Pacbrake 10220 KIT User manual

10220 KIT
Dodge Dakota (2WD/4WD)*†
† 2005 – All Dodge Dakotas
† 2006 - All Dodge Dakotas except Night Runner and R/T sub models
† 2007 - All Dodge Dakotas except SXT and TRX4 sub models
† 2008 - All Dodge Dakotas except Big Horn sub models
† 2009 – All Dodge Dakotas
† 2010 – All Dodge Dakotas
† 2011 – All Dodge Dakotas except Lone Star sub models
L6370_REV3_10.27.2020*See application guide for proper tment.

Dodge Dakota (2WD/4WD) L6370
1
KIT CONTENT
REQUIRED TOOLS
•7⁄16", 9⁄16" Open End or Box Wrenches
•Ratchet with 3⁄8", 9⁄16", and ½"
deep sockets
•3⁄8", 5⁄16" and 9⁄16" drill bits (very sharp)
•3⁄8" Nut Driver
•Crescent Wrench
•Torque Wrench
•Heavy Duty Drill
•Hoist or Floor Jacks
•Safety Stands
•Safety Glasses
•Air Compressor or Compressed
Air Source
•Spray Bottle with Dish Soap &
Water Solution
Make sure all the items shown in
the photo are provided in your kit
before starting the installation.
KIT CONTENTS
A Upper Bracket (2) HP0046
B Air Spring (2) HP10001
C Lower Bracket (2) HP0104
D Spacer Clamp Bar (4) HP0113
E Install Tool (1) HP0048
F Heat Shield (1) HP0012
G Gear Clamp (2) HP1001
H 3⁄8"-16 x4" Hex Cap Bolt (4) HP1437
I 3⁄8"-16 U-Bolt (4) HP1018
J 3⁄8" x1.25" Self-Threading Screw (4) HP1078
K 3⁄8" Flat Washer (4) C18006
L Tie Strap (6) C11618
M 3⁄8" Flat Washer SAE (12) C653
N 3⁄8"-16 Nyloc Nut (12) HP1000
O 2.70" Spacer (2) HP1439
P 2.55" Spacer (2) HP1438
Q 90° Swivel Air Fitting (2) HP1019
R 1⁄2
"-13 x7⁄8" Hex Head Cap Screw (2) HP1077
S 3⁄4" Washer, 2" OD (2) HP1010
T 3⁄4" Jam Nut (2) HP1076
U Tube Cutter (1) C3941
V Air Line Assembly (1) HP1344
A
N
Q
R T
S
D
K
B
H
J
I
LO P
V
G
C
M
E
F
U
WARNING: This product can expose you to the chemical Hexavalent Chromate, which is known to the State of California to
cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

Dodge Dakota (2WD/4WD) L6370
2
Q
T
A
O
K
P
C
I
R
S
D
M
B
N
H
J
N
K
M
12345678
A
B
C
D
E
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:10
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
B
SCALE:
PART NAME:
CAD NO.:
1
Assembly
OF
1
SHEET
12.1 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES:
;
SURFACE FINISH:
CHK:
F
G
10 12119 13
72 111 4 8 105 9 1263 13
G
B
E
D
A
F
C
ENG:
DWG NO.:
File: S:\masterfile\Documentation\PAC-091B-DOC_Rev2.SLDDRT Date: 23/Apr/2014
Assem2
DRIVER'S SIDE AIR SPRING ASSEMBLY
Note: Parts O & P will be switched for
the passenger side assembly.
Front of the vehicle

Dodge Dakota (2WD/4WD) L6370
3
Jack Stands
Frame
1A
1B
Thank you and congratulations on the purchase of an air suspension kit. Please read the entire installation manual prior
to starting the installation to ensure you can complete the installation once started. Should you have any questions during
the installation, please call 800.663.0096.
IMPORTANT:
This air suspension kit will not increase the GVWR (Gross Vehicle Weight Rating), as the GVWR is determined by the
axle rating. Do not exceed the maximum capacity listed by the vehicle manufacturer.
NOTE: Some vehicles are equipped with a real brake proportioning valve. Check this with the vehicle manufacturer before
installing the air spring kit, as it may affect braking performance.
BEFORE YOU START
1. Ensure the application information is correct for the make, model and year of the vehicle you are installing the kit on.
2. Check the clearance between the outside of the frame and the inside of the tire. A minimum of 6" is required for air
spring clearance.
3. It is recommended to use a good quality anti-seize on all fasteners. This
will reduce the chance of corrosion on the fasteners and will help facilitate
removal, if required at a later date.
1RAISE THE REAR AXLE
• Remove any unnecessary weight from the vehicle to attain normal
ride height. This is important for correct initial air spring setup
and adjustment.
• Park the vehicle on a level surface.
• Record the vehicle’s normal ride height, which is the distance between
the center of the axle and the top of the wheel well ange. Ensure
both sides are the same before raising the vehicle.
• Raise the rear axle high enough to remove both rear wheels and
attain a comfortable working height.
• Place two jack stands under the axle, as shown in the photo.
• Lower the oor jack until the vehicle axle is supported by the
jack stands.
• Ensure the normal ride height measurement recorded earlier is
the same.
• Adjust if necessary before proceeding.
• Once the rear axle is raised correctly, remove the rear wheels.
6" 6"

