K765 Instructions
Contents
1. i crossmember approximately factory compression A D 7 rearward from the fittings Secure the connection to stop bracket Q Y O compression siop bracket the 21 bracket with the factory X So iy as H OS clip n7 NOTE Take precautions while k aaa TA reforming the metal lines to avoid kinking or otherwise damaging the them FORM 9690 04 092605 PRINTED IN U S A PAGE 13 OF 16 20 REAR SHOCK CROSSMEMBER SS Drew all Measile DIAGRAM 10 INSTALLING THE 55 07 9690 oe 7 ER wea He Line up the rear shock crossmember with the marks aCtory rear compreSSIonN Have Stop made earlier then mark and drill the four mounting brackets and place a mark on the holes in the frame View is of the driver side frame as shown n DIAGRAM 10 Position the rear shock crossmember 55 07 9690 on the inside of the frame with the shock mounting tabs facing rearward toward the back bumper Line up the leading edge of the crossmember with the mark made earlier Check for proper clearance with the exhaust and spare tire It may be necessary coos to adjust the position of the Bap ae i top lip of crossmember in order to maintain T Ao d Z frame adequate clearance One the PSG position is set clamp the crossmember in place note tabs are pointing rearward QIU Mark the location of the four mounting holes two per side then remove the crossmember and drill at each mark using a 17 32 bit 85150 QIU2. front on the new springs and secure using the factory bolt Snug but do not fully tighten at this time Position the 01 181 spring on the vehicle with the end marked front in the forward spring hanger and secure both ends using the factory hardware Snug but do not fully tighten at this time Make sure the top of the DIAGRAM 5 REAR COMPRESSION STOP ASSEMBLY Mount the spring perches and the bottom 55 09 9690 and 55 10 9690 brackets as indicated then drill two of the springs are clean and free of any debris Position the Superlift blocks in between the leaf springs and the spring Ce Tif DRIVER SIDE ae FRAME RAIL 17 32 holes in the frame perches The blocks are machined flat so it does not matter which end faces front Install the supplied U bolts and plates then torque the bolts in an X 145 pattern a5 4 2 x 1 1 2 COMPRESSION TRAVEL kara gt STOPS reas a AaS N OA Remove the factory K TRON NN 1 2 y 1 4 compression travel stops from the frame Save the small sleeve on the compression stop bolt FORM 9690 04 092605 QU QU QU QU QU QU 19 DIAGRAM 5 Position the rear bump stop extension spacer 55 09 9690 on the compression stop frame mount as shown Position the sleeve removed with the factory compression stop over the supplied 7 16 x 2 1 2 bolt Secure using the supplied 7 16 nyloc nut 37 Position the compression travel
3. PAGE 16 OF 16 32 DOUBLE CHECKING TRACK BAR ADJUSTMENT Q After putting some miles on the vehicle remove the upper track bar bolt and check track bar alignment per step 24 The track bar s upper eye should line up with the track bar mount at the frame Readjust bar length as necessary and tighten per specs found in step 23 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 heigh
4. Reinstall the crossmember and secure it to the holes drilled in the frame using the supplied 1 2 x 1 1 2 bolts washers and nyloc nuts Tighten 57 NOTE For single shock usage use the supplied 1 2 x 2 1 2 bolts and nyloc nuts supplied with the kit For a multi shock application you will be supplied with new bolts and spacer sleeves nn Install the shock bushings boot and decal Install the shocks 85150 Tighten both shock eye mounts 46 21 ANTI SWAY BAR LINKS QIU Lubricate the supplied bushings and sleeves and install them in the eyes of the supplied rear anti sway bar links 55 08 9690 OW On each side connect the 08 links to the anti sway bar and frame using the factory hardware Tighten to factory specifications 22 TIRES WHEELS QO DIAGRAM 4 Tighten the lug nuts 148 in the sequence shown FORM 9690 04 092605 PRINTED IN U S A PAGE 14 OF 16 23 24 25 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 co
