9630 Instructions
Contents
1. Remove rear tires SHOCK ABSORBERS Disconnect and discard the factory shocks ANTI SWAY BAR LINKS On each side disconnect the sway bar link from the axle bracket and the sway bar body TRACK BAR Before removing the bar mark the driver and passenger end to aid in reassembly The plastic shield that covers the driver axle end of the bar is not reused UPPER LINK ARMS On each side detach the rear end of the arm from the axle Loosen do not remove the bolt at the frame end of the link This will allow the link to swing out of the way COIL SPRINGS Lower the axle assembly until the coil springs are free from their seats then remove the coils Inspect the thin disc shaped rubber gasket that insulates the top of the coil and replace if necessary FORM 5120 10 071511 PRINTED IN U S A PAGE 9 OF 13 REAR ASSEMBLY 27 oO 28 QU QU 29 30 QU QU CAM BOLT SLOTS On each side look at the axle bracket that captures the upper link s rear eye Knockout the perforated plug that makes the round hole a slotted hole If necessary dress the slot with a file and paint the exposed metal UPPER LINK ARMS On each side use Superlift cam bolt assembly 1 03 5062 to reattach the link to the axle Install the bolts from the inside so they point outward Rotate the cams so that the tall side of the lobes point straight up 12 O clock position Do not fully tighten the bolts are torqued in a l2. bolt 2 5 16 Nyloc nut 55 06 5064 torque shaft bracket 2 6mm x 20mm allen head bolt 2 6mm nyloc nut 55 01 5067 2 anti sway bar bracket front 2 3 8 x 1 1 2 bolt 2 3 8 nyloc nut 55 09 5064 casices 2 anti sway bar link front 2 7 16 x 2 3 4 bolt 2 7 16 Nyloc nut 4 poly bushing 4 sleeve 55 07 5120 cee 2 transfer case drop bracket 6 12mm x 80mm bolt 55 08 5120 eee 2 engine mount spacer plate 521025064 sass ieecetesatise 2 anti sway bar link rear 4 poly bushing 4 1 2 ID poly vinyl sleeve 063702 sane 2 poly compression stop front 55213 5100 eis is ceeds rear shock bracket extension 3 8 x 1 bolt driver side 3 8 SAE washer 1 2 1 3 8 nyloc nut 1 1 2 x 2 3 4 bolt 2 1 2 SAE washer 1 1 2 stover nut 1 5 8 OD x 1 2 ID x 1 3 8 sleeve 55 14 5100 eee rear shock bracket extension 1 3 8 x 1 bolt FORM 5120 10 071511 PRINTED IN U S A PAGE 3 OF 13 3 8 SAE washer 3 8 nyloc nut 1 2 x 2 3 4 bolt 1 2 SAE washer 1 2 stover nut 5 8 OD x 1 2 ID x 1 3 8 sleeve passenger side 2 1 1 2 1 1 See wes a 03 5062 nnna 2 cam bolt assembly OOS GR attatat tastes 2 front shock absorber 2 shock hardware pack BOT Divi cect socicecisecacwei cate 2 rear shock absorbet 2 shock hardw
3. Step 1 reading as possible This will minimize or eliminate shaft vibration due to excessive angle The 12 O clock position that the cams were initially adjusted to in Step 28 yields the least amount of angle It is important that both cams are adjusted identically To reduce vibration under acceleration rotate the cams to move the pinion bearing downward To reduce vibration under deceleration rotate the cams to move the pinion bearing upward HEADLIGHTS Readjust headlights to factory setting FINAL OVERALL INSPECTION and TORQUE CHECK Perform a front to rear inspection With the suspension supporting vehicle weight cycle steering lock to lock and inspect steering suspension driveline and brake systems for proper operation tightness and adequate clearances Retorque all fasteners TRANSMISSION SHIFTER MODIFICATION This step is only necessary if the vehicle exhibits problems shifting after the lift installation is complete Test drive the vehicle and shift through all gears If it is difficult to shift into or the transmission jumps out of Second Fourth or Reverse the shifter is likely hitting the edge of the transmission tunnel due to the transfer case drop and will need to be modified slightly Set the parking brake on the vehicle and put the transmission in neutral Remove the shift knob and upper shifter boot Shift the transfer case lever into neutral and remove the console lower shift boot and dust boot FORM 51
