View Instructions

View Instructions
#013411, 013611
2005 Ford Super Duty 4wd
4", 6" Suspension System
Read and understand all instructions and warnings prior
to installation of system and operation of vehicle.
BDS Suspension Co. recommends this system be
installed by a professional technician. In addition
to these instructions, professional knowledge of
disassembly/ reassembly procedures and post
installation checks must be known.
Certain BDS Suspension products are intended to
improve off-road performance. Modifying your vehicle
for off-road use may result in the vehicle handling
differently than a factory equipped vehicle. Extreme
care must be used to prevent loss of control or
vehicle rollover. Failure to drive your modified vehicle
safely may result in serious injury or death. BDS
Suspension Co. does not recommend the combined
use of suspension lifts, body lifts, or other lifting
You should never operate your modified vehicle
under the influence of alcohol or drugs. Always drive
your modified vehicle at reduced speeds to ensure
your ability to control your vehicle under all driving
conditions. Always wear your seat belt.
Pre-Installation Notes
1. Special literature required: OE Service Manual for
model/year of vehicle. Refer to manual for proper
disassembly/reassembly procedures of OE and
related components.
2. Adhere to recommendations when replacement
fasteners, retainers and keepers are called out in
the OE manual.
3. Larger rim and tire combinations may increase
leverage on suspension, steering, and related
components. When selecting combinations larger
than OE, consider the additional stress you could
be inducing on the OE and related components.
4. Post suspension system vehicles may experience
drive line vibrations. Angles may require tuning,
slider on shaft may require replacement, shafts
may need to be lengthened or trued, and U-joints
may need to be replaced.
5. Secure and properly block vehicle prior to
installation of BDS Suspension components.
Always wear safety glasses when using power
6. If installation is to be performed without a
hoist, BDS Suspension Co. recommends rear
alterations first.
7. Due to payload options and initial ride height
variances, the amount of lift is a base figure. Final
ride height dimensions may vary in accordance
to original vehicle attitude. Always measure the
attitude prior to beginning installation.
1. Check all fasteners for proper torque. Check
to ensure for adequate clearance between all
rotating, mobile, fixed, and heated members.
Verify clearance between exhaust and brake
lines, fuel lines, fuel tank, floor boards and wiring
harness. Check steering gear for clearance. Test
and inspect brake system.
2. Perform steering sweep to ensure front brake
hoses have adequate slack and do not contact
any rotating, mobile or heated members. Inspect
rear brake hoses at full extension for adequate
slack. Failure to perform hose check/ replacement
may result in component failure. Longer
replacement hoses, if needed can be purchased
from a local parts supplier.
3. Perform head light check and adjustment.
4. Re-torque all fasteners after 500 miles. Always
inspect fasteners and components during routine
102 S. Michigan Avenue • Coldwater, MI 49036
517-279-2135 •
rev. 3/30/2007
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Front Installation
Coil Spring (4" only)
Coil Spring (6" only)
Bolt Pack
Bolt Pack
Bolt Pack
Bolt Pack
Radius Arm Drop Bracket
Track Bar Bracket
Cam Washer
Sway Bar Drop Bracket
Bump Stop Spacer
Pitman Arm
ABS Line Bracket (05-06)
ABS Line Bracket (07-up)
Brake Line Bracket (4" only)
Brake Line Bracket (6" only)
Stabilizer Bracket
Alignment Cam (6" only)
Zip Tie
Park the vehicle on a clean, flat surface and block the
rear wheels for safety.
Disconnect the front track bar from the frame mount.
Retain hardware.
Raise the front of the vehicle and support under the frame
rails with jack stands. Note: As a result of the location of
the long radius arm suspension, support locations are
limited. Use your best judgment while supporting the
vehicle with sufficient strength stands at appropriate locations. The radius arms will need to move freely during this
Remove the front wheels.
Support the front axle with a hydraulic jack.
Disconnect the front brake lines from the axle and frame
(Fig 1). Retain hardware.
Bolt Pack 422
3/8"-16 x 1-1/4" bolt grade 8 yellow zinc
3/8"-16 prevailing torque nut yellow zinc
3/8" USS flat washer thru-hardened yellow zinc
Bolt Pack 430
3/4"-10 x 5" bolt grade 8 yellow zinc
3/4"-10 prevailing torque nut yellow zinc
3/4" SAE flat washer thru-hardened yellow zinc
FIG. 1
Free the hub vacuum lines from the axle (Fig 2, 3).