Dodge Dakota (2WD/4WD) L6370
4
2A
3B
3A
2ASSEMBLE THE INSTALLATION TOOL
• The installation tool will align the upper and lower
brackets as well as position the upper bracket for
drilling the bolt holes. The threaded section of the
installation tool is the range in which the air spring
height may be set. It is advisable to set it to the
maximum height possible.
• Using the large ½" fender washer (S) and the ½" x7⁄8"
bolt (R) provided, attach the installation tool (E) to the
lower bracket (C) and nger tighten.
• Install one of the 3⁄4" - 16 jam nuts (T) on to the
installation tool (E). Attach the upper bracket (A) to
the installation tool (E) and fasten it together with a
3⁄4" - 16 jam nut (T).
• Figure 2A shows how the nished assembly should
look. It will be used in the next step.
3ATTACH THE LOWER BRACKET
• Begin the installation process on the driver's side.
• Set the assembly on to the leaf spring, over the axle (see gure 3A).
• Use the optional spacers (D) to raise the lower bracket (C) if it
interferes with the stock U-bolts holding the leaf spring in place.
• Position the lower bracket (C) so that the rear leg of the upper bracket
(A) is ush against the weld where the two frame sections come
together (See gure 3B).
NOTE: The front leg of the upper bracket will mount on the raised
portion of the frame and the rear leg of the upper bracket will mount
on the recessed, rear portion of the frame
(See Figure 3B).
3/4" Jam Nut X 2 (T)
Upper Bracket (A)
Installation Tool (E)
Lower Bracket (C)
1/2" Washer (S)
1/2" Hex Cap Screw (R)
12345678
A
B
C
D
E
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:5
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
B
SCALE:
PART NAME:
CAD NO.:
1
InstallAssembly
OF
1
SHEET
9.7 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES: ;
SURFACE FINISH:
CHK:
F
G
10 12119 13
72 111 4 8 105 9 1263 13
G
B
E
D
A
F
C
ENG:
DWG NO.:
File: S:\masterfile\Documentation\PAC-091B-DOC_Rev2.SLDDRT Date: 23/Apr/2014
InstallAssembly
MIN. 1.50" OF CLEARANCE
Rear Leg of the
Upper Bracket
Frame Weld
Vehicle Frame
Front Lower Bolt
Rear Lower Bolt
12345678
A
B
C
D
E
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:5
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
B
SCALE:
PART NAME:
CAD NO.:
1
FrameAssembly
OF
1
SHEET
6.2 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES:
;
SURFACE FINISH:
CHK:
F
G
10 12119 13
72 111 4 8 105 9 1263 13
G
B
E
D
A
F
C
ENG:
DWG NO.:
File: S:\masterfile\Documentation\PAC-091B-DOC_Rev2.SLDDRT Date: 23/Apr/2014
FrameAssembly
Note: Figure 3B shows the assembly from
the driver's side. The passenger's
side will be the opposite of gure 3B

Dodge Dakota (2WD/4WD) L6370
5
4A
• Secure the lower bracket (C) to the leaf spring with two U-bolts (I),
four at washers (M) and four nyloc nuts (N).
(See driver's side air spring assembly, page 2).
• Torque the nuts (N) to 20 ft-lbs (27 N•m).
• The air spring will expand to 5.10" in diameter at maximum ination
pressure. Check horizontally along the shaft of the installation tool (E)
for sufcient clearance of 2.50" all around the tool.
4POSITION THE UPPER BRACKET
• Using the slot in the lower bracket (C), position the upper bracket (A)
so that the upper bracket (A) is ush against the frame rail.
• Use the two jam nuts (T) on the threaded portion to adjust the upper
brackets (A) height. It is recommended to set it to the maximum
height possible.
NOTE: There must be at least 1.50" of clearance above the upper
bracket to allow for installation of the air tting.
• With the rear leg of the upper bracket (A) ush against the weld, raise
or lower the bracket so the self-tapping screw will be below the radius
of the frame. (See Figure 5C)
MIN. 1.50" OF CLEARANCE
Rear Leg of the
Upper Bracket
Frame Weld
Vehicle Frame
Front Lower Bolt
Rear Lower Bolt
12345678
A
B
C
D
E
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:5
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
B
SCALE:
PART NAME:
CAD NO.:
1
FrameAssembly
OF
1
SHEET
6.2 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES:
;
SURFACE FINISH:
CHK:
F
G
10 12119 13
72 111 4 8 105 9 1263 13
G
B
E
D
A
F
C
ENG:
DWG NO.:
File: S:\masterfile\Documentation\PAC-091B-DOC_Rev2.SLDDRT Date: 23/Apr/2014
FrameAssembly
Note: Figure 4A shows the assembly
from the driver's side.