5. factory metal line and extension as necessary there is a metal bracket that holds the rear Dae L x rubber brake hose where it connects to D i ae 55 46 3120 7 2 the metal brake line Remove the clip securing this connection to the bracket then separate the rubber hose from the metal line Have a pan ready to catch any me spilled fluid as well as caps for the lines to F J PLS EP minimize fluid loss 09 9690 em SAR LP original hose eo L line position 4 DIAGRAM 8 Locate the rear brake hose bracket 55 21 9690 on the driver side compression stop spacer 55 09 9690 installed previously as shown then use ts the bracket as a template to drill the two 7 32 holes Secure the bracket to the frame with the supplied 1 4 x 1 2 self Np tapping bolt 87 in Ib pie factory brake hose QO Attach the supplied female adapter fitting 55 48 3120 to the factory metal line followed by the supplied 6 long metal brake line extension 55 46 3120 Use a line wrench to avoid damaging the fittings Q Carefully reform the factory metal line and extension as necessary to reach the new mounting bracket Position the factory rubber hose through the REAR RUGCKCROGEEE ee 21 bracket mounted earlier and attach it to the opposite end of the l supplied 46 brake line extension Z as shown in Diagram 8 Use a line i DRIVER SIDE bais leeding Fa oi wrench to avoid damaging the a ae
6. 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 FORM 9690 04 092605 PRINTED IN U S A PAGE 15 OF 16 m 26 27 ou 28 29 30 31 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 DRAG LINK ADJUSTMENT Point the tires straight ahead then note the position of the steering wheel If it is crooked or the spokes of the wheel are not level loosen the clamps on the drag link adjustment sleeve and adjust the length of the drag link in or out by rotating the sleeve Once the steering wheel is level tighten the clamps 49 IMPORTANT There must be a minimum of 1 3 8 thread engagement on each end of the drag link NOTE It may be necessary to make a small adjustment to perfectly center the wheel once the vehicle is test driven Repeat this step for any adjustment BLEEDING THE BRAKES Bleed the front and rear brakes according to the procedure found in the factory service manual Double check all fittings for any signs of leakage Activate four wheel d
7. nyloc nut 55 22 4540 oo eeeeeeeee brake line drop bracket rear 1 5 16 x 3 4 bolt 1 5 16 SAE washer 1 5 16 nyloc nut SOAS 3 1AGs a eladscnanceans 7 16 female female adapter 55 46 3120 aaaea 2 brake line extensions front 7 16 fittings OSS AEE rear block kit 4 5 8 x 3 5 8 x 14 U bolt 8 5 8 extra thick flat washer FORM 9690 04 092605 PRINTED IN U S A PAGE 4 OF 16 2 shock boot yellow 2 hardware pack and cable tie 2 shock boot yellow 2 hardware pack and cable tie Note Shock boots if desired purchased separately OLOS ene EAEE E E Superlift badge c cece alcohol wipe pad 00461 0 cece ceeeceeesen eens decal Warning To Driver FRONT 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 2 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 Q Remove the four bumper to frame bolts and lay the bumper aside 3 TRACK BAR ANTI SWAY BAR
8. FORM 9690 04 092605 PRINTED IN U S A PAGE 1 OF 16 SUPERLIFT SUSPENS Superlift 10 lift system for 1999 2004 Ford F 250 F 350 Super Duty 4WD INSTALLATION INSTRUCTIONS 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 This lift system only fits Super Duty trucks made on or after 3 1 99 This kit requires the front driveshaft to be lengthened approximately 2 1 2 This modification can be performed by any reputable driveshaft shop Prior to beginning installation examine the rear driveshaft of the vehicle and determine if it has a two piece driveshaft that utilizes a carrier bearing If the driveshaft is a two piece design a carrier bearing drop kit Superlift 9695 is required This carrier bearing drop kit is sold separately and includes separate instructions Front end realignment is necessary An arrow on diagrams indicates wh
