Expedition One EXPDSTC01 User manual

DSTC SYSTEMS
SWING ARMS & LATCHES
P L E A S E R E A D E N T I R E G U I D E B E F O R E I N S T A L L A T I O N
Recommended that you read this entire install guide before installation. Check that all hardware is
present before staring or scheduling an install. This guide is supplemental to mechanical knowledge and
ability. Anyone not familiar with automotive installation should seek professional installation.
I N S T A L L G U I D E
LAST UPDATE 9/12/23 v2 GEN3ARM
EXPDSTC01

INSTALL GUIDE
IMPORTANT INFO/FAQ
I N S T A L L G U I D E A L L
EXPEDITION ONE
113 N. 700 W. BUILDING 5C BAY 1
OGDEN, UT 84404
[email protected]
801-627-2921
INSTALLATION HELP
Please review terms and conditions for details
Recommended purchaser review Welcome Guide at time of purchase for details
Care and Maintenance available at www.exp-one.com/resources
We do our best to offer timely assistance with your installation questions however as most of our team
members are primarily engaged in the manufacturing process and packaging processes, we do not
currently offer a tech for on-demand calls and inquiries. For the more technical installs or installs that
are time-sensitive in nature, we would recommend our customers seek out the services of professional
shops with experience specific to aftermarket bumpers that can better meet your needs. We are happy
to make recommendations to you on shops familiar with our products in your area. We do our best to
respond to installation questions within 24-48 hours of contact as much as possible. Long-distance
problem assessment can be difficult, so photos and videos are often required for us to best assist you.
We highly recommend your initial contact regarding installation questions include both close-up and full
photos, detailed descriptions using our part descriptions as much as possible, and video. This enables us
to better assist without having the ability to see the install difficulties directly and assist you as quickly
as possible.
NOTE
Expedition One does not guarantee fitment with other aftermarket products, or reinstallation of take off
OEM parts.
Expedition One is NOT RESPONSIBLE for damage to paint or powder coating, items assembled in error
during installation or costs associated with install
OEM manufacture model refreshes/updates, factory build location and suppliers may cause variations in
fitment or installation and can not be verified, vehicle to vehicle .
*This product contains chemicals known to the state of California to cause birth defects or other reproductive harm. For more
information go to www.p65warnings.gov*
GSA# GS-30F-013CA
*This product contains chemicals known to the state of California to cause birth defects or other reproductive harm.
For more information go to www.p65warnings.gov*

INSTALL GUIDE
HARDWARE INFO
I N S T A L L G U I D E
HARDWARE
Please review for details and installation. Figures or data may vary. Leave all accessible hardware loose for
installation and tighten all hardware after everything is installed on the vehicle. Check and retighten all
hardware after the first 100 miles and/or after off roading. Some hardware locations do not require being
tightened to spec due to there design, location or material attachment (including rubber, plastic, and
aluminum). Over tightening may break or damage parts. Torque spec may vary, amounts listed are generic.
A L L
HARDWARE TORQUE SPEC –FT.-LBS.
SIZE SOCKET
WRENCH
GRADE 5
M- 8.8
GRADE 8
M –10.9
#8 1/4" X
#10 5/16”
1/4" 7/16” 6-8 9-10
5/16” 1/2" 13-14 18-20
3/8” 9/16” 23-26 33-37
7/16” 5/8” 37-41 52-58
1/2" 3/4" 57-64 80-90
9/16” 13/16” 82-91 115-129
5/8” 15/16” 112-118 159-180
3/4" 1-1/8” 200-223 282-315
7/8” 1-5/16” 322-355 454-501
1” 36MM X
M6 10MM 9-10 13-15
M8 13MM 22-24 32-35
M10 15MM 44-49 64-72
M12 18MM 76-83 112-123
GRADE 5
GRADE 8
CLASS 8.8
CLASS 10.9
NOTE - Extra hardware may be left over due
to model or option specific items that may
not be required for the install.
TYPES OF HARDWARE
HEX CAP BOLT WASHER NYLOC NUT
BUTTON HEAD BOLT FENDER WASHER HEX NUT
CARRIAGE BOLT INTERNAL TOOTH JAM NUT
SOCKET CAP BOLT CLIP NUT ACORN NUT
FLAT HEAD SCREW RIVET NUT COUPLING

