Kit Instructions-PDF
491 W. Garfield Ave., Coldwater, MI 49036
Phone: 517-279-2135
Web/live chat: www.bds-suspension.com
E-mail: [email protected]
Part#: 013812
Product: 8" 4-Link Suspension System
Application: 2008-2010 Ford Super Duty 4wd
Read and understand all instructions and warnings prior
to installation of system and operation of vehicle.
SAFETY WARNING
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.
PRODUCT SAFETY WARNING
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 devices.
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 tools.
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.
POST-INSTALLATION WARNINGS
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 servicing.
rev. 4/22/2012
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PARTS LIST
Part #
Qty Description
22526D
1
Front Brake Line (drv)
22526P
1
Front Brake Line (pass)
22523
1
Rear Brake Line
5188
3
Brake Line Clip
CCW-03-0504
3/8" Crush Washer
083404R
1
Pitman Arm
01528
1
Stabilizer Bracket
02030
2
Bump Stop Bracket
435
1
Bolt Pack
4
5/16"-18 x 1-1/4" bolt
4
5/16"-18 prevailing torque nut
8
5/16" SAE washer
2
1/4"-20 x 3/4" bolt
2
1/4"-20 prevailing torque nut
4
1/4" SAE flat washer
2Clamp
422
1
Bolt Pack
4
3/8"-16 x 1-1/4" bolt
4
3/8"-16 prevailing torque nut
8
3/8" USS flat washer
1
Sway Bar Drop Bracket
01044
01045
1
Sway Bar Drop Bracket
02034
1
Track Bar Bracket
02019
2
Cam Washer
02026
1
4-Link Bracket
Page 2 013812
02027
1
4-Link Bracket
3527RB8Bushing
60107
4
90° grease zerk
432
1
Bolt Pack
14
1/2"-13 x 1-1/2" bolt
1
1/2"-13 x 1" bolt
14
1/2"-13 prevailing torque nut
28
1/2" SAE flat washer
4
3/4"-10 x 5-1/2" bolt
4
3/4"-10 preveiling torque nut
8
3/4" SAE flat washer
2
Wire Clip
2
1/4"-20 x 3/4" bolt
2
1/4"-20 prevailing torque nut
4
1/4" SAE flat washer
7
4
1.000 x 0.120 x 3.250 Sleeve
02007
2
Upper Control Arm
02008
2
Lower Control Arm
01046
1
Fuel Module Spacer
01975
1
1" Block
01048
1
Hanger Bracket
436
1
Bolt Pack
1
8mm-1.25 x 75mm bolt
5/16"-18 x 1-1/4" bolt
1
3
5/16"-18 prevailing torque nut
7
5/16" USS flat washer
2
5/16"-18 x 2" bolt
INSTALLATION INSTRUCTIONS
Front Installation
1. Park the vehicle on a clean, flat surface and block the rear wheels for safety.
2. Disconnect the front track bar from the frame mount. Retain hardware.
3. 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 installation.
4. Remove the front wheels.
5. Support the front axle with a hydraulic jack.
6. Disconnect the front brake line brackets from the axle and frame (Fig 1). Retain hardware.
Fig. 1
7. Disconnect the rubber brake line from the hard line at the frame. Disconnect the brake line brackets at the frame
and retain mounting bolt.
8. Disconnect the brake line from the caliper. Retain the OE banjo bolt and discard the original crush washers.
9. The brake line axle bracket will need to be trimmed. Cut the brake near the rolled end holding the OE brake line
(Fig 2). Drill a ¼” mounting hole about 3/8” in from the cut edge and centered along the edge. Set the brackets
aside to be reinstalled later.
Fig. 2
10. Attach the new driver’s (22526D) and passenger’s (22526P) brake lines to the calipers using the provided new crush
washers and OE banjo bolt. Place a crush washer on each side of the brake line fitting. Torque bolt to 25 ft-lbs.