4. in materials or workmanship for so long as the original purchaser owns the vehicle on which the product was originally installed Your warrantor is LKI Enterprises Inc d b a Superlift Suspension Systems Superlift What is not covered Your Superlift Limited Warranty does not cover products parts or vehicles Superlift determines to have been damaged by or subjected to e Alteration modification or failure to maintain e Normal wear and tear bushings tie rod ends etc Scratches or defects in product finishes powdercoating plating etc e Damage to or resulting from vehicle s electronic stability system related components or other vehicle systems e Racing or other vehicle competitions or contests Accidents impact by rocks trees obstacles or other aspects of the environment e Theft vandalism or other intentional damage FORM 5120 10 071511 PRINTED IN U S A PAGE 13 OF 13 Remedy Limited to Repair Replacement The exclusive remedy provided hereunder shall upon Superlift s inspection and at Superlift s option be either repair or replacement of product or parts covered under this Limited Warranty Customers requesting warranty consideration should contact Superlift by phone 1 800 551 4955 to obtain a Returned Goods Authorization number All removal shipping and installation costs are customer s responsibility If a replacement part is needed before the Superlift part in question can be returned y
5. 20 10 071511 PRINTED IN U S A PAGE 12 OF 13 DIAGRAM 9 TRANSMISSION SHIFTER MODIFICATION O Remove the shifter from the Remove the shifter from the vehicle and bend slightly as shown transmission following the procedure found in the factory service manual Q DIAGRAM 9 Disassemble the shifter according to the diagram Place the lower portion of the shifter in a vice or press and bend it slightly about 3 degrees at the point shown It will be necessary to heat the shifter with a torch in order to bend it in most cases Do not heat the shifter excessively and do not bend it more than necessary 41 Reassemble the shifter and install it by reversing the steps followed for dissassembly 41 SAFETY DECAL Q Install Warning to Driver decal Refer to the NOTICE TO DEALER AND VEHICLE OWNER section below 42 ALIGNMENT QO Realign vehicle to factory specifications Limited Lifetime Warranty Warnings Your Superlift product is covered by the Limited Warranty explained below that gives you specific legal rights This limited warranty is the only warranty Superlift makes in connection with your product purchase Superlift neither assumes nor authorizes any retailer or other person or entity to assume for it any other obligation or liability in connection with this product or limited warranty What is covered Subject to the terms below Superlift will repair or replace its products found defective
6. 511 PRINTED IN U S A PAGE 4 OF 13 7 aa QU 8 oo LOWER LINK ARMS Cam bolts attach the lower links to the front axle housing Front end alignment is altered as the bolts are rotated Paint or scribe alignment marks on each cam bolt and axle bracket so the bolts can later be returned to their original position On each side remove the cam bolt assembly from the link s axle end Then remove the attaching bolt at the rear of the lower link arm where it connects to the frame rail and remove the link Save all hardware for reuse COIL SPRINGS Lower the jack axle assembly until the coil springs are free from their upper seats A retainer clip must be removed at the base of the driver side coil Remove the coils FRONT ASSEMBLY 9 QU QU 10 QU QU QU 11 QU QU COMPRESSION TRAVEL STOPS qty 2 06 5702 DIAGRAM 1 COMPRESSION TRAVEL DIAGRAM 1 On each side pry the STOP INSTALLATION factory compression stop from its mounting cup taking care not to damage the cup Install the replacement poly compression travel stops 06 5702 in the factory cups It may be necessary to raise the axle in order to press the stops in the cups It may also be necessary to trim the end of the stop slightly so that the stop s 06 5702 retaining groove fully engages the ee tabs in the cup 0 TS COIL SPRINGS 550 Lower the axle far enough to facilitate installing the coil springs Use cautio
