Installation Instructions for K375
Contents
1. DIAGRAM 4B Attach the STOP EXTENSION Install using the hardware shown factory cup to the i frame mount 1 2 tab nut compression travel stop P sleeve extension 55 09 4540 i G ge 1 2 x 1 3 4 bolt driver side and 55 10 4540 748 x 1 14 a passenger side using the supplied 3 8 x 1 1 4 bolt N foe special offset washer and reams nyloc nut 23 Take note of x how the bolt and offset washer installs in the bottom of the cup as shown in i D Diagram 4B 7 16 nyloc nut Se oset Tf BB x 114 bolt washer snubber cup note offset position FORM 4540 08 121713 PRINTED IN U S A PAGE 9 OF 19 QU QU QU 11 Position the 09 and 10 extensions over the OE compression stop bracket as shown in Diagram 4B Install the supplied 7 16 x 1 1 4 tab bolt from the top and secure with a 7 16 washer and nyloc nut as shown Do not tighten at this time Insert the supplied short spacer sleeve between the 09 and 10 bracket and the frame and line up the spacer with the slotted hole as shown in Diagram 4B Install the supplied 1 2 x 1 3 4 bolt through the slotted hole in the extension bracket sleeve and frame bracket then secure using the supplied 1 2 tab nut Tighten the 7 16 bolt 37 then tighten the 1 2 bolt 57 and press the factory compression stop back into the cup FRONT CROSSMEMBER DIAGRAM 5 With the help of an assistant raise the fron2. and chock rear tires Remove front tires FORM 4540 08 121713 PRINTED IN U S A PAGE 5 OF 19 2 QU QU QU 3 oO a0 oo QU QU 4 QU QU UNLOADING THE TORSION BARS WARNING Be extremely careful when loading and unloading the torsion bars there is a tremendous amount of energy stored in them Keep your hands and body clear of the adjuster arm assembly and the puller tool in case anything slips or breaks Remove the transfer case skid plate Save all hardware for reuse Mark each torsion bar s indexing in the lower control arms and torsion bar adjusters Make note of the number of threads exposed on the adjuster bolt for an approximate ride height setting All of these markings will be necessary for reassembly NOTE The torsion bars are side specific and stamped L and R respectively A special torsion bar puller tool is required to unload the torsion bars Use the tool to load the torsion bar then remove the adjusting bolt and nut block Unload the bar NOTE Because of the extreme loads generated by the torsion bars a standard two jaw puller tool tends to bend the lips of the crossmember which it uses for attachment and may pop out of place We have had the best results using a C clamp type puller tool See the notes section at the beginning of this instruction form Remove the torsion bars adjuster arms and crossmember Save all hardware and components for reuse INITIAL DIS
3. 2 2 4 2 2 2 2 1 5 16 flat washer 5 8 x 5 1 2 bolt 5 8 SAE flat washer 5 8 nyloc nut 1 1 4 ID x 3 1 8 spacer sleeve 7 16 x 1 1 2 bolt 7 16 SAE washer 7 16 double nut plate 90 09 4540 capa front crossmember assembly 55 06 4540 oe rear crossmember assembly 2 5 8 x 4 1 2 bolt 4 5 8 SAE washer FORM 4540 08 121713 PRINTED IN U S A 55 08 4540 oo eee belly PaMiccitictiicteistesctatattectetatiuts 55 09 4540 oo eee compression stop extension front driver side 55 10 4540 is acces compression stop extension front passenger side 55 14 4540 ee badge bracket front 00 55 15 24640 sienien compression stop extension rear driver side 55 16 4540 n n compression stop extension rear passenger side 55 33 4540 oiana 2 anti sway bar links front Grease upon installation 55 19 4540 tsa was 2 support sleeve 55 20 4540 n n brush guard frame optional PAGE 3 OF 19 5 8 nyloc nut offset spacer sleeve 1 2 x 4 bolt 1 2 SAE flat washer 1 2 nyloc nut 11 16 x 1 11 16 spacer sleeve 5 16 x 1 1 4 tapered allen bolt 5 16 double nut plate 1 2 x 1 3 4 bolt 1 2 USS flat washer 1 2 tab nut 3 4 ID x 1 2 spacer sleeve 7 16 x 1 1 4 tab bolt 7 16 flat washer 7 16 nyloc nut 3 8 x 1 1 4 bolt 3 8 USS
4. edges e Prior to operating a torch or saw protect any heat sensitive components located in the immediate area by covering them with a water saturated cloth Most undercoating are flammable but can be extinguished using a water filled spray bottle Have a spray bottle and an ABC rated fire extinguisher on hand e Paint or undercoat all exposed metal surfaces e Prior to attaching components be sure all mating surfaces are free of grit grease undercoating etc e Use the check off box Q found at each step to help you keep your place Two OQ denotes that one check off box is for the driver side and one is for the passenger side Unless otherwise noted always start with the driver side PARTS LIST 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 NEW ATTACHING HARDWARE Qty if more than one Qty if more than one 55 01 4540 oe knuckle driver side 55 02 4540 oo knuckle passenger side 55 03 4540 ocean cecal differential drop bracket rear 12mm x 30mm bolt driver side 12mm flat washer 12mm lock washer 1 2 x 2 1 2 bolt 1 2 SAE washer 1 2 nyloc nut 55 04 4540 oe torsion bar crossmember drop 7 16 x 3 3 4 bolt 3 3 3 3 6 3 1 bracket passenger side 2 7 16 SAE flat washer 1 7 16 nyloc nut 2 5 16 x 1 bolt 2 5 16 lock washer