Bolt Pack 431
5/16"-18 x 1-1/4" bolt grade 8 yellow zinc
5/16"-18 x 1" bolt grade 8 yellow zinc
5/16"-18 prevailing torque nut yellow zinc
5/16" SAE flat washer yellow zinc
5/16"-18 x 3/4" bolt grade 8 yellow zinc
6 1/4"-20 prevailing torque nut clear zinc
12 1/4" USS flat washer clear zinc
2 1/4"-20 x 3/4" bolt grade 5 clear zinc
4 1/4"-20 x 1" bolt grade 5 clear zinc
1 1/8" x 1" cotter pin clear zinc
Bolt Pack 639
Qty Description
2 1/4"-20 x 3/4" bolt grade 5 clear zinc
2 1/4"-20 prevailing torque nut clear zinc
1/4" USS flat washer clear zinc
5/16"-13 x 1" hex flange head self-drilling screw
Wire Clip (Fastenal #0708762)
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FIG. 2
11. Disconnect the OE steering stabilizer from the drag link
and the frame mount. Remove the two nuts (and bolt tab)
mounting the stabilizer frame mount and remove it from
the vehicle. Retain the frame bracket mounting hardware.
12. Install the new steering stabilizer bracket to the frame
using the original hardware (Fig 6). Mount the stabilizer
bracket to the back side of the frame crossmember in the
original mounting holes. Torque hardware to 55 ft-lbs.
13. Install the provided shock stud in the new stabilizer
bracket up through the bracket so that the stud points
down (Fig 6). Torque to 50 ft-lbs.
FIG. 3
Disconnect the sway bar end links from the axle mounts.
Retain hardware.
Remove the OE shock. Retain lower mounting hardware.
10. Remove the ABS line from the retaining tab on the radius
arm (Fig 4). Carefully pull the plastic retaining clip free
from the radius arm (Fig 5).
FIG. 6
14. Disconnect the (5) bolts mounting the OE track bar bracket to the frame. Remove bracket and retain hardware.
15. Disconnect the drag link from the pitman arm. Retain hardware. Free the drag link from the pitman arm with a pickle
16. Remove the pitman arm nut. Note the indexing of the
pitman arm in relation to the steering sector shaft and
remove the pitman arm from the steering box using the
appropriate puller.
FIG. 4
17. Remove all of the dri-lock compound on the threads of
the OE nut and steering sector shafts. This is important
to ensure that the new thread lock compound will adhere
18. Apply a bead of the supplied thread lock all the way
around the threads of the OE nut.
19. Install the new pitman arm (indexed the same as the OE)
and fasten with the OE nut. Torque the nut to 350 ft-lbs.
20. Lower the axle until the OE coil springs are free and
remove the springs from the vehicle. Retain the upper
spring isolator for use with the new springs. Note: Do not
over extend the brake lines.
FIG. 5
21. Install the new track bar bracket using the stock mounting
hardware as it was removed (Fig 7). Torque all (5) mounting bolts to 129 ft-lbs.
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24. Install the extended bump stop to the frame with the
original hardware and torque to 20 ft-lbs (Fig 9). The
closed face of the extension should face the outside of
the vehicle. Install the original bump stop in the relocated
bump stop cup.
FIG. 7 (from front)
FIG. 9
25. Loosen the four radius arm-to-axle mounting bolts but do not
remove. Once again, ensure that the front axle is well supported.
26. Starting with the passenger’s side, remove the upper
radius arm-to-axle mounting bolt. Remove the radius
arm-to-frame bolt as well. This will allow the radius arm to
swing down away from the frame.
FIG. 7 (from rear)
27. Install the new radius arm brackets in the OE frame
bracket (Fig 10) with two ¾” x 5” bolts, nuts and four SAE
washers from bolt pack #430. Torque bolts to 250 ft-lbs.
Note: May need to clearance the front mounting hole
slightly to provide proper bolt fitment.
22. Pull the OE front bump stops free from the bump stop
cups and remove the bolt mounting the cup to the frame
(Fig 8).
FIG. 10
28. Swing the radius arm up into the new bracket and fasten
with the original mounting hardware. Leave loose.
29. Repeat this procedure on the driver’s side of the vehicle.
30. With both radius arms relocated, reattach the upper radius
arm-to-axle mounting bolts. Leave loose. Note: All (6) radius
arm bolts will be torqued with the weight of the vehicle on
the axle.
