K618 Instructions
Contents
1. SUPERLIFT FRONT SHOCK ABSORBERS 85144 Install shock bushings boot and decal Install the shock Tighten the upper nut 76 and lower bolt 76 COMPRESSION TRAVEL STOP EXTENSIONS 55 15 9660 On each side attach a 01 300 poly bumpstop to a 15 extension bracket using the FORM 9666 05 092605 PRINTED IN U S A PAGE 6 OF 10 11 QU QU QU 12 QU QU QU 13 14 supplied washer and nut Bolt this assembly to the bottom of the frame rail at the factory stop s original position Use factory hardware 67 or the supplied 3 8 x 1 bolts and nyloc nuts 23 ANTI SWAY BAR DROP LINKS 55 03 9660 NOTE Inspect the factory sway bar end links If the links have traditional rubber bushings and sleeves replace the links with 55 10 9660 as described in this step If the links have captured swivel ends similar to a Heim or Johnny joint proceed to Step 12 Insert bushings and wear sleeves Each link takes one 12mm I D sleeve used at the top eye and one 1 2 D sleeve used at the bottom eye DIAGRAM 2 ANTI SWAY BAR DROP LINKS DIAGRAM 2 Install link to frame mount using original 12mm bolt and nut as shown Tighten 60 Install link to sway bar body using a furnished 1 2 x 2 1 2 bolt and Nyloc nut 57 FRONT ANTI SWAY BAR DROP BRACKETS 55 18 9660 AND 55 19 9660 NOTE Perform this step only if the anti sway bar links have captured swivel ends similar to a2. 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 FORM 9666 05 092605 PRINTED IN U S A PAGE 10 OF 10 be achieved varies greatly Several 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 desi
3. 1 COMPARING PITMAN ARMS Compare the indexing lugs must line up stock pitman arm with the supplied arm before installation exactly If a difference is noted i e the pitman arms do not line The symbol a indicates spline indexing lugs up contact Superlift before INCORRECT CORRECT proceeding PTN jr Position the Superlift pitman A arm 01 1109 on models made Pa j prior to 2 28 99 or 01 1112 on models made on or after 3 1 99 ao on the sector shaft in the exact supplied same position as the original epo arm arm Reinstall the factory jam nut and tighten 200 Reconnect the drag link to the pitman arm install the jam nut and tighten 67 Once the nut is torqued install a new cotter key FORM 9666 05 092605 PRINTED IN U S A PAGE 5 OF 10 7 8 9 aa QU 10 ou TRACK BAR BRACKET 55 07 9660 NOTE Perform this step only if the vehicle was made on or prior to 2 28 99 For vehicles made on or after 3 1 99 proceed to step 8 The production date can be found on the upper left corner of a label located on the driver side door post Install the new Superlift track bar bracket 55 07 9660 in the original track bar bracket location Reuse the factory fasteners 130 Attach the upper end of the track bar to the upper 07 bracket mounting hole using the supplied 5 8 x 3 1 2 bolt and 5 8 nyloc nut The track bar sleeve clearance is tight for this bolt and it may r
4. Heim or Johnny joint Remove the factory anti sway bar frame brackets where the upper end of the sway bar link attaches to the frame Save all hardware for reuse Attach the Superlift anti sway bar drop brackets 55 18 9660 passenger side and 55 19 9660 driver side to the frame in the same location as the original brackets using the factory hardware Tighten to factory specs Attach the upper end of the factory anti sway bar links to the 18 and 19 brackets using the supplied 12mm x 70mm bolt and 12mm stover nut Tighten 37 lb ft FRONT BUMPER If optional bumper spacer kit is being used to increase tire clearance install now If not reattach bumper using factory hardware Reattach the rubber splash panel Insert the block heater wiring loom Christmas tree plug FRONT BRAKE LINE BRACKET RELOCATION and INITIAL CLEARANCE FORM 9666 05 092605 PRINTED IN U S A PAGE 7 OF 10 QU QU QU 15 QU CHECK The brake line brackets are re formed to prevent overextending the rubber hoses With the vehicle still on jack stands lower the jack s so the suspension is hanging at full extension travel On each side there is a thin metal mounting bracket at the top of the frame rail where the rubber brake hose connects to the metal brake line Remove the bolt securing this bracket to the frame DIAGRAM 3 BRAKE LINE RELOCATION DIAGRAM 3 Carefully bend the hard line down from the facto