9. 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 QO Disconnect the track bar from it s upper and lower mounting brackets and remove the bar Now unbolt the bar s upper end mounting bracket The track bar and mounting bracket may be discarded but save all hardware for re use NOTE On each side anti sway bar links span from the sway bar body up to the frame rails QIU Disconnect the anti sway bar links from their attachment points to the frame n Remove the factory shock absorbers Save all hardware for re use NOTE On each side a rubber compression travel stop is bolted to the bottom of the frame rail just inboard of the shock absorbers n Remove the compression travel stops Save all hardware for re use 4 FRONT LEAF SPRING REMOVAL Leaf spring removal and installation is performed one side at a time Start with the driver side FORM 9690 04 092605 PRINTED IN U S A PAGE 5 OF 16 QU QU QU QU QU 5 QU 6 QU QU QU QU QU 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 Disconnect the axle vent hose and the vacuum lines connected to the the locking hub assemblies on the driver and passenger sides of the axle Th
10. ON TRAVEL STOPS Attach the supplied 01 300 poly compression travel stops to the bottom ends of the compression stop brackets 55 04 9690 passenger side and 55 05 9690 driver side using the supplied 3 8 washer and nyloc nut Attach the 04 and 05 brackets to the frame at the factory compression stop s original location using the factory hardware or DIAGRAM 2 ANTI SWAY BAR LINK ASSEMBLY Position 3 E Iti the supplied 3 8 x 1 bolts and nyloc the drop brackets and links as indicated View is from the front nuts The brackets should be positioned driver side so that the poly compression stop is offset toward the front of the vehicle Tighten 67 factory sway bar link mount ANTI SWAY BAR Remove the two bolts securing the factory upper anti sway bar link attachment points to the frame Save all hardware for re use DRIVER SIDE FRAME RAIL f he j Ij Pi t gt 5 J ih DIAGRAM 2 Attach the supplied anti sway bar drop brackets 55 02 9690 passenger side and 55 03 9690 driver side to the frame using the factory hardware Note that the upper tab should be positioned to the inside of the 55 01 9690 frame Install the supplied 12mm x UN note link offset 12mm x 70mm 80mm bolt through the upper tab and frame then secure using the supplied 12mm stover nut 37 FORM 9690 04 092605 PRINTED IN U S A PAGE 8 OF 16 QW Install the suppli
11. brake line drop bracket 2 7 16 x 1 1 4 bolt passenger side 2 7 16 SAE washer 2 7 16 nyloc nut 59 11 9680 front brake line drop bracket 2 7 16 x 1 1 4 bolt driver side 2 7 16 SAE washer 2 7 16 nyloc nut O19 1 S00 cae front brake hose driver side 2 7 16 crush washer 1 3 8 plug 02 91500 n front brake hose cceeeeeeeee 2 7 16 crush washer passenger side 55 07 9620 an Anais 2 front bumper spacer 4 12mm x 60mm bolt 4 7 16 extra thick flat washer vacuum and breather hose 2 3 16 x 4 rubber hose extension hardware front 2 3 16 plastic connector 1 5 16 x 9 rubber hose 1 5 16 plastic connector 55 07 9690 tan cries rear shock crossmembet 2 1 2 x 2 1 2 bolt 4 1 2 x 1 1 2 bolt 4 1 2 SAE washer 6 nyloc nut 55 08 9690 ii cvcicociseeisecs 2 rear anti sway bar link 4 bushing 4 sleeve 12mm ID 55 09 9690 w scciicestecies 2 compression Stop 06 2 7 16 x 2 1 2 bolt extension spacer rear 4 7 16 SAE washer 2 7 16 nyloc nut 55 10 9690 ee 2 compression StOP eee 4 1 2 x 1 1 4 bolt extension rear 4 1 2 x 1 1 2 bolt 8 1 2 SAE washer 4 1 2 nyloc nut 4 1 2 tab nut 55 13 9090 siiis 2 compression travel stop 2 3 8 x 2 bolt rear 2 3 8 USS washer 2 3 8
