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1. sleeve 12mm x 40mm bolt 12mm x 110mm bolt 12mm SAE flat washer 12mm USS flat washer 12mm nyloc nut 3 4 x 2 375 sleeve 12mm x 40mm bolt 12mm x 110mm bolt 12mm SAE flat washer 12mm USS flat washer 12mm nyloc nut 3 4 x 2 375 sleeve 18mm x 70mm bolt extra thick flat washer 18mm tapered lock nut 1 2 x 2 1 2 bolt 1 2 nyloc nut special half washer 1 1 4 x 1 bolt 1 1 4 SAE flat washer 1 1 4 nyloc nut 2 1 4 x 1 bolt 2 1 4 SAE flat washer 2 1 4 nyloc nut 1 4 x 1 bolt 1 4 SAE flat washer 1 4 nyloc nut FORM 4530 03 090402 PRINTED IN U S A PAGE 3 OF 13 01 4005 pitman arm 1994 1999 01 4006 naii pitman arm 2000 2001 55 09 4505 aa upper shock plate ceeee 1 1 2 X 1 bolt driver side 1 1 2 nyloc nut 1 travel limiting strap 55 10 4505 nn upper shock plate e 1 1 2 X 1 bolt passenger side 1 1 2 nyloc nut 1 travel limiting strap OO E EEA 2 shock absorber front 2 shock boot yellow 2 hardware pack and cable tie Note Shock boots if desired purchased separately BO1G4 AAEE T 2 shock absorber rear 2 shock boot yellow 2 hardware pack and cable tie QO 34 i ivciccciceciseriseciseciiess Superlift badge eee alcohol wipe pad 00461 eee eee cece ees decal Warning To Driver FRONT DISASSEMBLY 1 PREPARE VEHICLE QO Place v2. 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 HARWARE TIGHTENING SEQUENCE On each side torque the following fasteners QW Realign the eccentric cam bolts with the marks made in step 6 and tighten 110 QIU Tighten the rear lower link bolt 62 l Tighten the front upper link bolt 89 QIU Tighten the rear upper link bolt 62 REAR LIFT The rear lift is purchased separately and has separate instructions Install now 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 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 fr
3. 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 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 O0 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 4530 03 090402 PRINTED IN U S A PAGE 2 OF 13 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 55 04 4530 55 22 4530 55 09 4530 55 10 4530 1 14 4505 55 11 4530 DESCRIPTION Qty if more than one 2 coil spring front 2 upper link 2 lower link link arm drop bracket driver side link arm drop bracket passenger side track bar bracket vacuum hose relocation bracket 2 brake hose relocation bracket front 4 triangle reinforcement wedges brake hose relocation bracket rear NEW ATTACHING HARDWARE Qty if more than one 8 bushing half 4 3 4 x 2 65 sleeve 4 2 bushing half 3 4 x 2 375
4. 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
5. necessary to perform some minor trimming in order to gain a adequate clearance for the drag FE _ compression link he 52 stop contact Bae i point i COMPRESSION TRAVEL STOP REINFORCEMENT WEDGES DIAGRAM 9 On each side the stock frame compression stop contact points must be reinforced by welding in the supplied triangle shaped wedges Weld them in place following the diagram After the weld has cooled paint or undercoat all exposed metal surfaces TIRES WHEELS DIAGRAM10 LUG NUT TORQUE DIAGRAM 10 Tighten the lug nuts in the sequence SEQUENCE Use the a itip shown to the factory specifications shown to torque the lug nuts 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 while vehicle is in motion FORM 4530 03 090402 PRINTED IN U S A PAGE 11 OF 13 22 m 23 24 25 26 27 28 CLEARANCE CHECK Once again with the vehicle still on jack stands and the suspension hanging
6. the shock absorber through the mounting hole in the center of the Superlift shock plate Install the remaining bushing half and washer on the shock stem following by the retaining nut Tighten the nut until the shock bushings swell slightly Tighten the lower shock hardware 100 Attach the upper end of the limiting strap installed in step 4 to the upper shock plate tab using the 1 2 x 1 bolt washer and nyloc nut Tighten 57 ANTI SWAY BAR LINKS Attach the factory anti sway links to the bar using the factory bushings and hardware Connect the other end of the links to the axle brackets The links should be installed abve the axle brackets not below as they were from the factory Tighten to factory specifications FRONT BRAKE LINE RELOCATION DIAGRAM 8 Position the brake line DIAGRAM 8 INSTALLING THE 55 10 4530 BRAKE relocation brackets 55 10 4530 as LINE RELOCATION BRACKET shown in the diagram with the short 90 degree bend at the bottom and iioii D facing forward Secure the 10 bracket to the axle bracket using the I factory bolt stock brake line bracket Attach the factory brake line bracket crimped to the rubber line to the 10 bracket using the supplied 1 4 x 1 bolt washer and nyloc nut as shown in DIAGRAM 7 9 Check the clearance of the factory brake line bracket with the bolt heads of the Superlift axle bracket It may be necessary to bend the arm of the fact
7. D 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 FORM 4530 03 090402 PRINTED IN U S A PAGE 13 OF 13 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