FIG. 8
23. Install the cup on the provided bump stop extension with a
5/16” x 1” bolt, nut and 5/16” SAE washers from bolt pack
#431. The alignment tab on the bump stop cup will fit in the
second hole in the extension. Torque hardware to 20 ft-lbs.
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31. Install the new coil springs in conjunction with the OE top
isolator. Rotate the springs so that they seat in the bottom
coil perch properly.
32. Install the new shocks using the original lower mounting
hardware and the provided upper mounting hardware.
Torque the lower bolt to 100 ft-lbs and the upper until the
bushings begin to swell.
33. Note the orientation of the front sway bar (top verses
bottom). Disconnect the sway bar from the frame and
remove from the vehicle. Retain hardware.
34. Install the provided sway bar drop bracket to the original sway bar frame mounting locations with the original
hardware. Torque hardware to 30 ft-lbs. Note: The square
alignment tabs mount down toward the sway bar.
35. Attach the sway bar to the new drop brackets in the
correct orientation with the 3/8” hardware from bolt pack
#422. Torque hardware to 30 ft-lbs (Fig 11).
36. Install the sway bar link ends in the original axle mounts
and secure with the OE hardware.
FIG. 12B
2007-up Models Only
40. Remove the plastic ABS retaining tab from the radius
arm. Discard the tab.
41. Attach the provided ABS relocation bracket (01029) to the
radius arm using the existing slot (where the plastic tab
was removed) and the middle hole in the bracket. Fasten
the bracket with a 5/16” self-drilling screw (BP 639). Note:
The longer portion of the bracket goes up.
FIG. 11
05-06 Models Only
37. Remove the metal ABS retaining tab from the radius arm.
Attach the tab to the supplied extension bracket with a
5/16” x ¾” bolt, nut and two 5/16” SAE washers from bolt
pack #431. Torque to 20 ft-lbs.
38. Attach the extended ABS retaining tab to the original mounting hole on the radius arm with the OE bolt
(Fig 12A). Torque to 20 ft-lbs.
39. Install the ABS line in the retaining tab on the radius arm.
Reinstall the plastic ABS tab (near the axle) to the original
hole in the radius arm.
42. Attach the bracket to the radius arm through the lower
hole so that the bracket is straight up. Fasten the bracket
with a 5/16” self-drilling screw (BP 639). Using the hole
in the bracket as a templete, drill a 1/4" hole in the radius
arm. (Fig 12B)
43. Attach the ABS line to the top hole in the bracket with the
provided wire clamps and ¼” hardware (BP 639). Tighten
hardware securely.
4" Brake Line Drop
44. Install the provided brake line relocation bracket to the
original mounting hole on the coil spring bucket with the
OE bolt. (Fig. 13a)
45. Attach the brake line to the stud on the bracket and
secure with a ¼” nut and ¼” USS washer from bolt pack
#431. Torque OE bolt to 20 ft-lbs and ¼” nut to 10 ft-lbs.
FIG. 13a (4" only)
FIG. 12A
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6" Brake Line Drop
Both 4" and 6" Kits
46. Attach the short end of the brake line bracket to the coil
mount. (Fig 13b) Align the two holes in the bracket with
the existing coil mount holes. Install a 1/4" x 1" bolt, nut
and 1/4" USS washers (Bolt Pack #431) in the top hole
and the original bolt in the second hole down. Tighten
hardware to 10 ft-lbs.
57. Install the wheels and lower the vehicle to the ground.
58. Attach the track bar to the new bracket with the OE hardware. Turn the steering wheels to aid in aligning the track
bar in the bracket. Torque hardware to 406 ft-lbs.
6" Only: Install the provided cam washers between the
alignment tabs on the bracket so that the hole is closer to
the inside of the vehicle (Fig. 14)
4" Only: Install the provided cam washers between the
alignment tabs on the bracket so that the hole is closer to
the outside of the vehicle.
59. Torque all six radius arm bolts to 250 ft-lbs.
FIG. 13b (6" only)
47. Carefully reform the hard brake line in order to mount it to
the lower holes in the bracket. Attach with 1/4" x 1" bolt,
nut and 1/4" USS washers (Bolt Pack #431). Tighten to 10
48. Reattach the hub vacuum lines to the original locations.
6" Notes: Reform the driver's side vacuum line retainer
on the differential as necessary. Use the provided zip ties
to reattach the passenger's side line as necessary.