5. figure Minimum ride height is 2 30 maximum is 1 425 Ideal ride height is somewhere in between Raise height by tightening the torsion bar adjusting bolt lower height by loosening the bolt Adjust height 3 8 to 1 2 above the final desired ride height since the bars will settle slightly after the vehicle is driven NOTE Exceeding the stated minimum or maximum heights will cause the suspension to continually top out or bottom out This results in a harsh ride accelerated suspension component wear and possibly component failure FINAL CLEARANCE and TORQUE CHECK With vehicle on floor cycle steering lock to lock and inspect the tires wheels and the steering Suspension and brake systems for proper operation tightness and adequate clearance Activate four wheel drive system and check front hubs for engagement HEADLIGHTS Readjust headlights to proper setting SUPERLIFT WARNING DECAL Install the WARNING TO DRIVER decal on the inside of the windshield or on the dash within driver s view Refer to the NOTICE TO DEALER AND VEHICLE OWNER section below EXHAUST SYSTEM MODIFCATION Reroute the exhaust crossover pipe cut previously for front driveshaft clearance If necessary the vehicle can be driven a short distance to a qualified exhaust repair facility to have these modifications performed once the alignment procedure is complete ALIGNMENT Realign vehicle to factory specifications
6. necessary install the tires and wheels following the procedure in step 31 and lower the vehicle to the floor REAR PROCEDURE 26 PREPARE VEHICLE NOTE The following procedure is only applicable when add a leafs are being used to lift the rear of the vehicle If complete replacement rear springs are being used install now per separate instructions and then proceed to step 29 Use a floor jack positioned under the rear axle to raise the vehicle FORM 4540 08 121713 PRINTED IN U S A PAGE 16 OF 19 Place jackstands under the framerails a few inches in front of the forward hanger for the rear springs 4 Ease the jack down until the frame is resting on the stands but keep a slight load on the jack Q Chock the front tires to prevent the possibility of vehicle movement 27 SPRING PACK DISASSEMBLY n Remove spring to axle U bolts and move axle several inches away from springs QW Place C clamps approximately six inches on either side of the leaf springs center bolt Pinch the tie bolt head the portion that was located in the spring perch with a pair of pliers then remove the tie bolt nut Once the nut has been removed loosen the C clamps NOTE Be cautious when releasing the C clamps the springs are under load and will spring apart when released n The factory leaf springs have a roll pin installed through the leaf pack This will have to be removed Turn the bottom leaf axle side leaf 45 degrees then with a de
7. states offer exemptions for farm or commercially registered vehicles It is the owner s responsibility to check state and local laws to ensure that their vehicle will be in compliance Superlift makes no claims regarding lifting devices and excludes any and all implied claims Superlift will not be responsible for any altered product or any improper installation or use of our products We will be happy to answer any questions concerning the design function and correct use of our products IMPORTANT MAINTENANCE INFORMATION It is the ultimate buyer s responsibility to have all bolts nuts checked for tightness after the first 100 miles and then every 1000 miles The steering suspension and driveline systems along with wheel alignment should be inspected by a qualified professional mechanic at least every 3000 miles NOTICE TO DEALER AND VEHICLE OWNER Any vehicle equipped with a Superlift lifting device must have the enclosed Warning to Driver decal installed on the inside of the windshield or on the vehicle s dash within driver s view The Warning to Driver decal is to act as a constant safety reminder for whoever may be operating the vehicle The WARRANTY IS VOID unless this decal is in place INSTALLING DEALER It is your responsibility to install warning decal and forward these installation instructions to the vehicle owner for review of warnings product use and maintenance information Replacement warning decals are avail
8. this step only if not installing the optional skid plate at this time If the skid plate has been purchased proceed to the next step DIAGRAM 9 INSTALL THE 55 14 4540 BADGE BRACKET There are two holes located in the bottom of the 05 front A crossmember near the two CH holes drilled in step 11 Using the crossmember as a template drill out these two holes using an 11 32 drill bit DIAGRAM 9 Attach the badge bracket 55 14 4540 using the supplied 5 16 x 3 1 2 bolts washers and nyloc nuts For reference the bracket aag 5 16 X 3 1 2 bolts installs in the 11 32 holes drilled during step 11 Tighten 13 SKID PLATE NOTE The skid plate is optional and purchased separately If a skid plate has not been purchased proceed to the next step If not done already install the skid plate frame 55 20 4540 The frame attaches using the two bolts that attach the front legs of the LCAs to the crossmember assembly Refer to step 14 Attach the stainless steel skid plate 55 24 4540 using the supplied 3 8 x 2 sleeves 5 16 x 3 1 2 bolts washers and nyloc nuts For reference these bolts should be installed in the 11 32 holes drilled during step 11 Attach the skid plate to the 20 frame using the four supplied 5 16 x 1 1 4 allen head bolts washers and nyloc nuts Tighten all of the 5 16 hardware 13 TIRES WHEELS DIAGRAM 10 If