12. de prior to 2 28 99 or 01 1112 on models made on or after 3 1 99 on the sector shaft in the exact same position as the original 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 TRACK BAR BRACKET 55 07 9682 Install the new Superlift track bar bracket 55 04 9682 in the original track bar bracket location Reuse the factory fasteners 130 FORM 9690 04 092605 PRINTED IN U S A PAGE 7 OF 16 10 QU QU 11 QU QU 12 QU QU TRACK BAR INSTALLATION The track bar components are shipped assembled Double check the thread engagement of each track bar end in the adjustment sleeve the amount of engagement should be equal Lay the Superlift track bar next to the factory bar and adjust the eye to eye length of the new bar to match that of the original This will serve as a baseline for final adjustment Install the long 19 5 end of the track bar in the factory axle mount and loosely secure using the factory hardware Final adjustment and attachment to the frame will happen once the vehicle is on the ground SUPERLIFT FRONT SHOCK ABSORBERS 85160 NOTE If the optional front multi shock system has been purchased install now per separate instructions Install shock bushings boot and decal Install the shock Tighten the upper nut 76 and lower bolt 76 COMPRESSI
13. dy to catch any spilled fluid Then use a line wrench to disconnect the metal brake line from the rubber hose Place a cap on the metal line to minimize fluid loss OW Attach the supplied brake hoses 01 91500 driver side and 02 91500 passenger side to the metal line and tighten to the specifications found in the factory service manual Use a line wrench to avoid damaging the fitting NOTE Some models have two metal brake lines that attach to the driver side brake hose If two lines are present simply connect them to the supplied 01 91500 hose and tighten to factory specifications If only one metal line is present use the supplied 3 8 plug to cap off one of the two inlets built in to the 01 91500 hose QW Attach the other end of the hose to the caliper using the factory banjo bolt Use the new copper washers supplied with the hoses Tighten to factory specifications FORM 9690 04 092605 PRINTED IN U S A PAGE 9 OF 16 QU QU 15 QU QU QU Carefully reform the metal line to reach the factory DIAGRAM 4 LUG NUT TORQUE SEQUENCE Follow the pattern shown to torque the lug nuts brake line tab in its new location and secure using the factory hardware Tighten to factory specifications Attach the vacuum hose extensions to the vacuum lines leading to the locking hubs then reconnect the hoses to each hub Also attach the front axle breather extension at this time WHEELS TIRES WARNING When a wheel
14. ed bushings and sleeves in the anti sway bar drop links 55 01 9690 QU Position the links according to Diagram 2 and attach the upper end of the link to the 02 and 03 drop brackets using the supplied 12mm x 70 mm bolt QW Attach the lower end of the link to the anti sway bar using the factory hardware l Tighten the upper end 37 and lower end 60 DIAGRAM 3 BRAKE LINE DROP BRACKETS Install the 13 FRONT BUMPER 55 10 9680 and 55 11 9680 brake line relocation brackets on SPACERS exisitng holes in the frame with the supplied hardware Q Position bumper spacers aii 55 07 9620 between bumper and frame Place a 7 16 extra thick flat washer on each new 12mmx 60mm bolt prior Os to reinstalling the bumper 51 to 68 14 FRONT BRAKE HOSES A DRIVER SIDE AND VACUUM HOSE A Naa t9 fD FRAME RAIL EXTENSIONS ly ing an Dua z NOTE Perform the F following steps one side IW 3 factory brake ata time line bracket OWL On each side unbolt the brake line tab where the metal brake line connects to the rubber hose from the frame factory hardware A saon Cf PRC NTU QU DIAGRAM 3 Attach the supplied brake hose relocation brackets 55 10 9680 passenger side and 55 11 9680 driver side to the existing holes in the frame using the supplied 7 16 x 1 1 4 bolts washers and nyloc nutes Tighten 37 nn Loosen and remove the banjo bolt securing the brake hose to the caliper Have a catch pan rea