013812 Page 3
11. Run the opposite end of the new brake lines up through the OE frame brackets and attach to the OE hard line.
Tighten fitting securely. Attach the lines to the OE brackets with the provided clips (5188).
12. Free the hub vacuum lines from the axle (Fig 3, 4).
Fig. 3
Fig. 4
13. Disconnect the sway bar end links from the sway bar. Retain hardware.
14. Remove the OE shock. Retain lower mounting hardware.
15. Remove the ABS line from the retaining tab on the radius arm (Fig 5). Carefully pull the plastic retaining clip free
from the radius arm (Fig 6).
Page 4 013812
Fig. 5
Fig. 6
16. 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.
17. Install the new steering stabilizer bracket (01528) to the frame using the original hardware (Fig 7). Mount the
stabilizer bracket to the back side of the frame crossmember in the original mounting holes. Torque hardware to 55
ft-lbs.
18. Install the provided shock stud in the new stabilizer bracket up through the bracket so that the stud points down
(Fig 7). Torque to 50 ft-lbs.
013812 Page 5
Fig. 7
19. Disconnect the (5) bolts mounting the OE track bar bracket to the frame. Remove bracket and retain hardware.
20. Disconnect the drag link from the pitman arm. Retain hardware. Free the drag link from the pitman arm with a pickle
fork.
21. 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.
22. 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 properly.
23. Apply a bead of the supplied thread lock all the way around the threads of the OE nut.
24. Install the new pitman arm (indexed the same as the OE) and fasten with the OE nut. Torque the nut to 350 ft-lbs.
25. 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.
26. Install the new track bar bracket (02034) using the stock mounting hardware as it was removed (Fig 8). Torque all
(5) mounting bolts to 129 ft-lbs.
Fig. 8 (from front)
Page 6 013812
Fig. 8 (from rear)
27. Pull the OE front bump stops free from the bump stop cups and remove the bolt mounting the cup to the frame
(Fig 9).
Fig. 9
28. Position the cup on the provided bump stop extension (02030). The alignment tab on the bump stop cup will fit in the
second hole in the extension.
29. Pull the OE front bump stops free from the bump stop cups and remove the bolt mounting the cup to the frame
(Fig 9).
30. Install the cup on the provided bump stop extension with a 5/16” x 1-1/4” bolt, nut and 5/16” SAE washers from bolt
pack #435. The alignment tab on the bump stop cup will fit in the second hole in the extension. Torque hardware to 20
ft-lbs.
013812 Page 7
31. Install the extended bump stop to the frame with the original hardware and a 5/16" x 1-1/4" bolt, nut and 5/16"
SAE washers from bolt pack #435. The 5/16" hardware will go in one of the two remaining bracket mounting holes
that line up to an existing frame hole. Torque hardware to 20 ft-lbs. The closed face of the extension should face the
outside of the vehicle. Install the original bump stop in the relocated bump stop cup. NOTE: If there is not a second
existing hole in the frame, mark one of the holes and drill a 5/16" hole in the frame. Take care to check the area
before drilling.
32. Loosen the four radius arm-to-axle mounting bolts but do not remove. Once again, ensure that the front axle is well
supported.
33. Starting with the passenger’s side, remove the upper radius arm-to-axle mounting bolt. Remove the radius armto-frame bolt as well. This will allow the radius arm to swing down away from the frame. Remove the lower radius
arm-to-axle bolt and remove the arm from the vehicle. Retain hardware.
34.Lightly grease and install the provided bushings (3527RB) and sleeves (7-1) in the four new control arms (02023,
02024).
35. Install the provided 90° grease fittings in the threaded holes at the bushing end of the control arms. When installed
the fittings should point toward the body of the control arm. (Fig. 10)
Fig. 10
36. Locate the seven rivets that attach the OE radius arm mounting bracket to the frame. There will be four on the
outside and three in the inside of the bracket fastening the bracket to the bottom of the frame. (Fig. 11)
Fig. 11
37. Remove the seven rivets with a grinder, drill, air chisel or combination of these tools. Do not use a torch. The undercoating used on the frame is highly flammable. Also, the fuel system lines run inside of the driver’s side frame rail.