9. 30mm bolts flat washers and lock washers at the top and the supplied 1 2 x 2 1 2 bolts washers and nyloc nuts at the bottom Do not tighten at this time Tighten all of the differential bolts Driver side upper 1 2 bolts 57 Passenger side 1 2 bolts 57 DIAGRAM 4A REMOVE THE Q Driver side rear 12mm bolts 57 and 1 2 bolts 57 COMPRESSION STOP CUPS Using the differential companion flange as a reference cut the exhaust crossover pipe for later re routing around the front driveshaft NOTE If necessary the vehicle can be driven a short distance to a local exhaust shop to have exhaust modifications performed once the installation is complete Referencing the marks made during removal reconnect the front driveshaft to the differential using the factory hardware and tighten 85 Reconnect the differential vent hose and wiring COMPRESSION TRAVEL STOP EXTENSIONS Pry the factory rubber compression stop out of its mounting cup Save for reuse DIAGRAM 4A Using a cutoff wheel or similar tool remove the spot welds holding the factory compression travel stop cup to the frame Take precautions not to damage the cup as it will be reused Grind any sharp edges smooth and paint any exposed metal surfaces The bottom of the OE bracket where the cup used to be must be flat in order for the extension bracket installed in the next step to fit properly DIAGRAM 4B INSTALL THE 55 09 4540 COMPRESSION
10. 420 or www miller spx com part number 8682 Superlift offers a low cost one time use equivalent tool 4544 as an alternative If more than one installation of this system is anticipated Superlift recommends purchasing the factory tool A special tool is required to load unload the torsion bars step 2 The Dodge service manual calls for tool 8686 which is slightly different from the C clamp type puller tools commonly used on other IFS vehicles The factory service manual specifically states that striking the knuckle to loosen the ball joints or tie rod ends is prohibited because any sharp blows will damage the aluminum knuckle A special puller tool 8677 is recommended to separate these components from the knuckle Other special tools are specified in the factory service manual for disassembly of the front suspension Refer to the factory service manual Exhaust modifications are necessary for front driveshaft clearance Refer to step 9 Front end realignment is necessary An arrow on diagrams indicates which direction is toward the front of the vehicle A foot pound torque reading is given in parenthesis after each appropriate fastener Do not fabricate any components to gain additional suspension height Prior to drilling or cutting check behind the surface being worked on for any wires lines or hoses that could be damaged FORM 4540 08 121713 PRINTED IN U S A PAGE 2 OF 19 e After drilling file smooth any burrs and sharp
11. ASSEMBLY Remove the front shock absorbers Save all hardware for reuse Remove and discard the anti sway bar links Remove and discard the factory front skid plate if equipped Remove the brake caliper mount and rotor from the knuckle Leave the caliper attached to the mount and the brake hose and use mechanic s wire to tie it up and out of the way CAUTION Do not let the calipers hang from the hoses or the hoses will be damaged If equipped remove the ABS wheel speed sensor from the knuckle Save for reuse KNUCKLE REMOVAL WARNING Do not strike the knuckle to loosen the tie rod or ball joints This will damage the knuckle Remove the nut securing the tie rod end to the knuckle and using the appropriate puller tool refer to the notes section at the beginning of this instruction sheet separate the tie rod from the knuckle Use caution to avoid damaging the rubber seal Save all hardware for reuse Remove the half shaft nut from the hub assembly and save for reuse FORM 4540 08 121713 PRINTED IN U S A PAGE 6 OF 19 OWL Remove the nut securing the upper ball joint to the knuckle Using the appropriate puller tool separate the upper ball joint from the knuckle Use caution to avoid damaging the seal Save all hardware for reuse QW Tilt the upper portion of the knuckle outward away from the truck while carefully prying the half shaft away from the differential Use extreme caution to avoid damaging the rubber seal at th
