1994–2013 Dodge Ram 1500/2500/3500 4WD CNC Long Arm Conversion Upgrade Kit

Pre-Install Checklist

Required Tools

Floor jack (minimum 3-ton capacity)
Jack stands — minimum 3-ton rated, set of 4
Torque wrench
Power drill with metal drill bits
Angle grinder or trim tool (for factory bracket trimming)
Socket set — metric and standard, 3/8" and 1/2" drive
Grease gun compatible with 1/4"-28 zerk fittings
Pry bar and rubber mallet
Alignment gauge or caster/camber tool
Safety glasses, gloves, face shield, and steel-toed boots (PPE)

Vehicle Preparation

Park vehicle on a flat, level, hard surface
Engage parking brake fully
Chock all four wheels before lifting
Disconnect the negative battery terminal before beginning work
Allow exhaust and engine components to cool completely

Safety Warnings

⚠ ALWAYS use rated jack stands — never work under a vehicle supported only by a floor jack. Wear safety glasses and gloves at all times. Keep bystanders clear of the work area. Drilling and trimming of factory lower control arm frame mounts IS required — wear a face shield during this step.

Verify Fitment Before Starting

Confirm vehicle year matches one of the four supported year ranges in the fitment table below
Confirm model is Ram 1500, 2500, or 3500
Confirm drivetrain is 4WD — this kit does NOT fit 2WD models
Confirm your ordered SKU matches the year-range fitment table below

Year-Range Fitment Table

Year Range	Model	Drivetrain	SKU Base	Notes
1994–1999	Ram 1500/2500/3500	4WD	9-240	Axle-side bolts: Upper 12mm, Lower 14mm
2000–2002	Ram 1500/2500/3500	4WD	9-240F / 241S	Axle-side bolts: Upper 12mm, Lower 14mm
2003–2009	Ram 1500/2500/3500	4WD	9-241	Axle-side bolts: Upper 14mm, Lower 16mm
2010–2013	Ram 1500/2500/3500	4WD	9-242	Axle-side bolts: Upper 14mm, Lower 18mm

Control Arm Length Reference Chart

Measure center-to-center with vehicle at ride height. All measurements in inches.

Lift Height	Upper Control Arm Length	Lower Control Arm Length
3"	27 3/8"	32 1/4"
4"	27 3/8"	32 1/2"
5"	27 7/16"	32 5/8"
6"	27 1/2"	32 7/8"
7"	27 5/8"	33 1/8"
8"	27 7/8"	33 1/8"
9"	28"	33 3/4"
10"	28 1/4"	34"
11"	28 1/2"	34 7/16"
12"	28 7/8"	34 7/8"

Parts Checklist

Verify all items against your packing slip before beginning installation.

2x CNC laser cut & welded steel frame brackets (1/4" steel plate)
2x Lower control arms (long arm, adjustable, 1.25"-12 thread end)
2x Upper control arms
6x 9/16" bolts for frame mount hardware

Optional Add-On (if ordered): Axle-side hardware kit — included if selected at purchase. Verify on your packing slip.

Step-by-Step Installation Sequence

Step 1 — Safety Setup and Vehicle Lift

Complete all pre-install checklist items above
Position floor jack under the vehicle's designated jack points
Raise vehicle to a safe working height and place jack stands under rated frame points
Lower vehicle onto jack stands and confirm stability before proceeding
Remove front wheels and tires

Step 2 — Remove Factory Lower Control Arm Brackets

⚠ Note: Trimming of the factory lower control arm frame mounts is required and will be performed in Step 3 once the new bracket is in place. Wear a face shield during all trimming operations.

Remove factory lower control arm bolts and remove the lower control arm completely
Deburr any rough edges and clean the frame area
Factory lower control arms will not be reused

Step 3 — Position and Mark CNC Long Arm Frame Brackets

Position the new CNC long arm frame brackets against the front cab body mount and in front of the transmission crossmember
Attempt to keep both driver and passenger side frame mounts in the same location — either both against the body mount or both against the crossmember — so they are the same distance from a common reference point on each side
With the frame mount held firmly in place, mark the hole locations to be drilled through the frame
Remove the bracket and drill the marked holes through the frame
Reposition the bracket, align with drilled holes, and insert Grade 8 bolts from the hardware kit — hand-tighten only at this stage
Now trim the factory lower control arm frame mount as needed — with the new bracket in place you can see exactly how much material needs to be removed to clear the new long arm bracket
Deburr all trimmed edges and clean metal shavings from the frame area
Confirm bracket orientation and positioning matches on both sides before torquing

Step 4 — Remove Upper Control Arms and Prepare Axle for New Long Arms

Set the upper control arm length according to the supplied measurement guide before installing — do not install the upper arms without first setting the correct length
Remove the upper control arm bolts on both driver and passenger sides and remove both upper control arms completely — this frees the front axle to be moved forward for installation of the new long arms
Place a floor jack under the front axle to support it during long arm installation — do not allow the axle to hang unsupported

Note: If the axle is allowed to hang lower than ride height, keep in mind that the lower it hangs, the more the axle will pull off-center toward the driver’s side — this is caused by the track bar’s articulation radius. The further off-center the axle is, the harder it will be to align and install the new long arms. Support the axle at or near ride height to keep it centered and make installation easier.