15. ese will be relocated extended in a later step Remove the two spring to axle U bolts Now remove the top U bolt shock plate and the bottom U bolt cradle Remove the shackle to frame bolt Unbolt the spring s front eye from it s hanger then lower the jack enough to allow spring removal Do not overextend the brake lines SUPERLIFT SPRING HANGERS NOTE On 2001 and later model vehicles there is a small auxiliary crossmember bolted to the frame that will interefere with the Superlift spring hangers Remove and discard this crossmember Unbolt the factory spring hanger and install the Superlift hanger 55 01 9620 and 55 02 9620 in its place using the factory fasteners 76 The 01 installs on the driver side the 02 installs on the passenger side SPRING INSTALLATION Install the supplied differential vent hose extension and front hub vacuum tube extensions using the supplied rubber hose and fittings Position the leaf spring as it would be installed on the vehicle with the smaller diameter spring eye facing the rear of the vehicle Note that the supplied Superlift shackles 55 03 9620 are boxed on one end Attached the boxed end of the shackle to the smaller diameter spring eye using the factory hardware The shackle should be positioned so that the boxed end faces the rear of the vehicle and the bolt should be installed from the inside with the bolt head facing the center of the vehicle Do not tighten a
16. ich 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 After drilling file smooth any burrs and sharp edges Paint or undercoat all exposed metal surfaces Prior to attaching components be sure all mating surfaces are free of grit grease undercoating etc A factory service manual should be on hand for reference 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 FORM 9690 04 092605 PRINTED IN U S A PAGE 2 OF 16 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 OFS 216 Otters 2 front leaf spring diesel V 10 01 2190 asa cianca sia 2 front leaf spring gas V 8 Oak lata capitis 2 rear spring OTB EET pitman arm OLDS Zenna drag link adjustment sleeve 55 01 9620 front spring hanger driver side BB 02 9020 ie decnedenenenacen front spring hanger passenge
17. 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 Position wheel tire onto vehicle Turn the wheel until one lug is at the top of the wheel hub bolt circle Install the 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 NOTE Unless otherwise specified the remainder of the front hardware will be tightened once the rear lift is complete and the vehicle is on the ground with the suspension supporting the vehicle s weight REAR PROCEDURE 16 m m Q Q QU QU PREPARE VEHICLE Use a floor jack positioned under the rear axle to raise the vehicle Place jackstands under the framerails a few inches in front of the forward hanger for the rear springs Ease the jack down until the frame is resting on the stands but keep a slight load on the jack Chock the front tires to prevent the possibility of vehicle movement Remove and discard the anti sway bar links Save all hardware for re
18. made of heavy gauge wire Unbolt the bracket closest to the rear bumper the one that holds the E brake cable for the driver side brake from the frame DIAGRAM 7 Unbolt the other emergency brake cable bracket the one that holds the cable for the passenger side Place the supplied 55 22 4540 emergency brake cable drop bracket and the bracket for the driver side E brake cable on the factory bolt that formerly secured the bracket for the passenger side E brake cable as shown Position the driver side DIAGRAM 7 E BRAKE CABLE DROP BRACKETS Position and install as shown factory driver side E brake cable and bracket DRIVER SIDE FRAME RAIL at factory passenger side e brake cable and bracket A EE lt FRONT 6 0 N SS FORM 9690 04 092605 PRINTED IN U S A PAGE 12 OF 16 E brake cable bracket as indicated then drill an 1 8 hole in the frame for the bracket s locating tab as shown Reinstall the nut on the factory bolt and tighten 26 Q Attach the factory bracket for the passenger side E brake cable to the lower end of the 55 22 4540 bracket using the supplied 5 16 x 3 4 bolt washer and nyloc nut as shown DIAGRAM 8 REAR BRAKE HOSE EXTENSION Attach the 55 21 9690 brake line bracket to the 09 A Diagram 7 compression stop spacer then connect the 55 46 3120 ae f extension to the factory hose and line Carefully reform 0 On the inside of the driver side frame rail