12. FORM 4540 08 121713 PRINTED IN U S A PAGE 1 OF 19 SU SPEN S Superlift 4 5 5 lift system for 2002 and Newer Dodge Ram 1500 4WD INSTALLATION INSTRUCTIONS SUPERLIFT INTRODUCTION Installation requires a professional mechanic Prior to beginning inspect the vehicles steering driveline and brake systems paying close attention to the 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 Prior to beginning the installation check all parts and hardware in the box with the parts list below If you find a packaging error contact Superlift directly Do not contact the dealer where the system was originally purchased You will need the control number from each box when calling this number is located at the bottom of the part number label and to the right of the bar code A factory service manual should be on hand for reference A special tool is required to remove install the factory bushings for the lower control arms This tool is available from a Dodge dealer or from SPX Miller Special Tools at 800 801 5
13. Record the ride height measurement at time of alignment If in the future the torsion bars settle excessively alignment can be restored by adjusting up the bars to their original ride height FORM 4540 08 121713 PRINTED IN U S A PAGE 19 OF 19 IMPORTANT PRODUCT USE INFORMATION As a general rule the taller a vehicle is the easier it will roll over Offset as much as possible what is lost in roll over resistance by increasing tire track width In other words go wide as you go tall Many sportsmen remove their mud tires after winter hunting season and install ones more appropriate for street driving always use as wide a tire and wheel combination as possible to enhance vehicle stability We strongly recommend because of roll over possibility that the vehicle be equipped with a functional 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 performances and capabilities are decreased when significantly larger heavier tires and wheels are used Take this into consideration while driving 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 Most states have some type of law limiting vehicle height The amount of lift allowed and how the lift may be achieved varies greatly Several
14. able free upon request These instructions are to be kept with the vehicle registration papers and owners manual for the service life of the vehicle SUPERLIFT LIMITED LIFETIME WARRANTY Suspension products bearing the Superlift LKI Ent name are warranted for as long as the original purchaser owns the vehicle that the LKI product was originally installed on This warranty is non transferable Warranty covers only the product no labor time loss or freight incurred Any product that has been abused altered incorrectly installed or used in competition is not covered Product finish spring bushings Polyurethane products and normal wear is not covered The LKI product is subject to replacement or repair No other warranties are expressed or implied An authorized Superlift dealer must inspect the part in question and confirm that the Warning to Driver decal is properly displayed A copy of the sales invoice is required for warranty consideration SUPERLIFT SUSPENSION SYSTEMS 300 Huey Lenard Loop Rd West Monroe Louisiana 71292 9421 Phone 318 397 3000 Sales Tech 1 800 551 4955 FAX 318 397 3040 www superlift com
15. ad blow hammer strike the leaf until it is free from the leaf spring pack The roll pin will stay attached to the bottom leaf Use a punch and remove the roll pin from the leaf 28 SPRING PACK ASSEMBLY IU On each side insert the add a leaf between the number one and number two leaf from the axle side in the proper pyramid order Align the 3 8 hole in the add a leaf with the center bolt hole in the spring pack n Recompress the pack with the C clamp not the center bolt to avoid stripping the bolt or nut threads Once the spring is compressed insert the 3 8 x 5 center bolt through the leaf spring pack Tighten the center bolt nut 45 Once tightened trim excess bolt Remove the C clamps 29 REATTACHING THE AXLE QIU Using the floor jack s mate the springs to their pads being sure that the center bolt heads seat properly Evenly torque the supplied U bolts using a X tightening sequence 92 QU If the complete spring packs were removed from the vehicle snug up but do not fully tighten the stock shackle and stationary spring eye bolts These bolts are not torqued until the suspension is supporting vehicle weight 30 SHOCK ABSORBERS nn Install the bushings sleeves and boots on the rear shock absorbers 85150 n Install the shocks using the factory hardware On the lower mount insert the supplied 9 16 flat washers between the mount and shock bushing so that the bushing is sandwiched between a washer o
16. and jam nuts supplied Thread the appropriate jam nut onto the heim Thread the heim completely down into the new sway bar link body 55 33 4540 FORM 4540 08 121713 PRINTED IN U S A PAGE 14 OF 19 QU 20 QU QU QU QU 21 QU QU QU QU QU QU 22 oO Install 7 16 x 2 bolt through the side of the c bracket then the cone spacer 55 54 3280 followed by the heim 55 52 3280 or 55 53 3280 another cone spacer c bracket and nyloc nut 50 NOTE Make sure that the large diameter of the cone spacers faces the outside of the c bracket Repeat this step on the opposite end of the link BRAKE HOSE EXTENSIONS Unbolt the bracket securing the brake line to the frame Attach the brake line relocation bracket 55 21 4540 driver side and 55 22 4540 passenger side to the frame where the original bracket was just removed using the factory hardware Tighten 7 5 Carefully reform the steel brake line in order to line up the factory bracket with the 21 and 22 brackets Attach the brackets using the supplied 5 16 x 3 4 bolts washers and nyloc nuts Tighten 13 WARNING Use extreme caution when reforming metal brake lines to avoid damaging them If a line becomes pinched or otherwise damaged it must be replaced prior to proceeding Install the rotor and caliper on the knuckle then tighten the caliper mount bolts 130 If loosened during removal tighten the cal