INSTALL GUIDE
HARDWARE GUIDE
I N S T A L L G U I D E E X P D S T C 0 1
KICK PLATE
AKick Plate 2
BKick Plate Bump Stop 4
CKick Plate Nyloc Squares 4
DKick Plate Aluminum Spacers 4
EWelded Rod Plate 2
FLatch Assembly 2
A
B
C
D
E
F
G
H
I
J
HUB KIT
F DSTC Hub Cover 2
GHub Cover O-Ring 2
HBearing 4
IGrease Seal 2
JSpindle Hardware
1“-1 4 Nyloc Nut 2
1” X 2.000 USS Washer 2
O-Ring 2
Anti Seize 1

DROP PINS AND PIN PLATES
FULL SIZE TRUCK
KFull Size Truck Drop Pin 2
LFull Size Truck Pin Plate 2
Note –XD pins will have an hourglass logo
K
L
MID SIZE TRUCK
MMid Size Truck Drop Pin 2
N Mid Size Truck Pin Plate 2
M
N
SUV
OSUV Drop Pin 2
P SUV Pin Plate 2
O
P
Q Kick Plate Assembly Hardware
10 –32 x 3/4“ HEX DRIVE BUTTON HEAD 4
10 –32 x 1 1/4” HEX DRIVE BUTTON HEAD 4
10 –32 NLYOC NUT 4
1/4” – 20 x 3/4” HEX DRIVE BUTTON HEAD 14
1/4” – 20 x 3/4” COUNTER SINK SCREW 4
1/4” – 20 NYLOC NUT 8
1/4” – 20 EXTENDED CLIP NUT 8
5/16” – 18 x 3/4” HEX CAP SCR 8
5/16” – 18 x 1” HEX CAP BOLT 4
5/16” – 18 x 1” CARRIAGE BOLT 6
5/16” x 0.688” SAE WASHER 8
5/16” x 0.875” USS WASHER 6
5/16” – 18 NUT 2
5/16” – 18 NYLOC NUT 18
5/16” – 18 ACORN NUT 2
Q

LATCHES AND HANDLE MOUNTS
lATCH
R Latch Assembly 2
SLatch Hardware 2
See Kickplate Hardware Kit
TRUCK
TTruck Handle Mount 2
SUV
USUV Handle Mount 2
Q Kick Plate Assembly Hardware
5/16” – 18 x 1” CARRIAGE BOLT 6
5/16” x 0.875” USS WASHER 6
5/16” – 18 NUT 2
5/16” – 18 NYLOC NUT 4
5/16” – 18 ACORN NUT 2
RS
T U
V
NOTE
Sprinter and Truck XD Arms DO NOT use any
Bolt on handle mounts. They are welded on.
Extra hardware may be left over.
V Handle Mount Hardware
1/2” – 13 x 1 1/2” HEX CAP BOLT 8
1/2” – 13 x 1 1/2“ BUTTON HEAD BOLT 4
1/2“ USS WASHER 12
1/2” – 13 NYLOC NUT 8

KICK PLATE ASSEMBLY
Assemble both kickplates as shown below.
NOTE
Aluminum spacers provided for adjustment of nylon squares
if required. See fitment of closed arm and use as needed.

KICK PLATE INSTALLATION
Assemble both kickplates as shown below.
Welded Rod Plate should face inside the bumper
and mounted in the upper most position.
Adjust the Kickplate as needed for best arm
contact and latch travel.

DROP PIN INSTALLATION - TRUCK
Install the drop pins as shown for each swing arm.
NOTE
Drop pins will mount inside of the arm

DROP PIN INSTALLATION - SUV
Install the drop pins as shown for each swing arm.
NOTE
Drop pins will mount inside of the arm
SUV DROP PIN

RACES PRESSED INTO HUB
ARM MOUNTING
Attach the arm to the bumper spindle as shown.
1 - BOTTOM BEARING AND GREASE SEAL
Grease Bearings using marine-based lithium grease. Install the first bearing into the bottom of the
swing arm. Then Place a grease seal inside the bottom of the arm.

3 –SPINDLE HARDWARE
Place the washer into the swing arm, then insert the nut over the bolt. Tighten the nut using a 36mm
socket. Don’t over tighten to prevent binding.
2 –DUAL SWING ARM INSTALLATION
Unclip and remove the lower bumper from the vehicle. Check for any remaining hardware or connections
before removing.
4 –HUB COVER
Check that the hub cap has a O-ring and spread anti-seize around the cap before tightening on the arm.
Repeat each step for the other arm. Install the drop pin plate as shown in the diagram page
REPLACEMENT PARTS
Replacement parts available at local auto part stores or directly from the Expedition One Store (see Replacement Parts tab)
PART NUMBERS
Bearings –LM48548 or A5
Grease Seal –(WS or PN) 5121
NOTE
Use of the provided Anti Seize will allow for hub covers ease of removal
for future maintenance.

