Hi, I was just wondering how hard is it to replace the bushings,Do you replace just the bushings or the whole bar?Any links to suggested Parts?How do you know when it is time to replace?Any tips and help would be great. Thanks

 

instruction no. 15291
kit no 3827

ground force
02-05 dodge ram 1500 4wd front torsion bar leveling key kit installation
read instructions completely through before starting
failure to adhere to the instructions will void any ground force warranty
it is recommended that installation be done by a qualified mechanic
replace all stock parts that are damaged or worn
intermixing of parts is not recommended and will void the warranty
always wear eye protection
check to see that all parts listed are included:
2- torsion bar key adjusters 1- warning decal 1- instruction
measure and document the vehicle height from floor to fender lip.
Lf___________ rf___________ lr___________ rr_____________ front install
1. Before getting under vehicle, jack the front of vehicle up and place
jack stands under the frame rails. Lower the vehicle onto jack stands
and make sure stands are securely holding the vehicle.
2. Make sure that the front tires are off the floor while doing
this procedure.
3. Locate the factory torsion bar keys in the cross-member at the end of
the torsion bar under the cab. Warning: The torsion bars are under pressure. Extreme care must
be taken when removing and installing the torsion bar adjusters
to avoid injury. Follow the torsion bar tool manufactures
loading / un-loading instructions.
4. Torsion bar adjuster removal procedure. Make sure the jack stands
are secure under the vehicle frame.
A. Mark the torsion bars left or right and front or rear.
B. Measure and document the distance from the outside of the head of
the torsion bar adjusting bolt up to the torsion bar retaining
plate. Document both left and right adjusting bolt head heights.
Torsion bar adjuster bolt retaining plate.
Torsion bar adjuster bolt head.
Bolt head height
l_________ r___________
page 1 of 4 copyright @ 2012
c. Using a properly rated torsion bar loader / un-loader tool
(kent moore part no. 36202 or its equivalent)increase the tension
on the stock torsion bar adjusting arm.(follow the tool manufactures
instructions).
D. Remove the adjusting bolt and retaining plate.
E. Remove the torsion bar un-loader tool.
F. Slide the torsion bar rearward.
Note: You may have to tap on the end of the torsion bar to get it to
pop loose from the factory key and lower control arm, an air chisel
with a punch bit works well.
G. Remove the stock torsion bar key.
H. Repeat to other side of vehicle.
Note: On some of these vehicles the torsion bar will be rusted in the lower
control arm mount and very difficult to remove. If you can’t get the
torsion bar loose from the lower control arm mount you may need to loosen
torsion bar crossmember in order to replace the torsion bar keys. Make
sure both torsion bars are unloaded before the crossmember hardware is
removed. Remove and replace both factory keys with the supplied reindexed
keys. Reinstall the crossmember to the frame using the factory hardware
and toque the hardware to spec. Move to the next step if you were able to
remove the factory keys without removing the crossmember.
Page 2 of 4
torsion bar key
torsion bar loader /
un-loader
torsion bar crossmember
hardware removed
crossmember moved up far enough to replace the torsion bar key.
5. New re-indexed torsion bar key installation procedure.
New re-indexed torsion bar key being installed over the stock torsion bar.
A. Install the new torsion bar key onto the torsion bar and up into the
crossmember with the bottom of new torsion bar key just hanging
out from the bottom of the crossmember.
B. Slide the torsion bar forward and into the lower control arm.
C. Using the torsion bar loader / un-loader tool increase the tension
on the new torsion bar key (follow the tool manufactures
instructions).
D. Install the stock retainer plate through the crossmember with the
notches in the retainer pointing down.
E. Install the stock adjusting bolt up into the retaining plate and
turn the torsion bar adjusting bolt in until there is about 3/16”
more threads showing that was documented in the stock measurements
on step 4 b. This will be your starting point for adjustment.
(example the stock torsion bar adjusting bolt on the left side was
adjusted at 1.0” from the bottom of the adjusting plate down to the
outside of the torsion bar adjusting bolt head and with the new
torsion bar key that you installed you will have 1 3/16” from the
bottom of the adjusting plate down to the outside of the torsion bar
adjusting bolt head.
Crossmember
retained block
adjusting bolt
6. Repeat torsion bar key installation procedure to the other side of
vehicle.
Note: The vehicle height will need to be adjusted with the tires and
wheels that were on the vehicle when measured before kit installation.
Note: If the stock torsion bar adjusting bolts were adjusted from the
factory setting your adjustment may vary.
7. Check clearance of all front components while sweeping the steering
complete left to right lock.
8. Recheck the torque on all nuts and bolts affected by this procedure.
Page 3 of 4
9. Take the vehicle on a short test drive to get the vehicle
suspension settled into position.
10. The vehicle height should not be changed more than 2.0 from the
factory setting. Over adjusting the torsion bar key adjusting bolts
will affect ride quality and may cause damage to the vehicles front
cv half shafts, therefore it is not recommended.
Note: Making a height adjustment of 1/8” at the torsion bar adjusting
bolt head will make about 1/2” of change at the wheel.
Note: If you are installing the hd keys to compensate for the added
weight of a winch or aftermarket accessories make sure to have the
added accessories on the vehicle while making the final adjustments to
the torsion bar adjusting bolts.
11. Go back and check that all installation steps have been completed.
Check the torque of all nuts and bolts affected by this procedure. Recheck all nuts and bolts for tightness after the first 300 miles and at every regular service inspection.
12. Road test vehicle.
Note: If any torsion bar adjustments are made, the vehicle must be test
driven to get the suspension height settled in before re-measuring.
Note: Make all torsion bar adjustments before having the vehicle front
end alignment done.
13. The vehicle needs to have a front end alignment performed immediately
after the installation of this kit.
Note: Your headlights will need to be adjusted to the proper setting
after this installation is complete.
Warning: Part no 15237 warning sheet is included with this kit,
make sure all operators read and understand the warning sheet before
operating this modified vehicle.
Warning: Enclosed with this product is a warning label which is to be
affixed on the visor of the vehicle where visible to all occupants.