7. FORM 5120 10 071511 PRINTED IN U S A PAGE 1 OF 13 SUPERLIFT SUSPENS Superlift Part No 5120 4 lift system for 2003 and newer JEEP TJ with coil spring suspension INSTALLATION INSTRUCTIONS INTRODUCTION Installation requires a professional mechanic Prior to beginning inspect the vehicles steering driveline and brake systems paying close attention to the track bar suspension link arms and bushings anti sway bars and bushings tie rod ends pitman arm ball joints and wheel bearings Also check the steering sector to frame and all suspension to frame attaching points for stress cracks The overall vehicle must be in excellent working condition repair or replace all worn parts Read instructions several times before starting Be sure you have all needed parts and know where they install Read each step completely as you go NOTES If the optional Rockrunner System is being installed refer to those instructions before proceeding An inclinometer or similar angle measuring tool is required for a rear driveshaft angle reading If this tool is unavailable proper shaft angle can be attained by trial and error Front end realignment is necessary A factory service manual should be on hand for reference The manual will contain fastener torque specs assembly techniques and special tool requirements that are unique to this particular year and model vehicle Do not add or fabricate any components to gai
8. FT SHOCKS Install shock boot and A decal 1 N 55 13 5100 Eg 6 one Mai X _ Position shock and gt 112 x2 314 bot gt py tighten the two upper bolts 23 and the single lower bolt 74 TIRES WHEELS CAUTION Before installing each wheel be sure to remove any built up corrosion on the wheel mounting surfaces Ensure wheels are installed with good metal to metal FORM 5120 10 071511 PRINTED IN U S A PAGE 11 OF 13 QU 37 O oO OO 38 39 40 contact Improper installation could cause loosening of the wheel nuts Never use oil or grease on lug studs or nuts DIAGRAM 4 All wheel nuts should be tightened just snug the gradually tightened in sequence to the proper torque specification 80 to 110 With front of vehicle still on stands and suspension hanging at full extension travel check all components for proper operation and clearances Remove jack stands and lower vehicle to floor TIGHTEN the SUSPENSION COMPONENTS The suspension must be supporting the vehicle s weight when these components are torqued Track bar both ends 74 Lower link arm both ends 130 Upper link arm frame end 55 Upper link arm axle cam bolt end 85 NOTE Prior to torquing the cam bolts again use the inclinometer to take a rear driveshaft angle reading and compare this to the reading taken in Step 1 Rotate the cam bolts as needed to get shaft angle as close to the
9. are pack 01 86010 eee 4 yellow shock absorber boot 4 shock boot cable tie Note Shock boot if desired purchased separately rota hobs bing has Superlift badge alcohol wipe pad FRONT DISASSEMBLY 1 a 4 aa 5 oo PREPARE VEHICLE Place vehicle in low gear or park With the suspension supporting vehicle weight and the vehicle on level ground use an inclinometer to take a rear driveshaft angle reading One of the last installation steps will be to reset the driveshaft angle as close as possible to this reading Place vehicle in neutral Raise front of vehicle with a jack and secure a jack stand behind the lower link arms beneath each frame rail Ease the frame down onto the stands Support the outboard end of the driver and passenger side axle tube with a floor jack the frame is to remain on the stands TRACK BAR Remove the bolt at the bottom axle end of the track bar The upper frame end is not disconnected DRAG LINK and PITMAN ARM Remove the cotter pin and nut that connects the drag link to pitman arm Use a puller tool to detach the link from the arm SHOCK ABSORBERS Disconnect and discard the factory shocks ANTI SWAY BAR LINKS On each side disconnect the sway bar link from the axle bracket and the bar body SKID PLATE Remove and discard the factory front skid plate that is forward of the belly pan for the transmission FORM 5120 10 071
10. ater step On each side attach the link s front eye to the frame Do not fully tighten the bolts are torqued in a later step TRACK BAR BRACKET 55 03 5064 DIAGRAM 7 There are two existing holes in the factory track bar to axle mount where the plastic cover was attached Drill out these holes to 5 16 diameter The 03 bracket fits DIAGRAM 7 REAR TRACK BAR BRACKET down over the top of the factory mount as shown 9 5 16 X 3 4 BOLT Use the furnished 7 16 i fastener at the factory mount s bar eye hole 37 Tighten the 5 16 hardware 13 The track bar is installed in a later step NOTE It may be necessary to grind down the weld on the factory bracket to ensure the 03 bracket fits flush over the OE bracket Refer to Diagram 9 COMPRESSION TRAVEL STOP EXTENSIONS qty 2 9003 On each side Pry the factory compression stop from it s mounting cup taking care not to damage the cup Remove the 10mm bolt that attaches the cup to the spring tower Position the Superlift compression stop spacer between the tower and mounting cup as shown and install the new 10mm x 100mm bolt 80 Reinstall the factory rubber compression stop into the mounting cup FORM 5120 10 071511 PRINTED IN U S A PAGE 10 OF 13 31 32 33 QU QU 34 QU 35 ou QU 36 SUPERLIFT COIL SPRINGS 551 On each side position the coil spring on the axle pad It may be necessary to lo