19. r side 55 03 9620 ociacsne 2 spring shackle front 7 16 x 5 bolt 2 2 7 16 nyloc nut 2 shackle sleeve 2 2 OT SOD P 2 poly compression stop front 2 3 8 lock washer nyloc nut 55 07 9682 cccceeeee track bar bracket front 01 9698 nn track bar end link 10 long 02 9698 nn track bar end link 19 5 long OEE E oo eee eee adjuster sleeve with clamps NOTE Track bar components are shipped assembled 55 01 9690 wits ietentncl 2 anti sway bar links front link bushing sleeve 12mm ID sleeve 1 2 ID 1 2 x 2 1 2 bolt 1 2 Nyloc nut 55 02 9690 viscscsisinevieins anti sway bar drop bracket front passenger side 4 2 2 2 2 1 12mm x 70mm bolt 1 12mm x 80mm bolt 2 12mm stover nut 1 12mm x 70mm bolt 1 12mm x 80mm bolt 2 12mm stover nut 2 2 2 2 3 8 x 1 bolt 3 8 x 1 nyloc nut 3 8 x 1 bolt 3 8 x 1 nyloc nut front driver side 55 04 9690 compression stop extension front passenger side 55 09 9690 ncsanan compression stop extension 55 03 969 0 iisicc ete eas anti sway bar drop bracket front driver side FORM 9690 04 092605 PRINTED IN U S A PAGE 3 OF 16 55 06 9690 eee 2 compression stop plate rear 16 5 8 extra thick flat washer 8 5 8 nyloc nut 55 10 9680 n n front
20. rive system and check front hubs for engagement HEADLIGHTS Readjust headlights to proper setting SUPERLIFT NAME BADGE AND 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 Clean designated area with warm soapy water Rinse and wipe dry with a soft lint free towel 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 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 below ALIGNMENT Realign vehicle to factory specifications Alignment must be performed by a certified professional FORM 9690 04 092605 PRINTED IN U S A
21. stop extension bracket 55 10 9690 on the frame and over the 09 spacer as shown in Diagram 5 Secure the bottom of the bracket to the 09 spacer using the supplied 1 2 x 1 1 4 bolts washers and tab nuts Snug but do not fully tighten at this time Using the 55 10 9690 extension bracket as a template center punch and drill the upper mounting holes in the frame using a 17 32 bit as shown in Diagram 5 Install the supplied 1 2 x 1 1 2 bolts washers and nyloc nuts in the holes just drilled and tighten 57 Tighten the lower 1 2 bolts in the 10 bracket 57 PRINTED IN U S A PAGE 11 OF 16 DIAGRAM 6 REAR COMPRESSION STOP INSTALLATION M FROM fr _ 55 13 9690 5 8 nyloc ss Du 55 06 9690 5 8 U bolt_ a S washer UX Lh as factory OS ep U bolt teas ee 5 8 nyloc gt GI A N f A Pd XS i i EE Attach the supplied compression travel stops 55 13 9690 to the compression stop plates 55 06 9690 using the 3 8 hardware supplied with the stops DIAGRAM 6 Place a 5 8 U bolt washer on each U bolt followed by the 06 plate as shown Secure the plate using the remaining 5 8 U bolt washers and nyloc nuts 128 REAR BRAKE LINE AND EMERGENCY BRAKE CABLE MODIFICATION On the driver side frame rail just in front of the rear tire the emergency brake cables are retained by two brackets
22. t The amount of lift allowed and how the lift may 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 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 drivers 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
23. t this time It is easiest to install the Superlift spring from the front of the vehicle Position the large diameter spring eye in the Superlift spring hanger and secure using the factory harware The bolt should be installed from the outside Snug but do not fully tighten at this time Position the spring on the axle then raise the axle enough to line up the shackle with its frame mount Insert the supplied short spacer sleeves between the legs of the shackle and the frame mount Install the supplied 7 16 x 5 bolt through the shackle and frame mount The bolt should be installed from the outside Snug but do not fully tighten at this time Position the factory top U bolt plate on the spring and the U bolt cradle under the axle Install the supplied large radius U bolt and snug using the supllied washers and nuts Do not fully tighten at this time Repeat steps 4 6 on the passenger side FORM 9690 04 092605 PRINTED IN U S A PAGE 6 OF 16 PITMAN ARM 01 1109 OR 01 1112 AND ADJUSTER SLEEVE 55 10 9682 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 Co