Dodge Dakota (2WD/4WD) L6370
6
5D
J
H M
A
K
N
O/P
Radius of the frame
Outside of
the frame
Inside of
the frame
12345678
A
B
C
D
E
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:5
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
B
SCALE:
PART NAME:
CAD NO.:
1
Assem2-withframe
OF
1
SHEET
13.2 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES:
;
SURFACE FINISH:
CHK:
F
G
10 12119 13
72 111 4 8 105 9 1263 13
G
B
E
D
A
F
C
ENG:
DWG NO.:
File: S:\masterfile\Documentation\PAC-091B-DOC_Rev2.SLDDRT Date: 23/Apr/2014
Assem2-withframe
5ATTACH THE UPPER BRACKET
CAUTION: Before drilling, check the back side of the frame for
clearance issues such as, brake lines, gas lines, electrical lines, etc.
Any obstacles will need to be temporarily relocated to clear the area.
• Center punch both lower holes in the upper bracket (A) and drill two
3⁄8" holes all the way through both sides of the frame.
(See gure 5A - 5D)
• Center punch both upper holes in the upper bracket (A) and drill two
5⁄16" holes through the OUTSIDE WALL OF THE FRAME ONLY.
(See Figure 5A - 5D)
• Detach the installation tool (E) from the upper (A) and lower brackets
(C). Save the tool and its corresponding hardware as it will be reused
to mount the other air spring.
CAUTION: You may have to pull the electrical line holder out of the
frame on the inside of the driver-side frame. Reattach using the
provided tie straps (L).
• Drill the 3⁄8" holes on the inside of the frame to 9⁄16"in order to provide
enough room for the frame spacers to be installed into the frame.
(See Figure 5D)
• Attach the upper bracket (A) to the frame by inserting two 3⁄8" x4"
bolts (H), with two washers (M) through the lower holes in the upper
bracket (A) (See Figure 5D).
• Insert the spacers through the 9⁄16"hole drilled through the inside of
the frame. The long spacer (O) goes through the front lower bolt. The
shorter spacer (P) goes through the rear lower bolt.
(See gure 4A and 5D)
• Fasten the upper bracket (A) to the frame by installing two wide 3⁄8"
washers (K) and two 3⁄8" nuts (N) onto the 3⁄8" x4" bolts (H)
(See Figure 5D)
• Insert two self-threading bolts (J) into the top holes and tighten to
15 ft-lbs (20N•m), be careful not to overtighten. Torque the two
lower bolts to 44 ft-lbs (60 N•m).
5A
5B
5C

Dodge Dakota (2WD/4WD) L6370
7
NOTE: The spacers are to keep the frame from crushing. It is
possible that some crushing may occur while tightening the bolts.
6INSTALL THE AIR SPRING
• Prepare the air spring by ensuring that it is collapsed with the rubber
part of the bag folded over the bottom end cap. (See Figure 6A).
• Install the 90° air swivel tting (Q) into the top of the air spring (B).
Finger tighten the swivel tting and turn an extra 1.5 turns with a 7⁄16"
wrench to tighten.
• Guide the tting through the center mounting hole in the
upper bracket (A). (See driver's side air spring assembly, page 2).
• Attach the air spring (B) to the lower bracket (C) using a 1⁄2" at
washer (S) and a 1⁄2" bolt (R). Leave it loose to allow for adjustment.
(See driver's side air spring assembly, page 2).
• Install a 3⁄4" jam nut (T) over the air tting and onto the upper
threaded post of the air spring. Tighten to 25 ft-lbs (34 N•m).
Note: This jam nut will be required for the passenger side installation.
Install the jam nut over the threaded post of the air spring on the
driver's side AFTER completing steps 1-6 on the passenger's side.
7INSTALL THE AIR LINES
NOTE: This kit contains push to connect ttings, using scissors or wire cutters to cut the nylon airline will distort
the line and cause the connection to leak. USE THE PROVIDED TUBE CUTTER (U) TO CUT THE HOSE TO
LENGTH. Moisten the end of the airline prior to inserting it into the tting and push it in until it stops.
• Provided in the air spring kit are two ll valves attached to a nylon hose (V). Cut the hose into 2 equal lengths
with the tube cutter (U).
• The most common place to install it is to replace the license plate fasteners with the ll valves (Figure 7A).
• Alternatively, two 5⁄16" holes can be drilled in a convenient location and the ttings can be installed there.
• Choose a location and install the ll valve according to the diagram in Figure 7B.
7A
6A
7B
Air Line
Schrader Valve
Hex Nut
Flat Washer
Vehicle Body
Valve Cap
12345678
7654321 8
A
B
C
D
E
A
B
D
E
C
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:2
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
A
SCALE:
PART NAME:
CAD NO.:
1
AirLineAssembly
OF
1
SHEET
0.0 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES:
;
SURFACE FINISH:
CHK:
ENG:
AirLineAssembly
DWG NO.:
File: S:\masterfile\Documentation\PAC-091A-DOC_Rev2.SLDDRT Date: 23/Apr/2014

