIGHTEN kit

bolts to 75 ft. lbs.

2. Remove bolt from each bed mount on passenger side.

Remove Bolt

At These Mounts

Kit Block

Captive

Washer

Kit Bolt

(12mm x

180mm)

Bolt

Bed Mounts

Bed

1. Prepare to lift bed from frame

Bolts a. Loosen, but DO NOT REMOVE, bed mounting bolts on driver side.

Loosen Bolt

At These Mounts

Bolts

Bolt

Bed Mounts

WARNING

Use extreme caution when lifting the bed from the frame. To prevent serious personal injury, ensure the lifting device is securely placed. Keep your hands out from between the bed and frame.

CAUTION

To prevent damage to the vehicle while lifting the bed, continually check hoses, wires, brake lines, etc. to ensure everything is flexing properly and not binding.

Ensure clearance between bed and cab is maintained.

3. Bed passenger side a. Using a hydraulic jack and wood block, slowly lift bed just enough to install kit block onto frame.

NOTE

The number of bed mounting bolts may vary with the length of the bed.

13 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

b. Install kit block onto rear frame mount.

Remove each kit bolt, one at a time, and apply small amount of kit Loctite® onto threads.

Install kit bolt with kit washer (7/16” USS).

TIGHTEN kit bolts to 55 ft. lbs.

Kit Block

Kit Bolt

(12mm x 120mm),

Kit Washer

(7/16” USS) c.

Install kit blocks onto two (or three) other frame mounts.

Rear of Vehicle

1. Spare tire winch a. Remove two bolts and spare tire winch from crossmember.

Spare Tire

Winch

Bolts

Kit Block

Kit Bolt

(12mm x 100mm),

Kit Washer

(7/16” USS) d. Lower bed onto kit blocks.

e. At rear bed mount, install kit bolt (12mm x

120mm) and kit washer (7/16” USS). DO NOT

TIGHTEN.

At other bed mounts, install kit bolts (12mm x

100mm) and kit washers (7/16” USS). DO NOT

TIGHTEN.

4. Bed driver side a. Repeat previous steps on driver side of bed.

b. Set bed-to-cab spacing according to previous measurement.

Front b. Install kit bracket (spare tire winch) onto crossmember with factory driver side bolt. DO NOT

TIGHTEN.

Tire Winch

Mechanism

Kit Bracket

(Spare Tire

Winch)

Driver Side

Factory Bolt

Psgr. Side

Factory Bolt

Front c.

Install spare tire winch through hole in crossmember. Position spare tire winch onto kit

bracket (spare tire winch).

14 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

d. Turn kit bracket (spare tire winch) toward front of vehicle and slide spare tire winch cable through slot in kit bracket (spare tire winch).

Tire Winch

Mechanism

Slot

Cable

Crossmember

Front e. Install kit bracket (spare tire winch) onto crossmember with factory passenger side bolt and

TIGHTEN both passenger and driver side bolt.

Install spare tire winch onto kit bracket (spare tire winch) with two kit bolts (5/16” x 1”), four kit

washers (5/16” SAE), and two kit nuts (5/16”

Nylock).

Spare Tire

Winch

Kit Bolts

(5/16” x 1”),

Kit Washers

(5/16” SAE),

Kit Nuts

(5/16” Nylock)

Ratchet

Tube

Retaining

Clip h. Install kit bracket (spare tire ratchet tube) onto crossmember with two kit bolts (1/4” x 3/4”), four kit washers (1/4” SAE), and two kit nuts (1/

4”-20 Nylock). Install plastic ratchet tube guide into kit bracket (spare tire ratchet tube).

Plastic Guide

Tube

Kit Bracket

(Spare Tire

Ratchet Tube)

Kit Bolts

(1/4” x 3/4”),

Kit Washers

(1/4” SAE),

Kit Nuts

(1/4” Nylock) i.

Install ratchet tube onto spare tire winch with retaining clip.

g. Remove two wire loom clips from crossmember.

Crossmember j.

Install wire harness onto crossmember with kit

tie (zip).

Wire

Harness

Kit Tie

(Zip)

Wire Loom

Clips

15 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Verify ratchet tube is visible through hole in bed and plastic ratchet tube guide. Adjust kit bracket

(spare tire ratchet tube), if necessary.

b. Using a cut off wheel remove both rear bumper mounting pins.

Rear Bumper Mounting Pin

Ratchet Tube

Bed l.