8. FORM 4530 03 090402 PRINTED IN U S A PAGE 1 OF 13 SUPERLIFT SUSPENS I Superlift 5 lift system for 1994 2001 DODGE RAM 3 4 TON 4WD PICKUP 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 Welding is required Refer to steps 11 and 20 Rear lift is sold separately and includes separate instructions 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 After drilling file smooth any burrs and sharp edges Prior to operating a torch or saw protect any heat sensitive components located in the immediate
9. IN U S A PAGE 7 OF 13 CAUTION The mating surface of the factory track bar mount and the 22 bracket must be 100 percent smooth before proceeding If it is not the bracket will cause creaking and popping noises once the installation is complete and will greatly weaken the assembly as a whole QO Dab the end of the supplied 18mm x 70mm bolt with Loctite also provided and place the extra thick washer under the bolt head Start the bolt in the factory track bar mount as shown in DIAGRAM 5 and thread it all the way through the 22 bracket Install the supplied 18mm tapered lock nut and tighten until snug QO Position the 22 bracket so that it is flat against the frame crossmember Once again examine the mating surface to be sure the bracket makes full contact with the crossmember In some cases minor clearancing will be necessary If so mark the areas on the crossmember and use a die grinder or similar tool to gain the necessary clearance QO DIAGRAMS 4 amp 6 Using the 22 bracket as a template drill a 1 2 hole in the crossmember Be sure that this hole comes out below the weld on the front side of the crossmember as shown Q Insert the supplied 1 2 x 2 1 2 bolt with a flat washer in the hole then install the supplied special half washer and nyloc nut Position the half washer so that the thick half is under the weld and the thin half is over the weld as shown Basically the washer should provide an even surf
10. ace for the nut Q Torque the 18mm bolt 200 and 1 2 bolt 70 75 but be sure not to crush the crossmember DIAGRAM 6 CORRECT POSITIONING OF THE 1 2 HOLE TO BE DRILLED IN THE CROSSMEMBER Using the 05 track bar bracket as a template drill a 1 2 hole in the crossmember The hole should be below the weld in the crossmember as shown Also position the thick washer and hardware as shown ee thick washer 1 2 x 2 1 2 eee Ch are a COCO a T FORM 4530 03 090402 PRINTED IN U S A PAGE 8 OF 13 E 12 QU QU 13 QU QU 14 QU QU DIAGRAM 7 Clean the area where the gusset on the 22 DIAGRAM 7 WELDING THE TRACK BAR BRACKET BRACE Prep area and weld where indicated bracket contacts the frame Once the surfaces are prepped weld the gusset to the frame as shown Allow the area to cool then paint all affected surfaces Reform the previously relocated brake line so that it clears the 05 bracket and slide the down the line approximately 3 inches Drill a 19 64 hole in the crossmember and reattach the clamp using the factory self tapping bolt FRONT COIL SPRINGS Insert the original three bolt ring inside the coil tower and start the nuts to hold the ring in place do not tighten at this time NOTE If installing the optional dual shock system refer to those instructions before proceeding Place the coil springs in the cups on the di
11. 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 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 AN
12. complete remove the line from the top of the crossmember and relocate it to the bottom of the crossmember The line s retaining clips can be reused 11 TRACK BAR BRACKET Q DIAGRAM 4 Prior to installing the track bar bracket remove the bolt clamp that holds a steel brake line from the crossmember Carefully push the line up and out of the way approximately 2 inches OQ DIAGRAM 5 Position the track DIAGRAM 5 INSTALLING THE 55 22 4530 TRACK BAR bar drop bracket 55 22 4530 BRACKET View is from the front against the factory track bar SiS Z mount to get an idea where the aafe drop bracket will make contact with the original mount Closely examine the factory mount to be sure its surface is smooth where it 18mm x FX lt 70mm bolt u surface must i i crossmember be ground makes contact with the Superlift one m rae bracket Some heavy duty ae thick flat models have a reinforcement oe l Ja washer plate welded to the mount that MUST be ground smooth Also check the fit of the gusset on the 22 bracket that contacts the bottom of the frame for later l amp a welding see diagram 7 for e TS E AN reference In some cases it may a mii be necessary to trim the gusset slightly so that the bracket fits flush with the factory track bar mount Grind as necessary then check fit the 22 bracket once again to ensure it fully contacts the factory mount nut FORM 4530 03 090402 PRINTED
13. e upper holes on the sides of each factory axle bracket there are two holes per side are large enough for the bolt to pass through If not drill the holes out to 1 2 FORM 4530 03 090402 PRINTED IN U S A PAGE 5 OF 13 QU QU QU DIAGRAM 2 INSTALLING THE 55 03 4530 AXLE RELOCATION BRACKET DIAGRAM 1 Drill out the lower hole on the sides of each factory axle bracket to 1 2 This hole should be 55 03 4530 drilled from the outside and the bit should pass through both sides of the pe ge axle bracket as shown DIAGRAM 2 Position the supplied 3 4 x 2 375 sleeve inside the factory axle bracket and over the middle holes according to the diagram Install the supplied 12mm x 110mm bolt with in the lower hole through the sleeve with the supplied thick 1 2 washers on both sides Install a 12mm nyloc nut but do not tighten at this time Install the supplied 12mm x 40mm bolts washers and nyloc nuts in the 12mm x 110mm remaining holes of the 03 and 04 f brackets 2 per side Place a washer under each bolt head and each head should face the outside of the vehicle l Torque the 110mm bolts 52 55 and the 40mm bolts 73 77 9 m QU QU UPPER LINKS Lubricate the supplied bushing halves and sleeves and install them in the Superlift upper links 55 21 4530 On each side slide the front DIAGRAM 3 VACUUM LINE RELOCATION eye of the upper link far enough in