49. Attach the drag link to the new pitman arm, fasten with
the OE nut, and torque to 65 ft-lbs. Install the OE castellated nut cap and new cotter pin (BP #431).
50. Install the tapered steering stabilizer stud in the original
tapered mounting hole in the drag link. Torque hardware
to 55 ft-lbs.
51. Install the new steering stabilizer cylinder to the stud on
the frame bracket the new stud in the drag link. Torque
hardware to 45 ft-lbs.
Alignment Cam Installation (6" Only)
52. Remove the cotter pin from the upper ball joint.
53. Loosen the upper ball joint stud until the nut is level with
the top of the stud. Strike the axle “ear” near the upper
ball joint to release the ball joint to sleeve taper. Note:
The top of the stud can also be struck using a soft blow
hammer to aid in loosening the taper. Take care not to
damage the stud/nut threads.
54. Remove the OE ball joint sleeve from the axle using the
appropriate removal tool (SPC #41550 or equivalent).
55. Install the new sleeve with the arrow on the top of the
sleeve pointing toward the front of the vehicle. Using the
old sleeve, pound down on the new sleeve to seat it on
the ball joint taper. Make sure that the flat of the sleeve is
flush with the flat of the axle.
56. Install and torque the OE ball joint nut to 120 ft-lbs. Install
the cotter pin. Note: Do not loosen the nut to install the
cotter pin.
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FIG. 14
Rear Installation
60. Raise the rear of the vehicle and support with jack stands
under the frame rails just ahead of the spring hangers.
61. Remove the wheels.
62. Support the axle with a hydraulic jack.
63. Remove the OE shocks. Retain all mounting hardware.
Block Kit Only (4" only)
64. Disconnect the passenger’s side spring u-bolts.
65. Lower the axle enough to place the provided 3” lift block
between the axle and OE block.
66. Ensure that the mounting surfaces are clean of dirt and
corrosion and install the new block so that the short end is
toward the front. Also make certain that the OE block is on
top of the new block and that the bump stop wing is pointing inward.
67. Raise the axle to engage all of the block/spring alignment
pins. Fasten the entire assembly with the provided ubolts, high nuts and washers. Snug but do not torque the
u-bolts at this time.
68. Repeat block installation of the driver’s side. Take care not
to over extend the brake lines. Note: You may disconnect
the parking brake mounting tab on the spring plate before
removing the u-bolts and reattach after the installation is
Leaf Spring Kit Only
Block and Leaf Springs Kits
69. Disconnect the passenger’s side u-bolts and lower the
axle from the spring.
4" Kit: Remove the OE block, it will not be reused.
6" Kit: Retain OE block to be installed with new spring.
76. Install the new shocks with the original mounting hardware. Note: With the shocks installed, allow the axle to
hang at full droop. Check shock to shock mount u-bolt
clearance. In some cases, the shock may contact the
u-bolt. If this is the case, loosen the u-bolt and rotate the
mount up, moving the shock away from the axle tube.
Retighten the u-bolts to 90 ft-lbs. The bracket can also be
tack welded in place to prevent any movement, but is not
70. Loosen and remove the front spring-to-frame and rear
shackle-to-frame bolts and remove the spring from the
71. Remove the shackle from the OE spring and loosely install it
on the new rear spring. Be sure that the shackle is oriented
on the new spring identical to the old. The shackles mount
of the longer end of the spring (opposite of the end marked
with “FRT”).
72. Install the new spring in the vehicle with the OE bolts.
Leave hardware loose. All of the spring pivot bolts will be
torqued with the weight of the vehicle on the springs.
73. Remove all dirt and corrosion from the axle spring pad
and raise the axle to the spring while aligning the center
pin with the center pin hole. Fasten the spring with the
provided u-bolts. Snug but do not torque u-bolts at this
77. Install wheels and lower the vehicle to the ground.
78. With the weight of the vehicle on the axle, torque the ubolts to 130-150 ft-lbs.
79. Check all hardware for proper torque.
80. Adjust steering wheel.
81. Adjust headlights
82. Check hardware after 500 miles.
74. Repeat the procedure on the driver’s side. Disconnect the
parking brake cable bracket from the spring plate and retain
hardware (Fig 15). Take care not to over extend the brake
FIG. 15
75. Reattach parking brake cable bracket to the spring plate.
If more slack is needed remove the cable from the rearmost cable ring on the frame rail (Fig 16).
FIG. 16
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