With the axle supported, install the new lower long arms into the frame brackets (hand-tight only at this stage)
A ratchet strap may be used to pull the axle forward to the proper location to align with the new long arm geometry
Once the axle is in the correct position, install the new upper control arms on both sides
Hand-tighten all upper and lower arm hardware — do not torque until all arms are installed and axle position is confirmed

Step 5 — Install Long Arms and Adjust to Ride Height (4"–12" Lift Range)

Insert the new adjustable long arms into the CNC brackets
Arm orientation note:
- Tube-style lower arms: The lower arm has a bend in it — the bend should face inward toward the engine to allow proper tire clearance
- CNC box-style lower arms: These arms are built with an offset — when installed correctly, the arms should angle inward toward the engine as they go rearward toward the back of the truck
Compatible with 4"–12" suspension lift heights — adjust arm length accordingly
Thread the adjustable end (1.25"-12 thread) to achieve desired pinion angle and caster correction
Install the frame-side hardware — hand-tighten only at this stage
If optional axle-side hardware was ordered, install now per the axle-side instruction sheet

Step 6 — Torque All Fasteners

Using a calibrated torque wrench, torque all bracket-to-frame fasteners to specification
Torque in a cross pattern where multiple fasteners are present
Mark all torqued fasteners with a torque stripe for visual verification

Torque Specifications:

Frame bracket bolts: 100 ft-lbs
Long arm pivot bolts: 140 ft-lbs
Axle-side hardware — upper control arm: 120 ft-lbs
Axle-side hardware — lower control arm: 140 ft-lbs

Step 7 — Grease All Fittings (1/4"-28 Thread)

Locate all 1/4"-28 thread grease fittings (zerk fittings) on long arm ends and bracket pivot points
Using a grease gun, pump silicone grease into each fitting until grease purges from the bushing seal — use silicone grease only; petroleum-based grease will cause premature bushing failure
Wipe away excess grease
Confirm all fittings are seated and not cross-threaded

Step 8 — Lower Vehicle and Check Geometry

Reinstall front wheels and tires — torque lug nuts to vehicle manufacturer specification
Raise vehicle off jack stands, remove stands, and lower vehicle to the ground
Bounce the front suspension several times to settle the geometry
Visually inspect all brackets, arms, and hardware for proper seating
Check that no components contact the frame, body, or brake lines through full suspension travel

Step 9 — Schedule Professional Alignment (Required)

⚠ A professional 4-wheel alignment is REQUIRED after installation. Do not drive at highway speeds until alignment is complete.

Caster correction is built into the kit design — inform your alignment technician that a long arm conversion has been installed
Request a full caster, camber, and toe alignment

Step 10 — Road Test and Re-Check Torque After 50–100 Miles

Perform an initial low-speed road test — listen for unusual noises and check for vibration
After 50–100 break-in miles, re-torque all suspension fasteners to specification
Re-grease all fittings after the break-in period — use silicone grease only
Inspect all hardware for loosening or movement

Re-Torque Specifications (after 50–100 miles):

Frame bracket bolts: 100 ft-lbs
Long arm pivot bolts: 140 ft-lbs

Alignment & Post-Install Notes

Professional alignment is required after installation — do not skip this step
Caster correction is built into the kit design — inform your alignment technician
Re-torque all suspension fasteners after 50–100 break-in miles
Inspect all hardware for loosening at each oil change interval
Bushings are rebuildable — no special tools required for bushing replacement

Grease Interval: Apply a couple pumps of silicone grease at every oil change interval. Use silicone grease only — do not use petroleum-based grease.

Safety Disclaimers

This installation guide is provided for reference purposes. Apoc Industries assumes no liability for improper installation, use of incorrect torque values, or failure to follow all safety procedures. Suspension modifications affect vehicle handling characteristics. Always have suspension work inspected by a qualified mechanic, obtain a professional 4-wheel alignment, re-torque all fasteners after break-in, and comply with all local laws regarding vehicle modifications and lift height limits.

Apoc Industries | apocindustries.com | MPN: AP900240241242 | Document Version: v1.0