17. dust shield and hub on the new knuckle 55 01 4540 driver side and 55 02 4540 passenger side in the same position as they were on the original knuckle Tighten the three hub bolts 120 NOTE When installing the hub on a vehicle equipped with ABS position the opening in the hub for the speed sensor toward the front of the vehicle opposite the caliper mount KNUCKLE INSTALLATION NOTE Perform these steps one side at atime It will help to have an assistant that can assist with lining up all of the components NOTE The ball joint tapers must be clean and dry prior to installing the knuckles Loosely attach the knuckle to the lower ball joint and secure with the factory hardware Do not tighten at this time Line up the splines of the half shaft with the splines of the hub and slide the half shaft into place FORM 4540 08 121713 PRINTED IN U S A PAGE 13 OF 19 QU QU QU QU QU QU 18 QU QU QU QU 19 QU QU QU Tilt the neck of the knuckle outward away from the vehicle enough to line up the other end of the half shaft with the splines of the differential Engage the half shaft on the differential splines then tilt the knuckle inward while pushing on the half shaft boss until the shaft is fully seated on the differential Carefully tilt the neck of the knuckle back toward the vehicle to connect the upper ball joint Loosely secure using the factory hardware NOTE Be sure the half sha
18. e and lower the differential to the floor factory tool 8682 7 TRIMMING THE FRAME lhe el a Et QO DIAGRAM 1 Using a cut off wheel or grinder trim the frame bracket for the rear leg of the LCA on the driver side as shown Also square off the bottom edge of the bracket as shown Grind smooth any sharp edges and paint any exposed metal surfaces FORM 4540 08 121713 PRINTED IN U S A PAGE 7 OF 19 8 oo REMOVING THE LOWER CONTROL ARM BUSHINGS DIAGRAM 2 Using the special puller tool refer to the notes section at the beginning of this instruction sheet press the bushings for the LCA rear legs out of the frame Refer to separate instructions for operating the tool Make note of how each bushing is positioned as it will have to be installed the same way for later installation in the Superlift crossmember FRONT ASSEMBLY 9 a DIFFERENTIAL DROP BRACKETS DIAGRAM 3 Attach the passenger side differential drop bracket 55 26 4540 to the factory mount as shown with the lower portion of the bracket offset toward the front bumper Position the supplied extra thick flat washers as shown to span the distance between the 26 bracket and the recesses in the factory mount Loosely secure using the supplied 1 2 x 2 3 4 bolts USS washers and nuts installing the bolts from the front Do not tighten at this time DIAGRAM 3 INSTALL THE DIFFERENTIAL DROP BRACKETS driver side upper driver side rear passenger
19. e differential and the half shaft boot Once clear of the differential pull the half shaft out of the hub assembly and set aside DIAGRAM 1 TRIMMING THE FRAME Using a QU While supporting the knuckle use the cut off wheel or similar tool trim the lower control i arm rear leg mount on the driver side as shown appropriate puller tool to separate the knuckle from the lower ball joint Set the knuckle and hub assembly aside 5 LOWER CONTROL ARMS AND CROSSMEMBER OW Remove and discard the factory rear crossmember located between the lower control arm rear leg mounts OW Remove the bolts securing the lower control arms to the frame Save all hardware for reuse 6 DIFFERENTIAL n Mark the driveshafts orientation on the companion flange prior to removal Disconnect the driveshaft from the flange and tie the driveshaft up and out of the way Save all hardware for reuse QIU Disconnect the vent hose and wiring from DIAGRAM 2 REMOVING THE LOWER the differential CONTROL ARM BUSHINGS Position the special puller tool as shown to remove OIL Using a jack support the differential the bushings from the frame Loosen and remove the bolts on the driver side rear of the diff housing followed by the bolts securing the differential on the passenger side Save all hardware for reuse factory bushing nn With the help of an assistant to steady the differential remove the remaining differential bolts on the driver sid