5. lug nuts loosely Tighten the lug nuts only until snug using the lug nut tightening pattern shown in DIAGRAM 4 to minimize runout The lug nuts are fully tightened in a later step TORQUE SPECIFICATIONS and FINAL CLEARANCE CHECK Raise vehicle and remove jack stands Lower the vehicle to the ground so that the suspension is supporting the weight of the vehicle Torque the following QW 1 spring to axle U bolts 99 OW 2 front leaf springs rear shackle eye 185 nn 3 front leaf springs front eye 259 QO 4 5 8 track bar eye bolt upper end 112 OR factory track bar eye bolt upper end 129 QW 5 DIAGRAM 4 wheel lug nuts 148 CAUTION Failure to tighten the lug nuts in the sequence shown can result in high tire and wheel runout which speeds up the development of brake roughness shudder and vibration WARNING Retighten lugs at 500 miles after any wheel change or anytime the lug nuts are loosened Failure to do so could cause wheels to come off while vehicle is in motion Once again cycle the steering lock to lock suspension loaded and inspect the tires wheels steering suspension and brake systems for proper operation tightness and adequate clearances 17 REAR LIFT 18 ou QU QU 19 QU QU Superlift s rear block lift includes it s own generic installation instructions To eliminate any possible confusion we are verifying here that the Superlift lift blocks seat against the axle
6. FORM 9666 05 092605 PRINTED IN U S A PAGE 1 OF 10 SUPERLIFT SUSPENS I 6 Lift System for 1999 and newer Ford F 250 350 Super Duty 4WD Pickup INSTALLATION INSTRUCTIONS INTRODUCTION Installation requires a professional mechanic Prior to beginning check 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 e The rear lift is sold separately and includes separate installation instructions e Save all factory mounting hardware for reuse unless otherwise noted e A factory service manual must be on hand The manual will contain fastener torque specifications assembly techniques and or special tool requirements that are unique to this particular year and model vehicle e Do not add or fabricate any components to gain additional suspension height e Prior to attaching components be sure all surfaces are free of grit grease undercoating etc e A torque specification in foot pounds is shown in parenthesis after each fastener e Use the check off box Q found at each step to help you keep your place Two QQ denotes that one box is for the driver side and one is for the passenger side PARTS LIST The part number is stamped into each part or print
7. and the factory spacers are placed on top of the Superlift blocks Torque specification for the Superlift 5 8 diameter U bolts and Nyloc nuts is 185 REAR COMPRESSION TRAVEL STOP EXTENSIONS 55 06 9660 On each side unbolt the factory rear compression travel stops attached to the bottom of the frame Save the factory nut for reuse Attach the original compression travel stops to the 55 06 9660 extension brackets The supplied 7 16 ID sleeve should be installed under the factory nut to compensate for the excessive stud length of the factory snubber Attach the 55 06 9660 bracket to the bottom of the frame at the stop s original position using the supplied 7 16 x 1 3 4 bolt and nyloc nut Tighten 37 SUPERLIFT REAR SHOCK ABSORBERS 85168 Remove the factory shock absorber The lower end of the shock is attached to bracket which in turn attaches to the axle tube via FORM 9666 05 092605 PRINTED IN U S A PAGE 9 OF 10 a U bolt To shorten the required shock length loosen the U bolt and rotate the shock attachment point up There is a bracket locating tit on the axle tube the bracket U bolt assembly will rotate up until the U bolt makes contact with the tit Evenly tighten the U bolt nuts Ford axle 35 Dana axle 46 QU Install the shock bushings boot and decal Install the shock Tighten both shock eye mounts 46 20 HEADLIGHTS QO Readjust headlights to proper setting 21 SUPERLIFT NAME BADGE an
8. ar 2 7 16 nyloc nut 2 7 16 ID sleeve 85144 2 shock absorber front 2 shock boot tie decal 2 hardware pack tooho o E eerrrer errr er 2 shock absorber rear 2 shock boot tie decal 2 hardware pack Note Shock boots if desired purchased seperately O04 anesava savas Superlift badge cece alcohol wipe pad INSTALLATION PROCEDURE 1 PREPARE VEHICLE Place vehicle in neutral Raise front of vehicle and secure a jack stand beneath each frame rail behind the front spring shackles Ease the frame down onto the jack stands Leave the jack under the axle to support it while the suspension is disassembled Place transmission in low gear or park and chock rear tires Remove front tires FORM 9666 05 092605 PRINTED IN U S A PAGE 3 OF 10 3 QU QU QU 4 QU QU QU QU 5 REMOVE FRONT BUMPER Using a clip tool or a large flat head screwdriver disconnect the rubber splash panel from beneath the front bumper Disconnect the block heater plug Christmas tree clip from the bumper if so equipped Remove the four bumper to frame bolts and lay the bumper aside TRACK BAR ANTI SWAY BAR NOTE The track bar s lower end attaches to the passenger side of the front axle It s upper end mounts to a bracket that ties into the passenger side frame rail and the primary frame crossmember Disconnect the track bar from it s
