A SPECIAL F-150 GETS A DJM 2-4 DROP KIT

We install the perfect lowering kit for this Harley-Davidson F-150…

Story & photos by Marshall Spiegel

The new Harley-Davidson F-150 carries on the tradition of excellence well established by FoMoCo with this specialty model. When the owner of this brand-new Harley model showed up at Rapid Transit, the huge auto center in San Pedro, CA, he explained that he was delighted with everything about his new ride but the stance and the standard ride height. The 5.4L provided all the power he desired. He loves the stock electric sunroof and considers it a very attractive feature. He likes the room and comfort of the crew cab-seating configuration. And he can't fault the Harley's ride or handling. It was only the Ford's stock ride height and stance that didn't delight him. The experts at Rapid Transit suggested a 2¼" by 4" drop kit from DJM Suspension in Gardena, CA. Based on their experience with the DJM kit, the Rapid Transit guys felt confident the kit would vastly improve the Ford's stance and ride height while preserving the vehicle's excellent ride and handling. Installation duties fell to young, strong Rapid Transit technician " Big" Bruce Cazares, who, as the son of an experienced mechanic, virtually grew up with a wrench in his hand. The DJM kit calls for the installation of specially engineered lower control arms to drop the front end slightly more than two inches. The rear is dropped four inches by the installation of new brackets and a flip kit. The '07 Harley's stock ride height showed 20½ inches in the front and 23¾ inches in the rear when measured from the center of each wheel to the lip of the fender well. The installation of the DJM 2¼ -4 kit proved to be "clean" and straightforward. The best news is that the installation kept all of DJM's promises and left the new Harley two inches lower in the front and four inches lower in the rear with a greatly improved, much more aggressive stance and unaffected ride and handling.

2007 Harley Davidson F150 CALMAX Kit
#1. Big Bruce begins by recording the stock front ride height of 20½ inches measured from the center of the wheel to the lip of the fender well.	#2. The stock rear ride height, also measured from the center of the wheel to the lip of the fender well, registered 23¾ inches	#3. He the removes the front wheels.
#4. Here's a look at the 100% stock front suspension of the brand-new '07 Harley-Davidson F-150.	#5. The next step is to unbolt the ball joint nut.	#6. With the tie rod end loose, he begins dismantling the right front corner.
#7. He unbolts the stock lower control arm	#8. He then unbolts the sway bar.	#9. The stock lower control arm is almost free.
#10. The ball joint bolt is removed.	#11. A little careful hammer work breaks the ball joint free.	#12. The stock control arm is removed.
#13. Although barely discernible, the subtle differences in the engineering of the DJM control arm (left) and the factory arm make for the 2¼-inch front drop.	#14. To prevent damage in shipping, the zerk fitting are screwed into the predrilled lubrication holes in the twin sleeves of the DJM A-arms by the installer.	#15. Each inner sleeve is lubricated by hand with grease supplied in the DJM kit
#16. The zerk fitting are then tightened thoroughly.	#17. The twin sleeves are thoroughly lubricated through the zerk fittings and special attention is paid to be certain the grease is flowing smoothly	.#18. Each tie rod is measured and marked so our installer can comply with the requirement in the installation instructions to trim off 3/8th inch.
#19. Big Bruce carefully shortens the tie rod by trimming off 3/8th inch.	#20. The new DJM control arm is worked into position.	#21. The new arm is bolted in place.
#22. The ball joint nut is installed.	#23. Our installed positions an extension jack to support the new control arm in position while it is being bolted in.	#24. The brake caliper is reinstalled.
#25. Here's how the driver's front corner should look when the installation of the DJM arm is complete.	#26. The front wheels are installed.	#27 On the rear the first obstacle is the gas tank
#28 The spring pack is very close to the gas tank	#29 Another view of the gas tank and rear leaf spring	#30. As you can see by studying these views, the challenge with installing the rear flip kit has to do with the fact that the spring pack bolt on the right side is very close to the fuel tank and must be cut off or the fuel tank must be moved.
#31. After the installation is completed on the passenger front side, the rear wheels are removed to begin the rear drop.	#32. Big Bruce gets a hand with the rear drop from a colleague who removes the U-bolt and the spring plate.	#33. The leaf spring is removed.
#34. Our installer then removes both center bolts holding the leaf packs together.	#35. He then re-installs the rearmost center bolt by inverting it so that the locating pin will align with the new DJM bracket.	#36. The extension or lifting hanger is installed.
#37. Our installer taps the bracket thoroughly to seat it.	#38. He then tightens the bolt that prevents the bracket from moving.	#39. Here's a look at the finished bracket ready to accept the original spring.
#40. He re-installs the spring into the new bracket.	#41. The stock bump stop is then removed.	#42. The DJM bump stop screws easily into the stock mounting clip.
#43. The bolts for the top plate to the flip kit are installed, but not tightened until the pinion angle on the rear-end is adjusted.	#44. The new DJM U-bolts are installed.	#44. The new DJM U-bolts are installed.
#46. After adjusting the pinion angle to prevent rear-end vibration, our installer tightens the U-bolts and the top plates to lock the whole assembly together.	#47. The stock rear shocks are replaced.	#48. The new front ride height is measured 18¼ inches, a drop of exactly 2¼ inches.
#49. The new rear height after the DJM drop kit install measured 19¾ inches, a drop of exactly 4 inches.	#50. The '07 Harley-Davidson F-150 poses smugly with it modified ride height and greatly improved stance after the DJM 2¼" X 4" drop kit installation.
RAPID TRANSIT AUTO CENTER 114 N. Pacific Avenue San Pedro, CA 90731 Phone: (310) 832-6448 Fax: (310) 514-2910 Web-site: www.rapid-transit-online,com

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