20. ents to the bushings using the puller tool now rather than later BELLY PAN With the help of an assistant position the belly pan 55 08 4540 between the front and rear crossmembers Insert the four supplied 5 16 double nut plates in the crossmembers and loosely secure using the supplied 5 16 x 1 1 4 tapered allen head bolts Do not tighten at this time LOWER CONTROL ARMS Attach the lower control arms to the crossmember assembly using the supplied 5 8 x 5 1 2 bolts washers and nyloc nuts on the front legs and the factory hardware on the rear legs The bolts for the front legs install from the front the bolts for the rear legs install from the rear Snug but do not tighten at this time NOTE If the optional stainless steel brush guard has been purchased install the brush guard frame 55 20 4540 now while positioning the supplied bolts for the front legs The frame should step out and up toward the front bumper and engine BOLT TIGHTENING SEQUENCE Tighten the front assembly hardware in the following order QW 5 16 belly pan bolts 13 OW 5 8 crossmember bolts 112 QW Factory front crossmember bolts 112 QW 1 2 rear crossmember bolts 57 QU 7 16 front crossmember bolts 37 KNUCKLE PREASSEMBLY Loosen and remove the bolts attaching the hub assembly to the factory knuckle Note how the dust shield is indexed on the knuckle then detach the hub and dust shield Position the
21. er to separate inst for use NOTE It may help to use one of the View is from the rear supplied 1 4 thick spacer plates 55 27 on raid ee On eacn side the sma 4540 as a reference to help ensure there is ee void should be closest ia a proper gap between the bushing lip and the center of the vehicle the crossmember the large void should be closest to the outside of the vehicle CAUTION The bushings must be indexed exactly as shown in Diagram 7 or bushing service life will be decreased FORM 4540 08 121713 PRINTED IN U S A PAGE 11 OF 19 QU QU DIAGRAM 8 INSTALL THE 55 06 4540 REAR CROSSMEMBER 1 11 16 sleeve FRAME offset spacer sleeve SD p cam 1 11 16 sleeve 1 2 x4 bolt 5 8 x 4 1 2 SD offset spacer sleeve DIAGRAM 8 Insert the offset spacer sleeves in the holes of the factory LCA mounts where the bushings used to be Rotate each so that the sleeve is offset to the outside of the vehicle as shown With the help of an assistant raise the rear crossmember into position over the factory LCA mounts Line up the large mounting hole on each side with the offset spacer sleeves and install the supplied 5 8 x 4 1 2 bolt washers and nyloc nuts The bolts must be installed from front to rear Do not tighten at this time On the passenger side Insert two 11 16 ID x 1 11 16 spacer sleeves in the factory frame mounts and line up each with the two existing holes in the
22. frame as shown in Diagram 8 On the driver side insert the remaining spacer sleeve in the frame mount and line up with the existing mounting hole as shown On the passenger side insert the two spacer plates 55 28 4540 between the 06 crossmember and the frame as show in Diagram 8 For clarification these spacer plates should be sandwiched between the 06 crossmember and frame Line up the holes in the spacer plates with the holes in the 06 crossmember the finger tabs on these plates should point down as shown not up Insert the supplied 1 2 x 4 bolts through the crossmember spacer plates spacer sleeves and frame then secure using the supplied washers and nyloc nuts The bolts should be installed from the rear Do not tighten at this time On the driver side insert the two spacer plates 55 27 4540 between the 06 crossmember and the factory frame mounts as shown in Diagram 8 Line up the hole in each spacer plate with the hole in the crossmember Install the remaining 1 2 x 4 bolt through the crossmember spacer plates spacer sleeves and frame then secure using the supplied washers and nyloc nut Do not tighten at this time FORM 4540 08 121713 PRINTED IN U S A PAGE 12 OF 19 13 14 QU 15 16 QU QU 17 QU QU NOTE At this time it is recommended to test fit the lower control arms to ensure the bushings are pressed into place properly It is much easier to make adjustm
23. fts are fully seated on the differential If equipped install the ABS wheel speed sensor 190 in lb Tighten the upper ball joint nut 55 and lower ball joint nut 60 Tighten the half shaft nut 185 Attach the tie rod end to the knuckle and secure using the factory hardware 55 FRONT SHOCK ABSORBERS Assemble the bushings sleeves and shock boots on the front shocks 88490 Attach the lower end of the shock to the lower control arm Position a 5 8 flat washer between the shock bushing and the control arm mount prior to securing with the factory hardware Do not tighten at this time Place a washer and bushing half on the stem end of the shock and then position it in the upper shock mount Slide the other bushing half and washer in place then tighten until the bushings swell slightly Tighten the lower bolt 100 2 ANTI SWAY BAR LINKS SWAY BAR LINK DIAGRAM E a Install the 7 16 X 1 bolt 7 16 x 1 bolt y W through the inside of the c hne x 2 bor Em D bracket 55 51 3280 then through the sway bar body jah followed by a washer and nyloc 55 23 5570 Ti h 7 16 jam nut nut Tighten 50 nej ushe Install the 7 16 x 1 bolt A on through the inside of the c k faee nioc nut bracket 55 51 3280 then the 7 16 washer_y lower control arm followed by a 76 nyloc nut washer and nyloc nut Tighten 50 There are right and left hand threaded heim joints
