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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1. For the Dakota: Remove bumper, retaining all OEM fasteners for reinstallation.
Proceed to Step 2.
For the Durango: Prior to removing the bumper, cut and remove the center portion of the bumper and air dam as shown in the photo below. Retain the cut out section of the air dam to fabricate an air deflector in Step 8. Remove the remaining bumper assembly, retaining all OEM fasteners for reinstallation.
2. Clamp the driver-side mount plate to the outside of the driver-side vehicle frame. Make sure the mount alignment tab fits up against the back of the vehicle frame front plate, and the front and rear plate stiffeners are snug against the bottom of the frame. When positioned correctly, mount plate holes align near the center of the vehicle frame.
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REMOVAL & INSTALLATION
WARNING: Deactivate air bag system before performing any service operation. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Do not apply electrical power to any component on steering column without first deactivating air bag system. Air bag may deploy.
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The mounting procedure outlined below covers the 2000 – 2004 Dodge Dakota trucks. You will need to refer to the illustrations and familiarize yourself with each of the undercarriage components and their relative position to each other. Then proceed as follows:
1. Disconnect fog lamps from bumper if equipped on vehicle.
2. Cut rubber portion of air deflector attached to bumper and discard. Open vehicle hood and remove four vertical bumper bolts from existing Bumper Brackets (BB). Remove bolts from two outer bumper brackets if equipped on vehicle. Remove bumper.
3. Clamp existing Bumper Bracket (BB) to frame rail. Remove two existing Nuts (AA) from Bumper Bracket (BB). Use chisel and hammer between head of existing Bolts (CC) and Bumper Bracket (BB) to force them loose. Use caution to prevent damage to parts. Unclamp and remove Bumper Bracket (BB). Repeat process on opposite side of vehicle.
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Removal Timing Belt(Esteem)
1. Disconnect negative battery cable. Remove right side engine under cover. Remove power steering and A/C compressor drive belts. 2. Remove A/C compressor and power steering pump with hoses attached, and secure out of way. Support engine from above or with floor jack under oil pan. Remove air cleaner case with air cleaner outlet hose. 3. From timing belt end of engine, remove engine mount and mounting bracket. Loosen water pump pulley bolts. Remove water pump drive belt and pulley. 4. Remove 5 crankshaft pulley-to-crankshaft bolts. Remove pulley. It is NOT necessary to remove crankshaft center bolt. Remove timing belt cover. See Fig. 1 . 5. Rotate crankshaft clockwise to align timing marks. See Fig. 2 and Fig. 3 . Stamped “E” on camshaft sprocket must point straight up. Loosen timing belt tensioner bolt and stud nut. Move tensioner away from belt, and hand tighten bolt and nut. See Fig. 4 . 6. If reusing old belt, mark belt with an arrow indicating direction of rotation for installation reference. Remove timing belt.
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Precision manufactured using aircraft quality T-304 stainless steel; this system is designed to endure years of heavy use. Installing a Borla Performance Exhaust System on your vehicle will eliminate the restrictive design of the stock exhaust, allowing your engine to discharge exhaust gas easier. The result is more horsepower and torque, longer engine life, and a distinctive throaty growl- all this, with easy bolt-on installation. These installation instructions have been written to help you in the installation of your Borla Performance Exhaust System. Please read it completely before installing your system.
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Installation Procedure:
1. Remove truck bed
2. Chalk front tires to ensure truck does not roll.
3. Jack rear of truck up at FRAME RAIL and secure with jack stand at REAREND. Duplicate on both sides. Remove wheels, shocks, sway bar and mounts. When finished rear of truck should be suspended by 2 jack stands on axle with wheels removed and suspension STILL INTACT.
4. Using FRAME SECTION as guide, place FRAME SECTION next to outside of truck frame rail to check for clearances of rivets, tabs, and brackets etc. that will impede the FRAME SECTION from sliding onto frame rail.
5. Remove and/or relocate any rivets, tabs, brackets etc.
6. Slide FRAME SECTION over frame rail into place, it will be a tight fit and usually will need help with a mallet to knock onto frame rail.
7. Repeat steps 4 through 6 on opposite side.
8. With FRAME SECTION in place mount REAR CROSS MEMBER to top rear of notch next to upper bag placement. Loosely bolt REAR CROSSMEMBER in place to allow movement.
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Removal (Frontier, Pathfinder, QX4 & Xterra)
1. Disconnect negative battery cable. Remove the engine undercover. Drain coolant and remove the radiator.
Remove engine cooling fan and water pump pulley. Remove accessory drive belts. Remove spark plugs.
2. Remove distributor protector. Remove A/C compressor drive belt idler bracket. Remove fresh air intake
tube from rocker cover. Remove thermostat housing hose.
3. Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke. See Fig. 1 . Remove crankshaft
pulley bolt and remove crankshaft pulley. Remove front upper and lower timing belt covers. See Fig. 2 .
4. Align punch mark on left camshaft sprocket with punch mark on timing belt upper rear cover. Align
punch mark on crankshaft sprocket with notch on oil pump housing. See Fig. 3 . Install crankshaft pulley
bolt so that crankshaft can be rotated.
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Installation of a Performance Automotive group body lift will change the center of gravity and the handling characteristics of the vehicle. Because of the higher center of gravity and larger tires, the vehicle will handle and react differently both on and off road. You must drive it 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.
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