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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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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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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The mounting procedure outlined below covers the 2003 and Newer ū & 1 Ton Dodge 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. Remove the mounting hardware connecting the bumper to the driver side of the frame. Align the two vertical holes on Push Beam Support Plate (62B) with the bumper mounting holes on the outside of the frame. Attach Push Beam Support Plate (62B) to the frame using ―”-13 x 4-―” Hex Head Bolt (G) and ―”-13 Lock Nut (B). The rear and bottom mounting holes on Push Beam Support Plate (62B) must be drilled in the truck frame. With Push Beam Support Plate (62B) in place, drill two 9/16” diameter holes in the truck frame. Drill the hole in the side of Push Beam Support Plate (62B) through both walls of the frame. Drill the bottom hole through the bottom frame wall only. Repeat the process on the passenger side.
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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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The mounting procedure outlined below covers CHEVROLET (1988 – 2000), and 1 ton 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. Position the PUSH BEAM SUPPORT PLATES (Ref. 62A and 62B, Fig. 1) to the front frame rails of the truck. If the truck is equipped with tow hooks, remove the tow hook bolts, and tow hook before installing the PUSH BEAM SUPORT PALTES. Using M14 x 2.00 Hex Head Bolts and M14 Lock Washers provided, bolt the PUSH BEAM SUPPORT PLATES through the outside of the frame. Next use ―” – 13 x 1- ―” Hex Head Bolts, ―” Flat Washers, and ―” – 13 Hex Head Self Locking Nuts to bolt the PUSH BEAM SUPPORT PLATES through the bottom of the frame. Tow hooks may be relocated under the PUSH BEAM SUPPORT PLATES and reattached. Fasteners should only be finger tight.
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1. Module Installation: You will need to run the wiring harness thru the firewall and attach your power module to the harness inside the cab of your truck. Place the module under the dash out of the way
of your pedals.
2. Data Link Connection: The Data Link connector is located in different locations based on the year of the truck.
98.5-99: The triangle shaped connector is located on the driver’s side of the engine in the wiring harness near the power steering pump.
2000-2002: The three prong flat connector is located on the top of the fuel lift pump that is located on the driver’s side of the engine directly below the map sensor.
Note: on some 2001 trucks the connector is located on the driver’s side of the engine in the wiring harness near the power steering pump.
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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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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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