11. er mounting hole in the track bar s axle bracket where shown Shift the axle assembly as necessary to align the track DIAGRAM 3 FRONT TRACK MOUNTING HOLE Hole bar eye with the new hole location is moved inboard toward driver side 3 4 Hole Insert the stock fastener and Size is 7 16 SA B hand tighten only the bolt will be fully tightened in a later step DRAG LINK Connect the drag link to the pitman tighten nut 60 and install new cotter pin If the castellations and the cotter pin do not align tighten do l n Of Q f Wwe Sar aaa not loosen the nut until they uy is align iF A qty 2 55 09 5064 FOR FRONT ANTI SWAY BAR LINK ANTI SWAY BAR LINKS Note If optional Superlift Quick Disconnect links are being used install now per separate instructions FORM 5120 10 071511 PRINTED IN U S A PAGE 6 OF 13 QU QU QU QU 16 QU 17 18 Attach a 55 01 5067 bracket to each end of the sway bar body using a 3 8 x 1 1 2 bolt and nyloc nut 23 Insert the bolt facing up and be sure the bracket legs are facing downward Install the supplied bushings and sleeves into the eyes of each 55 09 5064 anti sway bar link Note that the smaller ID sleeve installs on the upper end of each link Position the upper end of each link into the 55 01 5067 bracket and secure using the supplied 7 16 x 2 3 4 bolt 38 Note that the bolts should be installed fro
12. m the outside Slide the lower end of each link into the stock brackets on the axle and secure using the stock hardware Tighten to factory specifications TIRES WHEELS CAUTION Before installing each wheel be sure to remove any built up corrosion on the wheel mounting surfaces Ensure wheels are installed with good metal to metal contact Improper installation could cause loosening of the wheel nuts Never use oil or grease on lug studs or nuts DIAGRAM 4 All wheel nuts should be tightened DIAGRAM 4 LUG NUT TORQUE just snug then gradually tightened in sequence to SEQENCE Follow the pattern the proper torque specification 80 to 110 shown to torque the lug nuts With front of vehicle still on stands and suspension eS hanging at full extension travel turn steering lock to lock while checking components for proper fa g 1 4 operation and clearances C a Remove jack stands and lower vehicle to floor TIGHTEN the SUSPENSION COMPONENTS a The suspension must be supporting the vehicle s 3 S 2 weight when these components are torqued i Lower link arm to axle cam bolt nut 85 Before tightening match up the alignment marks on the 5 cams and axle brackets that were made in Step 6 ee Lower link arm to frame nut 130 Track bar to axle bolt 55 TORQUE SHAFT BRACKET 55 05 5064 The torque shaft bracket is part of the transfer case shifter assembly This step prevents shifter bind afte
13. n additional suspension height a Any welding must be performed by a professional certified welder 2 After drilling file smooth any burrs and sharp edges or stress cracks may develop Paint or undercoat all exposed metal surfaces Prior to attaching components be sure mating surfaces are free of grease grit oil undercoating etc A torque specification in foot pounds is shown in parenthesis after each fastener Use the check off box OQ found at each step to help keep your place Two Q0 denotes that one check off box is for the driver side and one is for the passenger side An arrow on diagrams indicates which direction is towards front of vehicle Retain all factory hardware for reuse unless otherwise specified PARTS LIST FORM 5120 10 071511 PRINTED IN U S A PAGE 2 OF 13 The part number is stamped into each part or printed on an adhesive label Identify each part and place the appropriate mounting hardware with it PART NO DESCRIPTION ATTACHING HARDWARE Qty if more than one Qty 02 550 aiiai 2 front coil spring 02 95 iiris 2 rear coil spring 9003 2 compression stop extension 2 10mm x 100mm bolt 55 05 5073 2 lower trailing link front 8 bushing half 4 sleeve NOTE Trailing links are located in separate kit box 5073 55 09 5064 oie ices rear track bar bracket 1 7 16 x 1 bolt 1 7 16 Nyloc nut 2 5 16 x 3 4
