DK-63631K1 Instructions
Parts Included
1. Gather tools needed
a. Gather tools needed for the job:
- Breaker Bar
- Socket Wrench
- 21MM Socket
- 22MM Socket
- 24MM Socket
- 21MM Wrench
- Rubber Mallet or dead blow hammer
- Torque Wrench
2. Raise vehicle
a. Safely raise the vehicle by the frame and support the rear axle.
b. Remove the rear tires.
3. Shock hardware removal
a. With the rear axle supported, remove the lower shock mounting bolt.
4. U-bolt hardware removal
a. Remove the U-bolt nuts, U-bolt bottom plate, and U-bolts.
5. Leaf spring removal
a. Lower the rear axle while ensuring no lines are stretched.
b. Remove the front leaf spring mounting bolt.
c. Remove the rear shackle mounting bolt.
6. Leaf spring removal (continued)
a. Carefully remove the leaf spring from the vehicle.
b. Note: Two people are recommended for this removal.
7. Leaf spring assembly
a. Install the included bushings into both ends of the leaf spring dry. A rubber mallet can assist with installation.
b. Apply grease to the inner sleeves and inner diameter of the bushings, then press the included sleeves in. A mallet can typically be used, but a C-clamp can assist if needed.
8. Shackle removal & installation
a. Remove the shackle from the OE leaf spring if not proceeding with the long travel shackle.
b. Install the desired shackle on the DK leaf spring as shown in the image. Hand tighten the hardware and proceed to the next step while ensuring the nut faces outward upon installation in the vehicle.
c. Note: The shackle will be installed on the non-wrapped end.
9. Leaf spring installation
a. Place the leaf spring on the vehicle and snug all leaf spring mounting bolts. Do not fully torque this hardware, as everything will be torqued at ride height.
b. Note: Two people are recommended for this installation.
10. Leaf spring top plate installation
a. Place the corresponding top plate on the leaf spring.
b. Note: A form of U-bolt locator must be utilized. See the image to determine which one is needed for each application. If running a long travel setup that does not use the leaf over shock mounts (or similar), the plate pictured on the right must still be installed.
11. U-bolt installation
a. Raise the rear axle high enough to contact the leaf spring and ensure the center pin locates within the axle.
b. Install the included U-bolts and corresponding hardware.
c. Snug all nuts in a cross pattern but do not fully torque.
12. Shock hardware installation
a. Safely raise the axle high enough to reach the lower shock eyelet.
b. Install the hardware and torque to 118 ft-lbs.
13. Torque leaf spring hardware
a. Reinstall the wheels and torque the lug nuts to the wheel manufacturer’s specifications.
b. Lower the vehicle to the ground and allow the suspension to settle.
c. Torque the front leaf spring mounting bolt to 118 ft-lbs.
d. Torque the rear hardware to 85 ft-lbs. Ensure both the shackle mounting nut and leaf spring mounting nut are torqued at this time.
14. Torque U-bolt hardware
a. With the vehicle on the ground, begin torquing the U-bolt nuts following the order shown in the image.
b. First pass 59 ft-lbs, second pass loosen 180 degrees, third pass 59 ft-lbs, final pass 120–140 degrees.
15. Review your work and repeat steps on the other side of the vehicle
a. Inspect all components to ensure they are properly installed and have adequate clearance.
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