Dodge Dakota (2WD/4WD) L6370
8
9A
8A
• Route one end of the nylon hose from the ination valve to an air
spring tting (Q). Cut the hose and connect it to the air spring tting
(Q). Repeat with the other ll valve.
• Secure airlines with the tie-straps (L) provided. Ensure that the airlines
are away from moving items and
heat sources.
8ALIGN THE AIR SPRING
• With the bottom of the air spring (B) still loose, inate the air spring to
approximately 10 PSI.
• Use the slotted adjustment in the lower bracket (C) to correctly align
the air spring between the upper and lower brackets. This can be
accomplished by lightly tapping it inboard or outboard for proper
alignment. There should be a symmetrical cushion of air around the
base of the air spring when correctly positioned.
• Tighten the lower mounting bolt (R) to 25 ft-lbs (34N•m) with a torque
wrench and 3⁄4" socket.
• Repeat steps 2 - 8 for the passenger side airbag installation.
9INSTALL THE HEAT SHIELD
• Bend the tabs on the heat shield (F) so there will be the necessary ½"
dead space between the heat shield and the exhaust pipe when the
heat shield is attached.
• Attach the heat shield (F) to the exhaust pipe on the passenger side
using two gear clamps (G). Each hose clamp holds a tab against the
exhaust pipe. Make sure the heat shield is facing toward the
air spring.
10 CHECK THE SYSTEM FOR LEAKS
• Inate both air springs to 90 PSI, and then use a mixture of 1⁄5dish
soap and 4⁄5water on all air line connections to detect and air leaks.
Repair as necessary and retest.
• Inate the air springs to a predetermined value, and on the following
day recheck the pressure. If one or both the air springs have lost
pressure, an air leak is present. The leak must be repaired, and then
retested until no leaks exist.
10A

Dodge Dakota (2WD/4WD) L6370
9
11 AFTER THE INSTALLATION IS COMPLETE PLEASE
REMEMBER
• Install the wheels, and torque the fasteners to the manufactures
specications.
• Re-torque all the fasteners after the rst 500 miles of driving.
• For safe and proper operation, never operate the vehicle under the
minimum of 10 PSI or over the maximum of 100 PSI. Staying within
the pressure limit will ensure maximum air spring life. Failure in doing
so may result in a void warranty. (See below)
Thank you again, and congratulations on the installation of the air suspension kit.
OPTIONAL ACCESSORIES
Optional dual needle air gauges are available to monitor pressure in each spring from vehicle cab, as well as a full line of air
compressors, air tanks, and solenoids built to work with and control your air spring system.
OPERATING YOUR VEHICLE WITH AIR SUSPENSION
Air springs have minimum and maximum pressure requirements. Never operate your vehicle with less than 10 psi in air spring and
never inate air springs over 100 psi. Damage to air springs will result.
Check air pressure in air springs daily for rst couple of days to ensure a leak has not developed. Air springs are designed to
maintain the vehicles stock ride height with a load. Do not use the air springs as a means to lift vehicle with no load. This will result
in a harsh ride.
SERVICING YOUR VEHICLE WITH AIR SUSPENSION
When lifting the vehicle with a oor jack or hoist on the frame, never allow the air spring to limit the travel of the axle. Try to always
jack the vehicle on the axle. Suspending the axle with the air spring limiting the axle travel will damage the air spring and void the
air spring warranty.
WARRANTY
To be eligible for warranty, the owner must submit their warranty card or register online within 30 days of the purchase date.
NOTE: The owner’s warranty will be void if air springs are run with less than the minimum of 10 psi.