24. uld cause wheels to come off while vehicle is in motion CLEARANCE CHECK With the vehicle still on jack stands and the suspension 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 Lower vehicle to the floor TRACK BAR ADJUSTMENT Rotate the adjustment sleeve to lengthen or shorten the bar until the upper eye lines up with the track bar mount on the frame Secure the frame end of the bar using the factory hardware IMPORTANT Observe the amount of thread engagement in the track bar adjustment sleeve The threads can be observed through the slit present in the sleeve The minimum amount of each track bar end s thread engagement within the sleeve is 1 50 Tighten the track bar bolts at the axle and at the frame 129 Tighten the adjuster sleeve clamp bolts 25 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 front spring to axle U bolts 99 OW 2 front leaf springs rear shackle eyes 185 nn 3 front leaf springs front eye 259 QW 4 rear springs forward hanger 249 QW 5 rear springs both ends of shackle 175 QW 6 rear spring to axle U bolts 145 QU 7 DIAGRAM 4 wheel
25. unt the number of threads exposed on both sides of the drag link adjuster sleeve Make a note of the thread count and the orientation of the sleeve s retaining clamps Loosen the retaining clamps on the adjuster sleeve then unthread it from DIAGRAM 1 COMPARING PITMAN ARMS Compare the both ends of the drag link stock pitman arm with the supplied arm before installation The symbol amp indicates spline indexing lugs Thread the supplied 55 10 9682 adjuster sleeve on the INCORRECT CORRECT long end of the drag link then ae thread in the short end Match the number of threads exposed to the factory number noted earlier This will provide a baseline for final adjustement Snug but do not tighten the clamps at this time Reuse factory clamps 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 indexing lugs must line up exactly If a difference is noted i e the pitman arms do not line up contact Superlift before proceeding Position the Superlift pitman arm 01 1109 on models ma
26. use Remove the tires U bolts and shocks FORM 9690 04 092605 PRINTED IN U S A PAGE 10 OF 16 m 17 QU QU QU QU QU QU QU 18 QU Lower the axle by carefully easing down the jack Do not overextend the brake lines and axle vent hoses NOTE The spring perches are prone to collapse or warp where the leaf springs or blocks seat on the axle especially towards the ends Without a perfectly flat mounting surface the block may fail and roll out off of the perches If the perches are not flat fix them by welding on apiece of 14 plate or something similar or replace the perches completely REAR SPRINGS NOTE If the vehicle is equipped with a two piece driveshaft that utilizes a carrier bearing Superlift carrier bearing drop kit 9695 is required This kit is sold separately and includes its own instruction form If a carrier bearing drop bracket is required install now Install the supplied rear vent hose extension One end at a time and with the help of an assistant loosen and remove the bolts securing the spring to the front spring hanger and rear shackle at the frame Remove the spring from the vehicle Lubricate the supplied bushings and sleeves and install in the new rear springs 01 181 Note the orientation of the shackle on the factory springs including which way the bolt is installed then remove the bolt and shackle Position the shackle on the eye opposite the one marked
27. 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 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 Phone 318 397 3000 Sales Tech 1 800 551 4955 FAX 318 397 3040 www superlift com
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