DROPPING THE ’04 F-150

DJM launches a 2 ½ X 4 drop kit for the new Ford F-150

Story & photos by Marshall Spiegel

Notice some wondrous improvements with DJM’s new drop kit for the ’04 F-150. The corrugated packaging, especially the section for the lower control arms, is new, virtually impregnable and very impressive, a little like a jewelry box for fine jewelry (see photos). Those famous DJM twin sleeves that previously required drilling for grease fittings now come pre-drilled at the factory. This will come as great news to those who know DJM’s old “drill-’em-for-grease” twin sleeves. The new DJM flip bracket is stronger and clamps the rear end securely and correctly so that the installer is able to adjust the pinion angle to prevents rear end vibrations. The entire 2 ½ X 4 DJM kit is direct bolt on and requires no welding, drilling or modifications of any kind. In addition to the aforementioned improvements, shock replacement is required in the rear only. Stock front shocks are retained. Full front-end travel is retained because the spring and strut have not been modified in any way. Installing DJM’s new drop kit for the F-150 is relatively straightforward. To see just how it’s done, we watched technician Billy Cruz get the job done on an ’04 F-150 Supercrew at Rapid Transit in San Pedro, CA. The accompanying photos show the highlights of the installation.

#1. The lower control arms for the 2 ½ X 4 DJM drop kit with installation instructions are shipped in a new, protective shipping carton.

#2. Here’s a close look at the lower control arms that drop the ’04 F-150 front end 2 ½ inches

#3. The DJM hangers are a key component of this drop kit.

#4. Here are all the components of the 4-inch rear drop kit.

#5. Here’s a comparison of the DJM lower control arm (left) and the stock control arm

#6. Our installer, Billy Cruz, measures the front stock ride height from the ground to the fender edge at 34 ½ inches.

#7. The rear stock ride height measured at 37 inches.

#8. Billy removes the driver’s side stock spindle.

#9. The upper control arm is removed from the spindle.

#10. With the lower ball joint removed, Billy reattaaches the spindle and brake assembly to the upper control arm , thus holding it in place.

#11. The lower control arm is freed and the final bolt at the pivot point is removed.

#12. The stock lower control arm is removed.

#13. Billy begins preparing the DJM lower control arm for installation

#14. The inner sleeve for the twin tube pivot point is removed.

#15. The zerk fitting is positioned into the pre-drilled hole. (All installers are reminded to check that the grease holes in all the twin tubes have been pre-drilled.)

#16. Billy applies special urethane grease supplied in the DJM kit to the inner sleeve and bushing.

#17. The greased inner sleeve is then inserted into the twin tube pivot point.

#18. The zerk fitting is tightened securely

#19. The DJM lower control arm is installed exactly the same as the stock control arm.

#20. Here our installer tightens the control arm while retaining the same alignment points.

#21. He then tightens the lower ball joint.

#22. It is vey important that the bolt on the strut is installed exactly as the stock unit before each strut (which also reinstall just like the stock units) is reconnected and tightened.

#23. Billy prepares to begin the rear installation by removing the rear wheels

#24. He loosens the driver’s side U-bolt holding the rear leaf spring.

#25. He then removes the U-bolt and spring plate.

#26. The leaf spring is removed

#27. Billy then removes both center bolts holding the leaf pack together.

#28. He installs the aft center bolt by inverting it so that the locating pin will align with the new DJM bracket

#29. Billy installs the extension or lifting hanger.

#30. Billy taps the bracket thoroughly to seat it.

#31. He then tightens the bolt that prevents the bracket from moving

#32. Here’s the finished bracket ready to accept the original spring.

#33. He re-installs the spring into the new bracket.

#34. He then removes the stock bump stop.

#35 New bump stop

#36. He installs the bolts for the top plate to the flip kit (but he doesn’t tighten them until the pinion angle on the rear end is adjusted).

#37. The new DJM U-bolts are installed.

#38. The new DJM spring plate is installed.

#39. After adjusting the pinion angle to prevent rear end vibration, Billy tightens the U-bolts and top plates which then locks the whole assembly together.

#40. Only the stock rear shocks are replaced.

#41. After the wheels are remounted at all four corners, the front ride height is measured at 32 inches indicating a drop of exactly 2 ½ inches

#42. The rear ride height measured 33 inches for a drop of exactly 4 inches and all that remained was a trip to Rapid Transit’s alignment rack.