24. iper mounting pins 24 TORSION BAR CROSSMEMBER DROP BRACKETS Loosely attach the torsion bar crossmember drop brackets 55 31 4540 driver side and 55 04 4540 passenger side to the factory crossmember frame mounts using the factory hardware The two slots in the bottom of each bracket should line up with existing holes in the bottom of the frame If necessary drill out the frame holes using a 17 64 drill bit Tap the holes drilled using a 5 16 18 tap Install the supplied 5 16 x 1 bolts flat washers and lock washers in the tapped holes Do not tighten at this time Examine the torsion bar crossmember one side is marked front Position the crossmember appropriately and attach it to the 04 and 31 brackets using the supplied 7 16 x 3 3 4 bolts washers and nyloc nuts Tighten 37 Tighten the 5 16 hardware 13 followed by the factory hardware 75 TORSION BARS On each side reinstall the torsion bar and adjuster arm following the marks made during disassembly Using the puller tool load the bar and insert the nut block and adjuster bolt Unload and remove the puller tool NOTE Thread the adjuster bolts to the same position as they were prior to disassembly to get an approximate ride height Final ride height adjustments will be made once the vehicle is on the ground FORM 4540 08 121713 PRINTED IN U S A PAGE 15 OF 19 23 24 E 25 o BADGE BRACKET NOTE Perform
25. it Insert the supplied 7 16 double nut plate in the factory front crossmember through access holes located in the rear Line this plate up with the two 15 32 holes drilled previously and secure using the supplied 7 16 x 1 1 2 bolts and washers Do not fully tighten at this time REAR CROSSMEMBER Position the rear crossmember 55 06 4540 so that it can be determined which way it installs on the vehicle For reference the crossmember has a recess for front differential clearance on the driver side refer to Diagram 8 for further reference It is necessary to know which way the crossmember is positioned on the vehicle in order to properly install the bushings which is detailed next DIAGRAM 7 INSTALL THE FACTORY DIAGRAM 7 Using the special puller tool BUSHINGS IN THE 06 X MEMBER Bushings available separately from Superlift or SPX install from the rear On both sides pay close Miller press the OE rubber bushings into attention to how the bushing is indexed place in the 06 crossmember The bushings should be installed from the rear as shown Take special notice of the orientation of the bushing in the diagram and match the position exactly with the small void in each bushing facing the center of the vehicle as shown As you press the bushings in place leave a 1 4 gap between the crossmember sleeve and the flange on the flared end of the bushing 55 06 4540 puller tool ref
26. n each side Tighten the upper and lower mounts 100 NOTE If the optional dual shock system has been purchased install now per separate instructions FORM 4540 08 121713 PRINTED IN U S A PAGE 17 OF 19 31 ou QU QU 32 33 34 QU COMPRESSION TRAVEL STOP EXTENSIONS On each side unbolt the compression travel stop from the frame Save all hardware for reuse Attach the compression travel stop extensions 55 15 4540 driver side and 55 16 4540 passenger side at the factory location using the factory hardware 45 The Superlift S should face out Attach the factory compression travel stop to the DIAGRAM 10 LUG NUT TORQUE extension bracket using the supplied 3 8 x 1 bolts SEQUENCE Use the sequence shown to torque the lug nuts washers and nyloc nuts 23 TIRES WHEELS DIAGRAM 10 Tighten the lug nuts 135 in the sequence shown WARNING When the tires wheels are installed always check for and remove any corrosion dirt or foreign material on the wheel mounting surface or anything that contacts the wheel mounting surface hub rotor etc Installing wheels without the proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion WARNING Retighten lug nuts at 500 miles after any wheel change or anytime the lug nuts are loosened Failure to do so could cause wheels to come off
27. side mount mount mount extra thick extra thick flat washers flat washers 2 55 25 4540 5 J 1 2 x 2 1 2 55 03 4540 22a jl 12mm x 30mm 1 2 x 2 1 2 differential differential Attach the driver side upper differential drop bracket 55 25 4540 as shown in Diagram 3 with the lower portion of the bracket offset toward the center of the vehicle Use the supplied extra thick flat washers to span the distance between the 25 bracket and the recesses in the factory bracket as shown Loosely secure using the supplied 1 2 x 2 1 2 bolts washers and nyloc nuts The bolts should be installed from the inside out Do not tighten at this time With the help of an assistant raise the differential into position sliding it into the driver side upper and passenger side differential brackets at the same time Loosely secure the differential to the driver side upper bracket using the supplied 1 2 x 2 1 2 bolts washers and nyloc nuts Install the bolts from the inside out but do not tighten at this time FORM 4540 08 121713 PRINTED IN U S A PAGE 8 OF 19 E m 10 QU QU QU Attach the differential to the passenger side diff bracket using the supplied 1 2 x 2 3 4 bolts and nyloc nuts Install the bolts from the front but do not tighten at this time Attach the driver side rear differential bracket 55 03 4540 to the factory mount and differential as shown in Diagram 3 Use the supplied 12mm x