HANDLE MOUNTING
Mounted the latch handle into position as shown below.
REQUIRED LOCATIONS
OPTIONAL LOCATIONS
6x

HANDLE MOUNTING
Mounted the latch handle into position as shown below.

LATCH MOUNTING
Install the latch assembly as shown. The latch may require adjustment for fitment and alignment with the arm and bumper
kick plate.

CARE & MAINTENANCE
Re-tighten your coupling unit after a period of time or after a good off-road trip. Looseness in your hub assembly or seizing of
your carrier may be a sign you need to replace your bearings or that the 1” Nyloc nut in under the cap in your hub assembly has
come loose and needs to be tightened.
Always be sure to use the anti-seize when installing and re-installing your hub cover, otherwise removal will be very difficult!
Remove your hub cover and check inside your hub assembly regularly. If you live in a dry climate and off-road a “standard”
amount, we would recommend you check your hub assembly at least once per year. If you live in a wet climate, humid climate,
or a climate with extremes, we would recommend you check your hub assembly quarterly or with season changes. Climates with
heavy salt content are some the harshest conditions on your components and may need to be checked more frequently.
When installing and/or re-installing bearings be sure to use a white lithium marine-style grease for best results.
Once you have removed the cap, check the grease. Bad grease will be black or have lost most of its original color, will show signs
of moisture, and/or will have become “chunky”. If this is the case, remove your bearings and re-grease them.
Check your bearings. The bearing cage can become corroded over time and break. Looseness or seizing in your hub and carrier
assembly may be a sign that you need to replace your bearings.
Races generally do not need to be replaced unless you can see they have broken or are heavily corroded. Races can be knocked
out and replaced if/when needed.
Replacement parts. You can purchase a rebuild kit directly from us at Expedition One, however you can also find most of your
hub assembly components at your local automotive/hardware store. Replacement part #’s can be found below for your
convenience:
Dual Swing Arm Carriers
Grease Seals: PN 5121
Bearings: LM48548 or A5
Stiffness, binding, or rattling in your tire carrier arm may be an indicator for maintenance needed on the bearings in your hub
assembly. This could be caused by a number of factors including environment, impact, lack of/type of grease, corrosion, and/or
over-tightening.
Our carriers are designed for easy maintenance with easy removal of the hub cap to access the hub assembly. Zinc fittings are
generally not necessary, due to ease of access. Wear components and replacement parts can be easily sourced from your local
auto parts store and often have a variety of brands/pricing. The bearings used are a high-speed/high heat wheel bearings, but
for our applications are being used under moderate loads and low speed ( 0 rpms), so they will typically last a long time.
Instructions for bearing checks and maintenance:
•Loosen your hub cover cap. If anti-seize was used this should easily be done by hand or with a simple grip tool.
•Observe the top bearing. If there is a lot of moisture, discoloration, or corrosion you could have a grease problem. We
recommend using a water-resistant, marine grade grease for this reason.
•If you do not see a lot of moisture or discoloration and do not want to un-bolt the arm you can first try to pack the hub
assembly with a lot of marine-grade grease and cycle it through by moving the arm back and forth. This may fix your problem.
If movement is not improving with additional grease and cycling or you believe you have broken bearings continue by unbolting
and removing the arm.
•Take out the top bearing and examine it. If it rolls and does not show signs of damage or coming apart then it is probably ok.
Check the cage holding the bearings is in-tact. If you see any damage or broken parts you will need to replace the bearing.
•The bottom bearing is held in by the grease seal. You want to gently remove the grease seal by using a hammer and a tool such
as a center punch, aul, or screwdriver to gently tap out the grease seal so you can access the bottom bearing.
•Observe and examine the bottom bearing for signs of damage. Again, If the bearing does not roll or if parts are popping out or
there is damage to the cage you will want to replace the bearing.
•If the bearings are rolling and are just dirty or gummy, you can use WD40, brake cleaner, or penetration spray to clean them
out.
Be sure to re-pack with a lot of marine-grade grease when replacing cleaned and/or used bearings and use anti-seize when re-
installing your hub cover cap. Caps should be snug but be careful not to over-tighten, as this can put too much pressure on the
bearing cage and cause bearings to fail. We do not provide torque specs, as the exact right tightening for your application can be
hard to gauge with the Nyloc nut. We recommend you check to feel the Nyloc has been tightened and that the cap is snug and
not to tighten beyond that point.