9. d WARNING DECAL The system includes one 2 x 5 name badge 0034 Additional and or larger badges are available from Superlift or a Superlift dealer We suggest putting the badges on the front fenders tailgate or rear window The badge mounts by means of factory applied double backed tape Follow these instructions to ensure that badge sticks properly O Clean designated area with warm soapy water Rinse and wipe dry with a soft lint free towel Q Thoroughly prep the area with the furnished alcohol wipe pad and wipe dry with a soft lint free towel Do not touch the surface again with your hands they transfer body oils Q Remove mounting tape backing line up badge and press in place Do not touch mounting tape or allow tape to get dirty Press firmly on the badge face and hold a few seconds to seat mounting tape A superior adhesive bond forms over time We recommend allowing 24 hours of cure time before washing and waxing The emblem itself can be cleaned with any glass cleaner Install the WARNING TO DRIVER decal on the inside of the windshield or on the dash within drivers view Refer to the NOTICE TO DEALER AND VEHICLE OWNER section on the back page 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
10. ed 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 01 216 6 n 2 front leaf spring diesel V 10 01 225 6 oo 2 front leaf spring gas V 8 FORM 9666 05 092605 PRINTED IN U S A PAGE 2 OF 10 95 09 9660 caves 2 front anti sway bar drop 4 bushing link 2 sleeve 12mm ID early style anti sway bar links 2 sleeve 1 2 ID 2 1 2 x 2 1 2 bolt 2 1 2 Nyloc nut 55 18 9660 iis front anti sway bar drop 1 12mm x 80mm bolt bracket passenger side 1 12mm stover nut 55 19 9660 front anti sway bar drop 1 12mm x 80mm bolt bracket driver side 1 12mm stover nut late style anti sway bar links 55 07 9660 track bar bracket 1 5 8 x 3 1 2 bolt 1 5 8 nyloc nut ahs ba Oc Bonener er Cer er ee One ae pitman arm models made on or prior to 2 28 99 55 07 9062 2 dcsrecinensn acts track bar bracket Ons ba la I2 pitman arm models made on or after 3 1 99 55 06 9660 icc iccisnccsniics 2 compression travel 4 3 8 x 1 bolt stop extension front 4 3 8 nyloc nut 01 S00 pcthisiniethivivindiins 2 polyurethane bumpstop 2 3 8 lock washer front 2 nut 55 06 9660 08 2 compression travel 00 2 7 16 x 1 3 4 bolt stop extension re
11. equire some light taps with a hammer to seat fully use caution not to damage the bolt threads The bolt should be installed from front to rear and hand tighten only It will be fully tightened in a later step NOTE Because of the extremely tight clearance between the supplied track bar bolt and the sleeve in the upper end of the track bar it may be necessary on some vehicles to drill out the upper track bar sleeve using a 5 8 drill bit If this becomes necessary it is strongly recommended that the track bar be removed from the vehicle and placed in a vise or other suitable fixture for drilling NOTE While the factory upper track bar hardware will fit with the Superlift bracket failure to replace the factory hardware with the supplied 5 8 bolt will result in an intermitent popping noise especially while turning due to excessive clearance between the factory bolt and sleeve TRACK BAR BRACKET 55 07 9662 NOTE Perform this step if the vehicle was was made on or after 3 1 99 The production date can be found on the upper left corner of a label located on the driver side door post Install the new Superlift track bar bracket 55 07 9662 in the original track bar bracket location Reuse the factory fasteners 130 Attach the upper end of the track bar to the lower 07 track bar mounting hole using the factory hardware Insert the bolt from front to rear and hand tighten only the bolt is fully tightened in a later step