28. t crossmember 55 05 4540 into position For clarification the leading edge of the 05 crossmember mounts on the outside of the factory LCA mounts when viewed from the front of the vehicle so that the 05 crossmember steps toward the front bumper very slightly from the factory LCA mounts when viewed from the side The four holes belly pan mounting holes in the bottom of the 05 crossmember should be offset toward the rear of the vehicle Insert the supplied 1 1 4 ID x 3 1 8 long spacer sleeves in the factory LCA mounting locations as shown in Diagram 5 and secure using the factory hardware The bolts should be installed from the front Do not tighten at this time DIAGRAM 5 INSTALL THE 55 05 4540 FRONT CROSSMEMBER E j a O front frame crossmember ae eas 5 S555 lt 1 1 4 ID x 3 1 8 sleeve factory hardware FORM 4540 08 121713 PRINTED IN U S A PAGE 10 OF 19 E 12 QU QU DIAGRAM 6 Locate the two pairs of holes in the bottom DIAGRAM 6 DRILL THE MOUNTING HOLES FOR THE and roughly in the middle of FRONT CROSSMEMBER Using the 05 crossmember as a the 05 crossmember One of template drill two mounting holes with a 15 32 drill bit these pairs the ones farther away from the front bumper should line up with an existing frame hole while the other does not Using the 05 crossmember as a template drill out both holes using a 15 32 b
29. tainless steel skid plate 2 5 16 x 2 5 16 spacer sleeve optional 55 25 4540 oaae differential drop bracket 4 1 2 x 2 1 2 bolt upper driver side 4 1 2 SAE washer 2 1 2 extra thick flat washer 4 1 2 nyloc nut 55 26 4540 asn differential drop bracket 4 1 2 x 2 3 4 bolt passenger side 2 1 2 extra thick flat washer 4 1 2 USS washer 4 1 2 nyloc nut 55 27 4540 eee 2 rear crossmember spacer plate driver side 55 28 4540 eeeeeeee 2 rear crossmember spacer plate passenger side 55 31 4540 torsion bar crossmember drop 1 7 16 x 3 3 4 bolt bracket driver side 2 7 16 SAE flat washer 1 7 16 nyloc nut 2 5 16 x 1 bolt 2 5 16 lock washer 2 5 16 flat washer 984901 dir Sie 2 shock absorber front 2 shock boot yellow 2 hardware pack and cable tie Note Shock boots if desired purchased separately oroo T 2 shock absorber rear 2 shock boot yellow 2 hardware pack and cable tie 0 0 6 ee ee ere Superlift badge cee alcohol wipe pad 00461 cece eee ee eee sees decal Warning To Driver FRONT DISASSEMBLY 1 PREPARE VEHICLE Place vehicle in neutral Raise front of vehicle with a jack and secure a jack stand beneath each frame rail behind the lower control arms Ease the frame down onto the stands place transmission in low gear or park
30. washer 3 8 special offset washer 3 8 nyloc nut 1 2 x 1 3 4 bolt 1 2 USS flat washer 1 2 tab nut 3 4 ID x 1 2 spacer sleeve 7 16 x 1 1 4 tab bolt 7 16 USS flat washer 7 16 nyloc nut 3 8 x 1 1 4 bolt 3 8 USS flat washer 3 8 special offset washer 3 8 nyloc nut 5 16 x 3 1 2 allen head bolt 5 16 USS washer 5 16 nyloc nut 3 8 x 1 bolt 3 8 USS flat washer 3 8 nyloc nut 3 8 x 1 bolt 3 8 USS flat washer 3 8 nyloc nut 1 2 SAE flat washer 7 16 SAE flat washer 7 16 stover nut 4 poly bushing half 2 2 3 3 3 3 8 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 4 4 2 4 4 5 16 x 1 1 4 tapered allen bolt 4 5 16 SAE flat washer FORM 4540 08 121713 PRINTED IN U S A PAGE 4 OF 19 4 5 16 nyloc nut 55 21 4540 e brake line relocation bracket 2 5 16 x 3 4 bolt front driver side 4 5 16 flat washer 2 5 16 nyloc nut 55 22 4540 osc brake line relocation bracket 1 5 16 x 3 4 bolt front passenger side 2 5 16 flat washer 1 5 16 nyloc nut 90 24 ABA Ot erates s
31. while vehicle is in motion CLEARANCE CHECK With the vehicle still on jack stands and the suspension DIAGRAM 11 RIDE HEIGHT ADJUSTMENT hanging at full extension travel cycle steering lock to lock and check all components for proper operation and clearances Pay special attention to the clearance between the tires wheels and brake hoses wiring etc Tne I AGE ER PPL ST i R RARA AR Z 7 i GE GG Lower vehicle to the floor ADJUSTING FRONT RIDE HEIGHT Manually bounce the front and rear of vehicle to normalize the torsion bars and leaf springs A center of rear LCA pivot bolt to floor B center of wheel hub to floor B A Z height LA 7 H On each side fully tighten the LCA to crossmember bolts 150 FORM 4540 08 121713 PRINTED IN U S A PAGE 18 OF 19 QU QU QU QU 35 36 37 38 39 40 If applicable tighten the rear spring and shackle pivot bolts 120 Check the pressure of each tire and adjust as necessary in order to achieve the recommended pressure indicated on the sidewall of the tire normally 35 psi DIAGRAM 11 Position the vehicle on a level surface Measure from the LCA rear pivot bolt center down to the floor Record this as Measurement A Now measure from the center of the wheel hub down to the floor Record this as Measurement B Subtract Measurement B from A for the ride height
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