14. n to prevent over extending brake lines vent hoses etc Install the coils Position the coil in the tower first then slide it into place on the axle seat Reattach the retaining clip at the bottom of the driver side coil LOWER LINKS Lubricate and install the supplied bushings and sleeves in the 55 05 5073 lower links DIAGRAM 2 On each side install the 5073 lower links using the factory hardware The cam bolts install at the axle with the nut side facing inboard Only hand tighten the cam bolts they along with the links rear eye bolts are fully tightened in a later step 12 SUPERLIFT SHOCK ABSORBERS FORM 5120 10 071511 PRINTED IN U S A PAGE 5 OF 13 QU QU QU 13 QU QU 14 QU 15 On each side Install shock boot and decal DIAGRAM 2 LOWER LINK INSTALLATION Position the links as shown and install using the factory hardware With the lower half of the stem hardware in place insert the top end of the shock through Sticke hei the hole in the factory shock am A tower Install the other half of be a the hardware and tighten only until the bushings start to swell slightly Install jam nut Attach the lower end of the A Tey ERT shock to the axle using the seas bors NRR factory hardware 21 atadh TRACK BAR NOTE If the optional Superlift adjustable track bar 5070 has been purchased install now per separate instructions DIAGRAM 3 Drill a new 7 16 diamet
15. nctional roll bar and cage system Seat belts and shoulder harnesses should be worn at all times Avoid situations where a side rollover may occur Generally braking performance and capabilities are decreased when significantly larger heavier tires and wheels are used Take this into consideration while driving Also changing axle gear ratios or using tires that are taller or shorter than factory height will cause an erroneous speedometer reading On vehicles equipped with an electronic speedometer the speed signal impacts other important functions as well Speedometer recalibration for both mechanical and electronic types is highly recommended Do not add alter or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the Superlift product purchased Mixing component brands is not recommended All Superlitt material is copyrighted All images found in this catalog and in any Superlift marketing forums are the sole property of or licensed to Superlift Any reproduction of said materials in part or in whole with out the express written permission of Superlift is strictly forbidden Superlift Rockrunner Swamprunner Superide Superide SS and SSR Black Diamond XCL X2 Super Trac Torque Max Torque Max SS eXtreme Ring Rail Wrap Bullet Proof Brake Hose TruSpeed Frame Integrated Technology F I T Series and Rock Fink are registered tradema
16. osen the lower links front and rear eye bolts so the axle can drop enough for coil installation Raise the axle until the springs seat in their upper mounts Do not forget the stock coil gaskets for the top of the coils After both coils are in place jack up the axle assembly until the springs are seated Be sure the frame rails remain on the jack stands TRACK BAR Install the track bar Reuse the factory fasteners at both ends Hand tighten only both bolts are fully tightened in a later step It may be necessary to pry the axle assembly over in order to connect the bar ANTI SWAY BAR LINKS qty 2 55 10 5064 REAR ANTI SWAY BAR LINK Note If optional Superlift Quick Disconnect Links are being used install now per separate instructions Install the supplied bushings and poly sleeves in the eyes of each 55 10 5064 anti sway bar link Position the ends of each link in the stock brackets on the axle and the frame then secure using the stock hardware Tighten to factory specifications SHOCK BRACKET EXTENSIONS AND DIAGRAM 8 SHOCK BRACKET EXTENSIONS Install the 55 13 5100 shock SHOCKS bracket extensions using the hardware shown DIAGRAM 8 On each side attach the shock bracket extensions 55 13 5100 driver side and 55 14 5100 passenger side to the shock mounts on the axle using the 3 8 x 1 bolt washer and nyloc nut as shown A NG c Q pa x 3 8 nyloanut df amp mA OD WAN N SUPERLI
