1. Start by supporting the car on 4 jack stands. The car should be sitting on approximately the same angle as it does on the ground, or slightly lower in front. (If you are using a new pair of boxed frame rails, you can skip to step 5.)
2. Remove all the old front suspension components. We would recommend that at this point, you tack weld or clamp a temporary brace across the frame rails in front of the old crossmember as shown in Figure 1. This helps to maintain the rail dimension after the old crossmember is removed. Lastly, remove the old crossmember by drilling out the rivets.
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When working on, under, or around any vehicle exercise caution. Please allow the V€hlLl€ s exhaustsystem to cool before removal, as exhaust system temperatures may cause severe burns If working without a lzfi always consult vehicle manual for correct lifting specifications. Always wear safety glasses and ensure a safe work area. Serious injury or death could occur if safety measures are not followed.
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The ES200 together with its associated adaptors supports or raises the engine from underneath during maintenance operations without the use of a trolley jack or conventional over-engine support beam. It allows unimpeded access to the engine from above and also permits safe movement of the vehicle whilst the engine is raised. Vehicle specific adaptor sleeves mount onto the vehicle structure and the base unit is then attached to the sleeve. The engine is raised by a screw adjusted pad. The unit is ideal for rapid and safe cambelt changes, engine mount replacement, transmission removal, etc. The adaptor sleeves shown below are not supplied with the base unit and must be ordered separately.
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This kit will add a forward adjustment to the lower control arm. This adjustment will allow the caster to be adjusted at the lower control arm as well as the upper control arm.
Instructions:
1. Remove the lower ball joints from the spindles.
2. Cars with sway bars will need to remove the sway bar end links.
3. Remove the control arm pivot bolts from the frame.
4. Remove the strut rod bushing nuts. Remove the lower control arm and strut rod assemblies from the car.
5. Remove the spot welds that secure the strut rod mount to the frame and core support. A common method is to use a spot weld drill bit and drill the spot welds in the strut rod mounting bracket. Do not drill into the core support or the frame! Remove the strut rod mounts from the frame.
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Dodge Transmission Instructions
REMOVAL:
1. Disconnect the negative battery cable(s).
2. Remove the torque converter access cover and inspection plate.
3. Remove the transmission pan, drain the fluid and re-install the pan.
4. Remove the fill tube bracket bolt and pull the tube out of the transmission. Retain the fill tube seal. On 4WD models, it will also be necessary to remove the bolt attached to the transfer case vent tube to the converter housing.
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Installation Procedures:
1. Before you remove anything off the truck, measure the pinion angle on the bottom of the differential. Make sure to record the measurement here _____. Once the kit is installed, it is required to put the axle back to this measurement. This will keep the correct caster and camber.
2. Remove the transmission skid plate and then remove the front driveshaft. Take it to a drive line shop and have it extended 1 1/8”. Disconnect the sway bar end links and remove the sway bar. Place a jack under the differential and lift the truck until the wheels are 4-5” off the ground. Place a jack stand on each side of the frame, right under the radiator support. Remove the tires, shocks and steering arm, pan-hard bar / trac bar, sway bar and pitman arm. Let the jack down and remove the coil springs (they should have little tension left on them). NOTE: Set the lower shock bolt and nut aside as they will used in step 10.
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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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REMOVAL:
1. Disconnect the negative battery cable(s).
2. Remove the torque converter access cover and inspection plate.
3. Remove the transmission pan, drain the fluid and re-install the pan.
4. Remove the fill tube bracket bolt and pull the tube out of the transmission. Retain the fill tube seal. On 4WD models, it will also be necessary to remove the bolt attached to the transfer case vent tube to the converter housing.
5. Rotate the crankshaft with a pry bar from under the vehicle until the converter bolts are accessible.
6. Mark the drive shaft and pinion yokes for assembly alignment. Disconnect and remove the drive shaft. On 4WD models, remove both drive shafts.
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This conversion is not as easy as some people make out but can still be done by the back yard mechanic with some basic skills. You will need: Type 9 gearbox from a Sierra 1600 (about 1988-92) Bellhousing to suit the Pinto 2000 engine 20mm thick spacers to go in the cross member mounts (optional) Clutch, flywheel, pedal box, clutch cable, etc.
The cross member off the automatic transmission fits the Type 9 but needs to be lowered 20 mm otherwise the g/box will hit the underside of the transmission tunnel.
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FRONT INSTALLATION Read complete instructions before beginning installation, the following special tools are recommended: Coil spring compressor, floor jack, ball joint separator, jack stands, and metric hand tools. Jack the vehicle in the center of the front cross member. Support the vehicle by placing jack stands on the frame cross member so that the front tire/wheels are off the ground. Remove the front tires/wheels. Disconnect the sway bar end links and remove the upper ball joint cotter pin and nut. Separate the upper ball joint from the spindle. (Using ball joint separator or a suitable tool) Remove upper strut nuts on the strut tower (3) on each side of vehicle that holds strut Read the rest of this entry »

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