Spohn D09-1500-104R Adjustable Rear Panhard Track Bar User Manual

1. Introduction

This manual provides detailed instructions for the installation, adjustment, and maintenance of your Spohn D09-1500-104R Adjustable Rear Panhard Track Bar. This component is designed to enhance the performance and stability of your 2009-2022 Dodge Ram 1500 truck's rear suspension system. Please read all instructions carefully before proceeding with installation or adjustment.

2. Product Features

• Allows for precise lateral centering of the rear axle housing after modifying ride height (lowering or lifting).
• Facilitates lateral alignment of the rear end, crucial for clearance when utilizing larger tires.
• Constructed from 1.00" x .095" wall DOM tubing for superior strength.
• Equipped with fluted polyurethane bushings and grease fittings for easy lubrication and extended lifespan.
• Features a right-hand and left-hand threaded CNC machined 4140 chrome moly double adjuster, integrated into TIG welded 4130 chrome moly threaded tube adapters for maximum thread strength and on-the-truck adjustability.
• Designed for 100% bolt-in installation, reusing factory mounting hardware.
• Finished with a durable, bright red powder coating.

3. What's in the Box

Your package should contain the following item:

• 1x Spohn D09-1500-104R Adjustable Rear Panhard Track Bar

Figure 1: The Spohn D09-1500-104R Adjustable Rear Panhard Track Bar, showcasing its full length and red powder-coated finish.

4. Setup and Installation

Installation of the Spohn D09-1500-104R Panhard Track Bar is a direct bolt-in process. Basic hand tools are required. Always ensure the vehicle is safely supported on jack stands or a lift before beginning work. It is recommended to have the vehicle's weight on the suspension when tightening the panhard bar bolts to ensure proper alignment and prevent bushing preload.

4.1 Safety Precautions

• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure the vehicle is securely supported on a level surface. Never work under a vehicle supported only by a jack.
• Refer to your vehicle's service manual for specific torque specifications for suspension components.

4.2 Installation Steps

1. Park the vehicle on a level surface and engage the parking brake.
2. Safely lift the rear of the vehicle and support it with jack stands under the frame, allowing the rear axle to hang freely or be supported at ride height, depending on the specific vehicle and desired initial adjustment.
3. Locate the factory rear panhard bar.
4. Using appropriate wrenches, remove the bolts securing the factory panhard bar to the frame and axle. Retain the factory hardware as it will be reused.
5. Carefully remove the factory panhard bar.
6. Position the new Spohn Adjustable Rear Panhard Track Bar in place. The bar is designed to reuse the factory mounting hardware.
7. Insert the factory bolts through the bushings of the new panhard bar and into the mounting brackets on the frame and axle. Do not fully tighten at this stage.
8. Lower the vehicle until its full weight is on the suspension. This is crucial for proper alignment and to prevent binding of the bushings.
9. With the vehicle at ride height, tighten both mounting bolts to the manufacturer's specified torque.

Figure 2: Close-up view of one end of the panhard bar, showing the polyurethane bushing and the Spohn Performance branding.

Figure 3: An installed view of the Spohn panhard bar under a vehicle, demonstrating its position relative to other suspension components.

5. Operation and Adjustment

The primary function of the adjustable panhard bar is to laterally center the rear axle housing. This adjustment is typically required after altering the vehicle's ride height (e.g., installing a lift kit or lowering springs).

5.1 Adjusting the Panhard Bar

1. With the vehicle on a level surface and at its normal ride height, measure the distance from the tire to the fender on both sides of the rear axle. The goal is to make these measurements equal, indicating a centered axle.
2. Loosen the jam nuts on the double adjuster located in the center of the panhard bar.
3. Rotate the center adjuster body. Turning it in one direction will lengthen the bar, pushing the axle to one side. Turning it in the opposite direction will shorten the bar, pulling the axle to the other side.
4. Make small adjustments and re-measure the tire-to-fender distances. Repeat until the axle is centered.
5. Once the axle is centered, securely tighten both jam nuts on the double adjuster to prevent the bar from changing length during operation.

Figure 4: Close-up of the double adjuster mechanism, illustrating the right-hand and left-hand threaded components for on-the-truck length adjustment.

6. Maintenance

The Spohn D09-1500-104R Panhard Track Bar features fluted polyurethane bushings equipped with grease fittings for easy lubrication. Regular lubrication is essential to maintain bushing performance and longevity, and to prevent squeaking.

6.1 Lubrication Schedule

• Inspect and lubricate the bushings every 3,000 to 5,000 miles, or more frequently if the vehicle is exposed to harsh conditions (e.g., off-road driving, heavy rain, road salt).

6.2 Lubrication Procedure

1. Locate the grease fittings on the polyurethane bushings at each end of the panhard bar.
2. Using a grease gun, apply a small amount of high-quality, marine-grade grease suitable for polyurethane bushings.
3. Pump grease until a slight bulge is visible around the bushing, indicating it is adequately lubricated. Avoid over-greasing, which can damage the bushings.
4. Wipe off any excess grease.

7. Troubleshooting

While the Spohn Panhard Track Bar is designed for durability and performance, minor issues can sometimes arise. Here are some common troubleshooting tips:

• Squeaking Noise: If you hear squeaking from the rear suspension, it is likely due to dry polyurethane bushings. Refer to Section 6.2 for lubrication instructions.
• Rear Axle Not Centered: If the rear axle appears off-center, re-check your measurements and follow the adjustment procedure in Section 5.1. Ensure the jam nuts are securely tightened after adjustment.
• Loose Feeling in Rear End: Verify that all mounting bolts and adjuster jam nuts are tightened to the correct torque specifications. Inspect bushings for wear or damage.

If you encounter persistent issues that cannot be resolved with these steps, contact Spohn Performance customer support for further assistance.

8. Specifications

9. Warranty and Support

For information regarding product warranty, returns, or technical support, please contact Spohn Performance directly. Details can typically be found on their official website or through your original point of purchase. Always provide your product model number (D09-1500-104R) when seeking support.