17. ou must first purchase the replacement part Then if the part in question is deemed warrantable you will be credited refunded Other Limitations Exclusion of Damages Your Rights Under State Law e Neither Superlift nor your independent Superlift dealer are responsible for any time loss rental costs or for any incidental consequential or other damages you may have e This Limited Warranty gives you specific rights You may also have other rights that vary from state to state For example while all implied warranties are disclaimed herein any implied warranty required by law is limited to the terms of our Limited Lifetime Warranty as described above Some states do not allow limitations of how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequential damages so the limitations and exclusions herein may not apply to you Important Product Use and Safety Information Warnings As a general rule the taller a vehicle is the easier it will roll over Offset as much as possible what is lost in rollover resistance by increasing tire track width In other words go wide as you go tall Many sportsmen remove their mud tires after hunting season and install ones more appropriate for street driving always use as wide a tire and wheel combination as feasible to enhance vehicle stability We strongly recommend because of rollover possibility that the vehicle be equipped with a fu
18. r the case is lowered DIAGRAM 5 From under the vehicle locate the torque shaft bracket It is attached to the inside of the transmission tunnel and acts as a pivot for the transfer case shift lever Remove the two bolts that attach the swivel plate to bracket Also remove the swivel plate gasket FORM 5120 10 071511 PRINTED IN U S A PAGE 7 OF 13 m 19 QU QU QU Attach the swivel plate and gasket to the Superlift torque shaft bracket 55 06 5064 using the factory bolts and nuts 18 Insert the torque shaft through the swivel plate then attach the 06 bracket to the factory torque shaft bracket as shown using the supplied 6mm x 20mm allen head bolts and nuts 18 DIAGRAM 5 TORQUE SHAFT DROP BRACKET 55 06 5064 torque shaft bracket abreast S factory bolts l Werni PAN Loosen but do not transfer case ERNS linkage remove the transmission mount Place a block of wood under the transmission bellhousing and engine oil pan and position a jack so that it supports but does not raise the engine Take precautions to avoid damaging any components On each side remove the two bolts that secure the engine mount to the frame Save all hardware for reuse Carefully raise the engine approximately 3 8 and slide DIAGRAM 6 LOWERING THE TRANSFER CASE the engine mount spacers ee 55 08 5120 between the engine mount and frame mount WARNING Use extreme caution to avoid placing finger
19. rks of Superlift Suspension Systems Superlift Suspension Systems is a Division of Bret Lovett s Lift Kits Incorporated SUPERLIFT SUSPENSION SYSTEMS 300 Huey Lenard Loop Rd West Monroe Louisiana 71292 Phone 318 397 3000 Sales Tech 1 800 551 4955 FAX 318 397 3040 Web Site www superlift com
20. s or any other body parts between the engine and frame at any time while the engine is unbolted from the frame Line up the bolt holes in the engine mounts spacer plates and frame then lower the engine Reinstall the factory hardware and tighten to factory specifications FORM 5120 10 071511 PRINTED IN U S A PAGE 8 OF 13 20 o m LOWERING the TRANSFER CASE 55 07 5120 DIAGRAM 6 Position a jack beneath the driver side of the transfer case crossmember skid plate just inboard of the plate to frame mounting bolts Load the jack so that it will support the plate s weight when the three bolts are removed After removing the driver s side bolts loosen do not remove the passenger s side plate to frame bolts Lower the jack just enough to install the driver side drop bracket 55 07 5120 and insert the new 12mm x 80mm bolts Leave bolts loose so the other side can be installed Relocate the jack to the passenger side and repeat the installation procedure for the other 07 drop bracket Tighten all six plate bolts 31 Tighten the transmission mount to factory specifications REAR DISASSEMBLY 21 Q 22 oO 23 QU 24 25 oO 26 ou SECURE VEHICLE Raise rear of vehicle with a jack positioned at outboard ends and secure a jack stand beneath each frame rail in front of the lower link arms Ease the frame down onto the stands but leave a slight load on the jack Chock front tires
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