38. With the rivets removed, free the radius arm bracket from the frame. Ensure that all of the rivets are removed from
the holes in the frame.
Page 8 013812
39. Place the new passenger’s side 4-Link bracket (02027) up to the frame and align the existing rivet holes with the
corresponding holes in the bracket. Attach the bracket with ½” x 1-1/2” bolts, nuts and ½” SAE flat washers from
bolt pack #432. Torque ½” hardware to 90 ft-lbs. (Fig. 12,  13)
Fig. 12
Fig. 13
40.Install the assembled upper control arm in the new frame bracket and fasten with a ¾” x 5-1/2” bolt, nut and ¾”
SAE flat washers from bolt pack #432. The two tabs on the control arm go up. Leave hardware loose. (Fig. 14)
013812 Page 9
Fig. 14
41. Attach the axle end of the control arm with the original hardware. Leave hardware loose. (Fig. 15)
Fig. 15
42. Install the new lower control arm in the new frame bracket with a ¾” x 5-1/2” bolt, nut and ¾” SAE flat washers.
Install arm so that the grease fitting is up. Leave hardware loose.
43. With the axle well supported, disconnect the driver’s side radius arm from the axle. Retain hardware.
44.Attach the new passenger’s side lower control arm to the axle with the original hardware. Leave hardware loose.
45. If equipped, remove the 3 nuts mounting the fuel module to the inside of the driver’s side frame rail above the radius
arm bracket (Fig 16A). Remove the fuel lines from the clip just ahead of the fuel module on the inside of the frame
and pull the module in, away from the frame (Fig 16B). Retain hardware.
Page 10 013812
Fig. 16A
Fig. 16B
46.Repeat the frame bracket and control arm installation procedure on the driver’s side of the vehicle. When mounting
the new bracket, use a ½” x 1” bolt in the 2nd (from the front) outside mounting hole (Fig 17A). This shorter bolt
is necessary to properly clear the fuel module when it is reinstalled. Note: Use the nut that was removed from the
radius arm-to-frame bolt for the upper control arm-to-axle mount bolt when installing the new control arm. The OE
nut in this position is welded to the radius arm.
013812 Page 11
Fig. 17A
47. Install the provided fuel module spacer plate over the 3 studs of the fuel module bracket and reinstall the module in
the original holes with the factory nuts (Fig 17B). Torque nuts to 20 ft-lbs.
Fig. 17B
48.With all of the control arms attached, reinstall the fuel junction block (if removed) on the driver’s side frame rail.
Torque hardware to 20 ft-lbs.
49. Attach the plastic ABS wire clip to the front tab on the new upper control arm. Secure the wire to the rear tab with
the provided wire clip and 1/4" x 3/4" bolt, nut and 1/4" USS washers (BP 432). Torque 1/4" hardware to 10 ft-lbs.
(Fig.  18)
Page 12 013812
Fig. 18
50. 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.
51. 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.
52. 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.
53. Install the provided sway bar drop bracket (01044, 01045) to the original sway bar frame mounting locations with
the original hardware. Mount the drop bracket with the open face toward the inside of the vehicle and the bracket
offset toward the front. Torque hardware to 30 ft-lbs.
54.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 19).
Fig. 19
55. Install the sway bar link ends to the sway bar and secure with the OE hardware. Torque to 90 ft-lbs.
56. Fasten the modified OE brake line axle brackets to the axle in their original location with the factory hardware.
Torque hardware to 10 ft-lbs.
57. Attach the new brake line to the bracket with a provided clamp, ¼” x ¾” bolt, nut and washers (BP 435) using the
hole drilled earlier. Torque bolt to 10 ft-lbs.