Install spare tire onto vehicle (see owner’s manual).

Spare Tire c.

Apply small amount of kit Loctite® onto threads of factory bolts. Install two kit brackets (rear bumper) onto frame and bumper with two factory bolts and nuts with captive washers and two

kit bolts (1/2” x 1-1/4”) and install rear bumper onto kit bracket (rear bumper, middle) with two

kit bolts (7/16” x 1-1/2”), four kit washers (7/16”

USS), and two kit nuts (7/16” Nylock). DO NOT

TIGHTEN.

Kit 1/2” Bolts and Nuts

Kit Bracket

(Rear Bumper)

2. Rear bumper

WARNING

The following procedure is intended only to enhance the appearance of the vehicle. The rear bumper will no longer be rated for towing of any kind. Towing with the rear bumper after it has been lifted can result in death, serious personal injury, or damage to the vehicle. Towing after the bumper has been lifted should be accomplished using a rated Class III receiver type hitch.

a. Apply small amount of kit Loctite® onto threads of factory bolts. Install kit bracket (rear bumper, middle) onto trailer hitch with two factory bolts.

DO NOT TIGHTEN.

Kit Bracket

(Rear

Bumper,

Middle)

Factory Bolts d. Measure, Mark & Cut rear bumper center section to clearance kit bumper (center) bracket.

Mark & Cut

Rear Bumper

Kit Bracket

(Rear Bumper)

16 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

e. Apply small amount of kit Loctite® onto threads of two kit bolts (7/16” x 1-1/2”) and install rear bumper onto kit bracket (rear bumper, middle) with two kit bolts (7/16” x 1-1/2”), four kit wash-

ers (7/16” USS), and two kit nuts (7/16” Nylock).

DO NOT TIGHTEN.

Kit Bolts

(7/16” x

1-1/2”),

Kit Washers

(7/16” USS),

Kit Nuts

(7/16” Nylock) b. Repeat above step for driver side.

WARNING

Use extreme caution when working near the fuel lines and the fuel tank. Clean up spilled fuel immediately. A spark could cause an explosion or fire resulting in serious personal injury and property damage.

2. Fuel filler a. Remove two hose clamps and fuel filler assembly from fuel tank.

Fuel Filler

Assembly

Cut Mark

Kit Bracket

(Rear

Bumper,

Middle) f.

Align rear bumper to previous bed-to-bumpermeasurements. TIGHTEN all hardware.

g. Connect wiring harnesses onto bumper.

h. Install license plate onto rear bumper with two factory screws.

Underside of Vehicle

1. Crush blocks

WARNING

A certified welder should perform all welding.

a. Weld two kit blocks (3” crush) onto passenger side frame, below bed, where shown.

Kit Blocks

(3” Crush)

Front

Hose

Clamps b. Carefully cut vent and fuel hose 2” from end of metal tubes.

Install kit extension (1-1/2” x 5” long) between cut ends of fuel hose with two kit clamps (#28 hose). DO NOT TIGHTEN.

Kit Extension

(1-1/2” x 5” Long)

Kit Clamps

(#28 Hose)

Kit Clamps

(#10 Hose)

Kit Extension

(3/4” x 3” Long) d. Install kit extension (3/4” x 3” long) between cut ends of vent hose with two kit clamps (#10 hose). DO NOT TIGHTEN.

e. Install fuel filler assembly onto fuel tank with two hose clamps.

17 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Install fuel filler assembly onto bed with three factory bolts. Install fuel cap. Adjust fuel filler and TIGHTEN all hose clamps.

Fuel Cap a. Install kit bracket (studded) to frame on driver side with factory bolt.

Kit Washers

(1/4” SAE),

Kit Nut

(1/4”-20 Nylock)

Kit Bracket

Bolts

Factory Bolt

3. Manual transfer case shift linkage a. Loosen bolt and move trunnion along shift rod to align with 4WD shift lever. DO NOT move 4WD shift lever. TIGHTEN bolt.

b. Install trunnion in 4WD shift lever.

b. Install ground strap to kit bracket (Studded) with two kit washers (1/4”-20 x 1”) and kit nut (1/4”-

20 Nylock).

6. Install ground strap onto lower driver side firewall with nut.

Bolt

Transfer Case

Input Lever

Firewall

Ground

Strap

Trunnion

Shift Rod

Nut

Front

7. Install automatic transmission shifter cable onto clip with kit tie (zip).

Verify the 4WD shift lever operation. Ensure there is complete engagement in all ranges. It may be necessary to adjust the position of the trunnion on the shift rod to obtain proper engagement in all ranges.