12. gn 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 available 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 l
13. hicle weight FORM 9666 05 092605 PRINTED IN U S A PAGE 4 OF 10 QU QU Position the spring onto the axle Raise the jack and mate the rear spring eye to the shackle Insert factory bolt from the inside facing outward Install factory nut and hand tighten only Position top U bolt plate and bottom U bolt cradle and install the supplied U bolts Snug up do not fully tighten U bolts As with the spring eye bolts they are fully tightened later Repeat steps 4 and 5 on passenger side PITMAN ARM 01 1109 OR 01 1112 Inspect all steering link ends for looseness and or wear and replace as necessary Center the steering wheel so that the tires if they were on the vehicle point straight ahead Make a note of the factory pitman arm s position in relationship to the steering box frame Remove the cotter key and jam nut on the drag link where it attaches to the pitman arm Use a pickle fork or other suitable tool to separate the drag link Remove the jam nut on the end of the sector shaft Using a pitman arm puller tool available at most auto parts stores separate the pitman arm from the sector shaft IMPORTANT Prior to installing the dropped pitman arm compare the spline count and indexing lugs of the stock pitman arm with the supplied pitman arm to verify the correct arm has been applicated for the vehicle This can be accomplished by stacking the stock arm on the supplied arm see DIAGRAM 1 The splines and DIAGRAM
14. oss 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 Phone 318 397 3000 Sales Tech 1 800 551 4955 FAX 318 397 3040 Web Site www superlift com
15. ry position as shown in the diagram The indexing tab on the metal bracket should line up with an existing hole in the frame approximately 1 1 2 inches down from the factory position Line up the bracket in the new location then mark and drill the location for the new mounting hole Attach the bracket using factory hardware and tighten to factory specs WARNING Use extreme caution when bending the brake hard line Avoid pinching or crimping the line and adjust the line as necessary to avoid contact with any other components DIAGRAM 4 LUG NUT TORQUE With the suspension still hanging cycle steering SEQUENCE Follow the pattern lock to lock and check all components for proper shown to torque the lug nuts operation and clearances WHEELS TIRES WARNING When a wheel is installed always check for and remove any corrosion dirt or foreign material on the mounting surfaces of the wheel or the drum rotor surfaces that contact the wheel Installing wheels without 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 NOTE Inspect the lug nut and washer assemblies Replace the assembly if the washer portion will not spin freely FORM 9666 05 092605 PRINTED IN U S A PAGE 8 OF 10 QU QU 16 Position wheel tire onto vehicle Turn the wheel until one lug is at the top of the wheel hub bolt circle Install the
16. upper mounting bracket and let the bar hang Now unbolt the bar s upper end mounting bracket NOTE On each side anti sway bar links span from the sway bar body up to the frame rails Remove the anti sway bar links Remove the factory shock absorbers NOTE On each side a rubber compression travel stop is bolted to the bottom of the frame rail just inboard of the shock absorbers Remove the compression travel stops FRONT LEAF SPRING REMOVAL Leaf spring removal and installation steps 4 and 5 is performed one side at a time Start with the driver side Position the floor jack under the driver side knuckle Load the jack so that it supports not raises the axle the frame rail is to remain securely on the jack stand Remove the two spring to axle U bolts Now remove the top U bolt shock plate and the bottom U bolt cradle Remove the spring shackle bolt and swing the shackle back and away from the spring Unbolt the spring s front eye from it s hanger then lower the jack enough to allow spring removal SUPERLIFT SPRINGS OW There is not a designated front or rear spring eye both ends are dimensionally the same It is easiest to insert the Superlift spring from front of vehicle Position the spring eye in the front hanger and install the factory bolt from the inside facing outward Install factory retaining nut and hand tighten only The bolt is fully tightened in a later step when the suspension is supporting ve
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