58. Properly bleed the brake system of air and top off the brake fluid reservoir with the proper type of fluid (see owners
manual).
59. Install the wheels and lower the vehicle to the ground.
013812 Page 13
60. Attach the track bar to the new bracket with the OE hardware. Turn the steering wheel to aid in aligning the track
bar in the bracket. Install the provided cam washers (02019) between the alignment tabs on the bracket. The cam
washers have an offset hole. Position the cam washer in the position that best centers the axle under the vehicle.
Fasten with the OE bolt and nut. Torque hardware to 400 ft-lbs.
61. Torque all six radius arm bolts to 250 ft-lbs.
Fig. 20
Rear Installation
62. Raise the rear of the vehicle and support with jack stands under the frame rails just ahead of the spring hangers.
63.Remove the wheels.
64.Support the axle with a hydraulic jack.
65. Remove the OE shocks. Retain all mounting hardware.
Note: For diesel applications, perform exhaust relocation at end of instruction sheet before proceeding.
66.Disconnect the passenger’s side u-bolts and lower the axle from the spring.
67. Loosen and remove the front spring-to-frame and rear shackle-to-frame bolts and remove the spring from the
vehicle.
68.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”).
69. 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.
70. 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 time.
71. Repeat the procedure on the driver’s side. Disconnect the parking brake cable bracket from the spring plate and
retain hardware (Fig 21). Take care not to over extend the brake lines.
Page 14 013812
Fig. 21
72. Reattach parking brake cable bracket to the spring plate. If more slack is needed remove the cable from the
rear-most cable ring on the frame rail (Fig 22).
Fig. 22
73. 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 necessary.
74. Install wheels and lower the vehicle to the ground.
75. With the weight of the vehicle on the axle, torque the u-bolts to 130-150 ft-lbs.
76. Leaf spring to front spring hanger torque bolts to 22 ft.lbs.
77. Leaf spring to shackle and shackle to frame mount torque bolts to 185 ft.lbs.
78. Check all hardware for proper torque.
79. Adjust steering wheel.
80.Adjust headlights
81. Check hardware after 500 miles.
013812 Page 15
Exhaust Relocation—Diesel Only:
1. Remove the bolts mounting the rear exhaust hanger to the frame. Retain hardware.
2. Remove the nuts mounting the exhaust hanger located just ahead of the rear axle. The nuts are accessed from
above the crossmember. Remove the bracket from the crossmember and the rubber exhaust grommets.
3. Using a hammer, remove the captive studs from the front bracket (Fig A)
Fig. A
4. Reinstall the front bracket to the crossmember along with the provided 1” spacer block (01975). Fasten the OE
bracket and spacer block through the original crossmember holes with 5/16” x 2” bolts, nuts and washers (BP 436).
Torque bolts to 20 ft-lbs (Fig B).
Fig. B
5. Reinstall the rubber exhaust grommets on the relocated front exhaust hanger. A small amount of grease on the
rubber grommet will ease installation.
6. Fasten the provided rear exhaust hanger relocation bracket to the original hole on the side of the frame with a 5/16”
x 1-1/4” bolt, nut and washers (BP 436). Leave hardware loose.
7. Attach the OE rear exhaust hanger to the relocation bracket with OE bolt run from inside the relocation bracket out
into the captive nut on the OE hanger. Run a provided 8mm x 75mm bolt/washer up through the bottom OE hanger
mounting hole, through the relocation bracket and into the captive nut in the bottom of the frame. With all the
hardware installed torque bolts to 20 ft-lbs (Fig C).
Page 16 013812
Fig. C
Notice to Dealer/Installer
These instructions, the warning card, and included decals must be given to the owner of this BDS Suspension product.
For questions, technical support and warranty issues relating to this BDS Suspension product, please contact your distributor/installer before contacting BDS Suspension directly.
Sold/Installed by:
013812 Page 17
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