4. 2006 Models: Parking brake cable

8. Install wire harness and clip onto driver side body mount bracket.

Harness Clip a. Install front parking brake cable onto parking brake mount.

Body Mount

Bracket b. Pull slack into rear parking brake cable and retain slack with locking pliers. Connect front parking brake cable to rear parking brake cable with junction.

Release locking pliers.

5. Ground strap

CAUTION

18 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Some slight bending of the brake lines is required to align brackets with holes in frame rail. Use caution when bending brake line.

9. Carefully bend brake lines and install brake line bracket and two bolts onto driver side.

Brake Lines b. Scribe a line along side of transmission shift lever (below lowest bend). Measure diameter of shift lever (below lowest bend). Cut lever into two pieces and deburr as necessary.

Kit

Extension

Shift Lever

Bracket

Scribed

Line

Bolts

Front

Inside of Vehicle

WARNING

DO NOT DAMAGE any of the parts attached to the shift levers during cutting and/or welding. Damage to the shift lever equipment could result in serious injury or property damage.

WARNING

A certified welder should perform all welding.

1. Some Models: Manual transmission and transfer case shift levers a. Remove two plastic shift tabs, plastic ball, shim and mounting plate from shift lever.

Mounting

Plate

NOTE

If shift lever diameter is 5/8”, use kit extension (shifter,

5/8” x 3”). If shift lever diameter is 3/4” or larger, use kit

extension (shifter, 3/4” x 3”).

Scribe a line along side of kit extension. Position kit extension between two pieces of transmission shift lever. Ensure scribed lines on kit

extension and transmission shift lever align.

Weld kit extension in place.

Kit

Extension

Shim

Plastic Shift

Tabs

Plastic Ball d. Grind welded surfaces smooth in order to install mounting plate and shim to shift lever.

Shift Lever

19 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

e. Install two plastic shift tabs, plastic ball, shim, and mounting plate onto shift lever.

Install center console onto floor with three screws.

Shim

Mounting

Plate

Plastic Ball

Plastic Shift

Tabs

Screws

Center

Console f.

Install shift lever onto shift tower with four Torx bolts.

Torx Bolts

Mounting

Plate

Shift tower g. Install rubber cover onto shift tower.

Rubber

Cover j.

Screw transmission shift lever onto shift tower lever.

Install transfer case shift lever boot onto center console.

Install rubber cup holder inserts onto center console.

m. Install two shift knobs, two nuts, and two caps onto transmission and transfer case shift levers.

n. Check transmission and transfer case shift lever operation. Ensure complete engagement in all gears.

2. Current Models: Manual transmission shift lever

NOTE

Installing manual transmission shift lever requires Kit#

SE 9627 available separately.

Shift Tower h. Install shift lever boot seal onto floor with six bolts.

Shift Lever

Boot Seal

Bolts

20 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

a. Install kit extension (shifter) onto shift tower with two kit bolts (8mm x 30mm), four kit wash-

ers (8mm), and two kit nuts (8mm Nylock).

Shift Lever

OE Nuts

Kit Extension

(Shifter)

Kit Bolts

(8 x 30mm),

Kit Washers

(8mm),

Kit Nuts

(8mm Nylock)

Shift Tower b. Install manual transmission shift lever onto kit

extension (shifter) with two OE nuts.

Install shift lever boot seal onto shift lever and floor with six bolts.

Shift Lever

Boot Seal d. Trim manual transmission shift lever boot as shown.

Before Cut

Rear Of Boot,

Cut Here

Front Of Boot,

Cut Here

After Cut

e. Trim shifter console as shown.

Before Cut

Rear Of

Console,

Cut Here

Bolts

After Cut

21 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Install shifter console onto floor with two screws.

Engine Compartment

1. Steering shaft

Shift Lever

Boot

Shifter

Console

Screws g. Install manual transmission shift lever boot onto shifter console.

h. Install center console onto floor with three screws.

Screws

Center

Console i.

Install transfer case shift lever boot onto center console.

Install rubber cup holder inserts onto center console.

Install two shift knobs, two nuts, and two caps onto transmission and transfer case shift levers.

Check transmission and transfer case shift lever operation. Ensure complete engagement in all gears.

