Why is there little room for error with cutting the rear cross member? Isn't the cut to make room so the diff can clear that part?
If you look at step #39 in the BDS instructions they leave part of the OE cross-member mounting hole. If you watch the Rough Country install video at 2:08 you can see they cut both holes out of the cross-member. The important cut IMO is the top line(horizontal) cut. By cutting a straight line like the BDS kit states it makes it hard to cut straight through in one pass with a reciprocating saw. I used a reciprocating saw for the vertical cuts. I then had to cut the top line with a die grinder because the angle would have cut to much off the top portion of the horizontal cut. If you cut the vertical lines at a slight angle like in the Rough Country video it would be a lot easier to make the whole cut in one pass with the reciprocating saw or you can just use a die grinder and be done with it. If I had more time I would've just cut both sides, grabbed the welder a piece of scrap metal and box both sides in.
In my last post I was referring to rear install step #12 about drill for the upper control arm relocation brackets. I had to only drill out two holes for those brackets since my axle had them pre drilled out already.
If you look at the rear install step number #20 you'll see figure 6A and 6B pictures. Now look at the BDS panhard relocation bracket in the two pictures, they're mounted differently. In figure 6A the BDS panhard bracket is towards the rear of the vehicle and in 6B the bracket is mounted towards the front of the vehicle. In this link below you can see they mounted the panhard bracket as pictured in figure 6B.
Lift Your Ram Tough: BDS Suspension’s 4-Inch Suspension Lift For Ram 1500
Also in the rear install do step #21 before step #20, it my be a little easier to tighten the bump stop bolts before the panhard bar bracket is installed.
That is all I can think of for now. I hope that helps someone because I'm by no means a mechanic but I did stay at a Holiday Express last night.