INSTALLATION
NOTE: You will need a #50 Torx bit for this installation
1. Assemble the harness support rods as shown below using the provided heim joints and nuts. Leave at least ¼” of thread showing on each heim joint to allow for adjustment during installation. Do not fully tighten the nuts at this time. NOTE: One end of each of the support rods has reversed thread.
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1. Peel the protective vinyl coating off of the top and bottom brackets and attach them to the fan shroud with the screws provided as shown.
2. Hold the fan assembly so that it is approximately centered over the radiator core. The long 6mm bolts will be used in the slots of the bottom bracket with the threaded end pointing down. The threaded end of the bolts, with rubber caps placed over the ends, will slide into the holes on the bottom of the radiator. Determine which set of slots you will use by looking at which slots line up over the holes. This fan kit is designed to accomodate both the OEM radiator as well as popular aftermarket radiators. These bolts may go in the inside or outside slots on the bottom brackets depending on which radiator you have. Leave these loose for now - you will need to tighten them after you install the fan assembly.
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1. Temporarily remove the grille and permanently remove the airdam. 2. Disconnect the fog lamp wiring if applicable and then remove the plastic bumper cover from the bumper. 3. Remove the bolts that attach the bumper from the end of the frame rails. 4. Install the hanger plates (Ref 7 & 8). Note: On the drivers side make sure not to pinch the power steering hoses and airbag sensor wire. The top plate on the rear of the hanger plate must install above the hoses. Loosely install the u-bolt (Ref 6) with washers (Ref 11) and nuts (Ref 13) thru the top rear plate and use the bumper bolt temporarily to hold the front of the hanger plate in position. Finger tighten the fasteners until all undercarriage parts are in place. 5. Install the pushbeam (Ref 1) square with the bottom of the hanger plates and secure with bolts (Ref 12), (more…)

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START WITH THE REAR BAR
1. Drive the vehicle onto a 4-post lift or floor ramps. THE CAR NEEDS TO BE AT NORMAL RIDE HEIGHT FOR PROPER INSTALLATION. You cannot have the suspension hanging while installing this bar!
2. Once vehicle is raised, take a moment and observe the stock rear bar and the way in which it is mounted.
3. Release rear exhaust hangers and middle hangers then let hang. (ok to use small amount of WD40 to loosen) Or, you may unbolt the hanger brackets using an extension and 13mm socket.
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Turn the front wheels all the way to the left or right for mud guard installation. However, it may be necessary to remove the wheels depending on the tools being used for installation.
Clean and degrease the mud guard location area on the fender before installation.
1. Remove existing fasteners from locations A, B, and E (Figure 1).
2. Install a u-clip at location E.
3. Install the mud guard with small #8 screws and washers at locations A and B. Check fit and parallel and adjust accordingly before tightening.
4. Install #10 screw and washer at location E.
5. Using the mud guard as a template, drill a 1/8” hole at location D (Figure 1).
6. Install a #10 screw and washer at location D.
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Installation Procedure:
1. Remove the PLASTIC BUMPER FASCIA mounted to the bottom of the front bumper. For the Avalanche, remove the entire plastic bumper. Disconnect the fog lamp electrical harnesses prior to removing the bumper. Note: The airfoil/bumper will need to be permanently removed or notched to accommodate the undercarriage assembly.
2. Remove and discard the three bolts that secure each tow hook to the truck frame. The tow hooks should remain in the same position.
3. Align the undercarriage mount pockets (at each end of the PUSH BEAM WELDMENT) with the tow hook mounting brackets on the vehicle. Note: Use a floor jack to help facilitate the installation procedure.
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INSTALLATION NOTES
1. Unless specified, mount all Sub-Frame components to vehicle before tightening any bolts.
2. Vehicle should be parked on a level surface with the
front suspension normally loaded.
MOUNTING INSTRUCTIONS
1. Locate existing slotted holes in vehicle frame rails directly above front axle.
2. Install Mounting Bracket (#3)RH, using three (3) 5/8″ x 2″ Capscrews (#10) Washers, and Nylock Nuts provided.
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This undercarriage fits all models listed but the cross member connection will vary. Refer to step “a” for the 1987–96 Dodge Dakota, 1997–03 Dodge Dakota Sport, 1997–03 Dodge Dakota SLT Extended Cab and 1998–03 Dodge Durango SLT models. Refer to step “b” for the 1997–04 Dodge Dakota and 1998–03 Dodge Durango.
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This undercarriage fits all models listed but the crossmember connection will vary. Refer to step “a” for the 1987-1996 Dodge Dakota, 1997-2003 Dodge Dakota Sport, 1997-2003 Dodge Dakota SLT Extended Cab and 1998-2003 Dodge Durango SLT models. Refer to step “b” for the 1997-2004 Dodge Dakota and 1998-2003 Dodge Durango
1. Disconnect the fog lamp harnesses if applicable, and then remove the bumper.
a. Remove the bumper mount plates from in between the frame rail and radiator. Discard the mount plate hardware.
b. Permanently remove the air dam from the truck frame crossmember. Remove the fasteners that are pressed into the bumper bracket on the frame rail. Secure the bracket and frame wall with vise grips and then use a hammer to punch out the fasteners.
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REMOVAL OF EXISTING MIRROR:
1. Have both windows in the down position. Remove the trim panel on both doors, start by removing two philips screws. One is located in the hand hold and the other is in the corner in front of the window. (note - there are two trim panel clips below the window).
2. Remove the foam insulation covering the stock mirror mounting nuts.
3. Support the stock mirror while removing the 3 mirror mount nuts and then remove the stock mirrors.
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