Kit Extension

(Steering)

WARNING

Verify the steering extension is securely installed as specified in the instructions. Failure to do so may cause steering malfunction, resulting in property damage or serious personal injury.

a. Install kit extension (steering) into lower steering shaft. Ensure marks on upper and lower steering shaft are aligned.

Upper Steering Shaft

Kit Bolt

(3/8” x 1-1/2”),

Kit Washers

(3/8” SAE),

Kit Nut

(3/8” Nylock)

Kit Extension

(Steering)

Factory Bolt

Lower Steering Shaft b. Install upper steering shaft into kit extension

(steering), ensuring marks on upper and lower steering shaft are aligned.

Apply small amount of kit Loctite® onto threads of factory bolt and kit bolt (3/8” x 1-1/2”).

d. Install factory bolts into lower steering shaft and

kit extension (steering) and TIGHTEN to 33 lb.ft.

22 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

e. Install kit bolt (3/8” x 1-1/2”), two kit washers (3/

8” SAE), and kit nut (3/8” Nylock) into upper steering shaft and kit extension (steering) and

TIGHTEN to 33 lb.-ft.

2. Install two push clips and block heater cord onto passenger side frame.

Frame

Front of Vehicle

1. Radiator Installation a. Remove engine fan and clutch harness from fan shroud. (Note: If Required) b. Locate factory lower fan shroud insert shield and two kit side shroud drop plates.

Push Clips

Block

Heater Cord

3. Install brake sensor wiring harness push clips onto passenger and driver side wheel wells.

Driver Side

Wire Harness

Connectors

Kit Fan Shroud Drop Plate c.

Using a pair of visegrips or clamps; create a 3” gap at the center of the fan shroud by separating

& squaring the main engine fan shroud with the lower fan shroud insert shield; then clamp the assembly together using two kit side shroud

drop plates at each side.

Fan Shroud

Measured

Main Fan

Shroud Edge

Lower Fan

Shroud Insert

Edge

Passenger

Side

Lower Fan

Shroud Insert

Shield

Kit Fan Shroud Drop

Plate Installed

d. Once you have shaped and placed each kit fan

shroud drop plates into place; reclamp and secure each kit shroud plate at a 3” gap and mark each 1/4” holes for drilling.

Note: Leaving each kit drop plate in place, while drilling, will ensure that you drill through the proper locations while drilling all four holes during this process.

2010-2012 Dodge HEMI 2500/3500 - Kit 60223

e. Once you have drill each hole use four kit

(1/4”x 3/4”), nuts & washers to fasten each kit

fan shroud drop plates into place. Do not

tighten at this time.

Note: Do not attempt to over tighten kit hardware against fan shroud, damage will occur to shroud.

Upper Fan

Shroud f.

Assemble both pairs of kit fan shroud block of

plates using two kit bolts(1/4”x3/4”), washers

& nuts in center of kit plates as shown below.

(Leave brackets slightly loose until mounted onto fan shroud, this will allow you to adjust the plates as needed to fit shroud properly.)

Kit Fan Shroud

Block Off Plates

Assembled

g. With both kit fan shroud block off plates assembled, face the tabs inwards so that the kit

fan shroud block off plate assembly mounts evenly with the edge of the upper fan shroud.

Kit (1/4x3/4”)

Hardware

Upper Fan

Shroud

Kit Fan Shroud

Block Off Plates

Assembled

Upper Fan

Shroud

Kit (1/4x3/4”)

Hardware

h. Once you have matched the kit fan shroud

block off plate assembly to the upper fan shroud, Mark & Drill all four 1/4” holes. i.

Use four kit bolts(1/4”x3/4”) washers & nuts to secure kit fan shroud block off plate assembly to upper fan shroud. Tighten kit hardware at this time.

Note: Be sure to install all kit (1/4”) hardware from inside to outside of kit fan shroud brackets. Doing so will eliminate the chance of kit hardware contacting the engine fan blades after shroud is reinstalled into vehicle j.

Using second pair of kit fan shroud block of

plates. (Leave brackets slightly loose until mounted onto fan shroud, this will allow you to adjust the plates as needed to fit shroud properly.) With both kit fan shroud block off plates assembled, face the tabs outwards so that the

kit fan shroud block off plate assembly mounts evenly with the inside edge of the lower fan shroud assembly. (Tighten assembly now.)

Lower Fan

Shroud

Kit Fan Shroud

Block Off Plates

Assembled

Kit (1/4x3/4”)

Hardware

24 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Install kit lower fan shroud block off plate

anchor onto kit lower fan shroud block off

plate assembly by using existing kit (1/4”) hardware and drilling a 1/4” hole into center of the shroud and installing kit (1/4”) hardware to anchor center of lower shroud assembly.

Note: Do not attempt to over tighten kit hardware against fan shroud, damage will occur to shroud.

Lower Fan

Shroud

Kit Fan Shroud

Block Off Plates

Assembled

Reinstall AUX fan back onto fan shroud before placing shroud back onto radiator mounts.

AUX Fan Reinstalled

Kit (1/4x3/4”)

Hardware

Lower Fan

Shroud m. Carefully reinstall engine fan & fan shroud back into lower locking tabs and engine fan clutch back onto engine water pump pulley with correct tooling.

Radiator

Locking Tab

Engine

Engine Fan

Fan Shroud

Kit Lower Fan Shroud Block Off Plate Anchor

25 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

2. Transmission cooler models a. Reinstall four OEM bolts from transmission cooler and lower radiator.

Transmission

Cooler

Radiator

Bolts

3. Front bumper

a. Mark and trim two front bumper brackets as shown. Test fit front bumper onto vehicle.

Bumper

Bracket

Mark & Trim

Here c.

Install two kit brackets (front bumper) and kit

spacer (2-1/4” long) onto driver side front bumper bracket with kit bolt (12mm x 100mm), two kit washers (7/16” USS), and kit nut (12mm

Nylock). Ensure head of kit bolt (12mm x

100mm) is facing towards center of vehicle. DO

NOT TIGHTEN.

Bumper Bracket

Kit Bolt

(12mm x 100mm),

Kit Washers

(7/16” USS),

Kit Nut

(12mm Nylock)

Kit Spacer

(2-1/4” Long)

Kit Brackets

(Front Bumper)

Center Of Vehicle d. Repeat above step for driver side front bumper bracket.

e. Position front bumper to frame. Ensure both edges of fender well fit on backside of bumper edge.

Front Bumper

Edge

Fender Well

Behind Front

Bumper Edge b. Apply small amount of kit Loctite® onto threads of factory front bumper bolts.

26 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

Install front bumper onto frame with four kit

washers (1/2”, thick), two double bolt fasteners and four nuts. Install kit washers (1/2”, thick) on bottom bolt of double bolt fasteners, between kit

bracket (front bumper) and frame. Snug hardware, but DO NOT TIGHTEN.

Kit Bolt

(12mm-1.75 x

120mm),

Kit Washers

(7/16” USS),

Kit Nuts

(12mm

Nylock) h. Connect fog light harness at driver side of front bumper and install connector onto front bumper, if equipped.

Fog Light

Connector

Fog Light

Front

Bumper

4. Engine Compartment Airbox

Nuts

Kit Brackets

(Front

Bumper)

Double Bolt

Fastener a. Reinstall wiring harness, intake hose, clamps and airbox vent hose from airbox and engine.

Intake

Hose

Hose Clamps

Wiring

Harness

Airbox Cover

Kit Brackets

(Front

Bumper)

Kit Washer

(1/2”, Thick)

5. Radiator Fan Shroud a. Reinstall upper radiator hose onto fan shroud

Upper

Radiator

Hose

Clip

NOTE

It may be necessary to compensate for space between

kit brackets (front bumper) and frame on bottom bolt of double bolt fastener. Do so with additional kit washers

(1/2”, thick) or kit washers (7/16”) when required.

g. Align front bumper-to-cab spacing to previous measurements. TIGHTEN all hardware.

Fan Shroud

6. Front grill a. Reinstall front air shield onto grill and core support using clips.

27 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

b. Reinstall grill into core support and secure grill using four bolts.

2. Connect both battery cables onto both batteries.

Connect positive cables first, then negative cables.

Install Clips onto Air Shield

Negative

Cable

Install Grill

Front

Bumper

Positive

Cable

After Completing Installation

Engine Compartment

Airbag fuse

NOTE

The location of the airbag fuse may vary; check the owner's manual. a. Install airbag fuse(s).

Miscellaneous

1. Apply kit label (warning) to dashboard in plain sight of all vehicle occupants.

2. Check all fasteners to ensure they are tight.

3. Ensure all wires, hoses, cables, etc. are properly connected and there is ample slack.

4. Adjust headlights.

5. Dynamic Vehicle Check

6. Test-drive vehicle. Check steering in both directions to ensure that there is no bind. Check operation of clutch, brake system, and parking brake. Check operation of transmission and transfer case. Ensure there is full engagement in all gears and 4WD ranges. Check battery connections and electrical component operations.

WARNING

Retorque all fasteners after 500 miles and after off road use. All body lift components should be visually inspected and fasteners retorqued during routine vehicle servicing.

Fuse Cover b. Install fuse cover.

28 2010-2012 Dodge HEMI 2500/3500 - Kit 60223

CAUTION

Performance Automotive Group does not recommend any particular wheel and tire combinations for use with its body lifts and cannot assume responsibility for the customer’s choice of wheels and tires. Refer to your owner's manual for recommended tire sizes and warnings related to the use of oversized tires. Larger wheel and tire combinations increase stress and wear on steering and suspension components, which leads to increased maintenance and higher risk for component failure. Larger wheel and tire combinations also alter speedometer calibration, braking effectiveness, center of gravity, and handling characteristics. Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle.

NOTE

All warranty information, instruction sheets, and other documents regarding the installation of this product must be retained by the vehicle owner. Information contained in the instructions and on the warranty card will be required for any warranty claims. The vehicle owner needs to understand the modifications made to the vehicle and how they affect vehicle handling and performance. Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury.

Accessories:

Kit # 6628: Front Gap Guards

NOTE

Depending on the vehicle configuration (automatic or manual transmission, cab length, bed length, etc.), some parts may not be used.

PARTS:

Qty.

Description

Block (3”)

Block (3” crush)

Bracket (front bumper))

Bracket (radiator, outside)

Bracket (radiator, driver lower/upper)

Bracket (radiator, passenger lower/upper)

Bracket (rear bumper, driver/passenger)

Bracket (rear bumper, middle)

Bracket (spare tire ratchet tube)

Bracket (spare tire winch)

Tube (bumper, spacers)

Extension (1-1/2” x 5”)

Instruction sheet

Label (logo)

Label (warning)

Label (warning, rear bumper)

1 Loctite® (6mL bottle)

- BP60223 -

Bolt (12mm-1.50x 100mm)

Bolt (12mm-1.75 x 120mm)

Bolt (12mm-1.75 x 180mm)

Bolt (12mm-1.75 x 220mm)

Bolt (3/8” x 1-1/2”)

Nut (3/8” Nylock)

Washer (3/8” SAE)

Washer (7/16” USS)

Washer (1/2”, thick)

1 Extension (steering)

- HP60223 -

Bolt (1/4” x 3/4”)

Bolt (5/16” x 1”)

Bolt (7/16” x 1-1/2”)

Bolt (1/2” x 1-1/4”)

Nut (1/4” Nylock)

Nut (5/16” Nylock)

Nut (12mm Nylock)

Nut (7/16” Nylock)

Nut (1/2” Nylock)

Tie (zip)

Washer (1/4” SAE)

Washer (5/16” USS)

Washer (7/16” SAE)

Washer (1/2”, USS)

Bracket (3” w/ stud)

Bracket (L-shape, anchor)

Extension (3/4” x 3”)

Extension (shifter, 5/8” x 3”)

Extension (shifter, 3/4” x 3”)

Clamp (#10 hose)

Clamp (#28 hose)

2010-2012 Dodge HEMI 2500/3500 - Kit 60223

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Key Features

Increases Ground Clearance
Improved Off-Road Capability
Aggressive Look
Detailed Installation Instructions
Pre-assembled Parts
High-Quality Hardware
Compatible with Dodge HEMI 2500/3500
Requires Professional Installation
Safety Warning Included

Frequently Answers and Questions

Can I install this kit myself?

The instructions state that proper installation requires knowledge of factory procedures. They highly recommend a certified mechanic familiar with similar components install the kit.

What is the recommended tire size for this body lift?

The instructions warn that larger tire combinations increase stress on steering and suspension components and suggest consulting an experienced off-road shop for recommendations.

Are there any safety considerations for using this body lift?

The instructions emphasize the importance of driving safely after installation, avoiding sudden turns, and making sure all occupants are wearing seatbelts. They also warn against extreme off-road maneuvers like jumping.

What are the implications of installing a body lift?

The instructions highlight that the lift will alter the vehicle's center of gravity and handling characteristics, both on and off-road. They strongly advise driving with caution and avoiding sudden maneuvers to prevent rollovers or loss of control.