14. ee 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 FORM 4530 03 090402 PRINTED IN U S A PAGE 12 OF 13 Installthe 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 29 ALIGNMENT QO Realign vehicle to factory specifications 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
15. ehicle in neutral Raise front of vehicle with a jack and secure a jack stand beneath each frame rail behind the lower trailing arms Ease the frame down onto the stands place transmission in low gear or park and chock rear tires Position a jack so that it supports but does not raise the front axle Remove front tires 2 FRONT SHOCK BRACKETS QW Open the hood and remove the upper shock nuts and retainers on each side Also remove the 3 retaining nuts for the upper shock brackets and remove the brackets l Remove the lower shock retaining hardware and pull the shock up through the coil tower under the hood Save all hardware for reuse 3 TRACK BAR AND DRAG LINK Q Disconnect the track bar at the axlehousing then remove the bolt that attaches the bar to the frame Save all hardware for reuse Remove the factory steering stabilizer Separate the drag link from the pitman arm and let hang Remove the pitman arm retaining nut then separate the pitman arm from the steering sector shaft using a puller tool Save all hardweare for reuse FORM 4530 03 090402 PRINTED IN U S A PAGE 4 OF 13 4 aa QU 6 a0 E ANTI SWAY BAR On each side unbolt the anti sway bar links from the axlehousing then unbolt the anti sway bar from the frame Flip the bar upside down so that the ends of the bar step up instead of down and reinstall on the frame in the factory position COIL SPRINGS Carefully lower the front axle un
16. fferential Place the rubber isolators on top of the coils and carefully raise the differential until the coils are firmly seated in the coil towers Keep a load on the jack to hold the coils in place but not enough to lift the vehicle frame off the jack stands FRONT SHOCK ABSORBERS Install the bushings sleeves shock boots and stickers on the front shock absorbers 85304 Extend the shock absorber to its approximate running length of 21 Slide the new shocks down through the coil towers and secure the lower ends using the factory hardware Do not tighten at this time Install a cup washer and bushing half supplied with the shock on the upper stem mount of the shock UPPER SHOCK PLATES AND LIMITING STRAPS Install the supplied 1 2 x 1 bolt on the limiting strap tab of the upper shock plate 55 09 4505 driver side and 55 10 4505 passenger side The bolt should be installed from the inside It must be positioned now because there is not enough room for installation once the plate is in place Remove the nuts holding the factory three bolt ring in place Install the upper shock plate O9 driver side and 10 passenger side over the three bolts with the limiting strap tab facing the rear of the vehicle Reinstall the factory nuts and tighten to factory specifications FORM 4530 03 090402 PRINTED IN U S A PAGE 9 OF 13 QU QU QU 15 QU QU 16 QU QU QU 17 Maneuver the stem mount of
17. ory bracket slightly to avoid rubbing against the bolt heads PITMAN ARM Install the dropped pitman arm 01 4005 for 1994 1999 models or 01 4006 for 2000 2001 models on the steering sector shaft using the original lock washer and nut and tighten to factory specifications 185 Loosen the turnbuckle clamps on the drag link and rotate the end of the drag link 180 Install the drag link in the bottom end of the pitman arm and secure using the original castellated nut 65 with a new cotter pin supplied Rotate the turnbuckle clamps so that the bolts are above the drag link and tighten 40 FORM 4530 03 090402 PRINTED IN U S A PAGE 10 OF 13 18 m 19 20 QU QU 21 TRACK BAR Raise the track bar and connect it to the bottom of the track bar bracket Install the original castellated nut and tighten 62 Be sure to install the new cotter pin supplied Now retorque the lower track bar bolt on the axle to factory specifications CLEARANCE CHECK DIAGRAM 9 COMPRESSION TRAVEL STOP REINFORCEMENT With the vehicle still on jack WEDGES Position and weld the 1 14 4505 wedged as shown stands and the suspension hanging at full extension travel cycle steering lock to lock and check all components p e ee f 4 14 4505 for proper operation and ff clearances Pay close attention to the clearance of the anti sway bar end link mounts and the drag link tie rod assembly On some 94 97 models it may be
18. til the coil springs become loose Remove the coils rubber insulators and tower ring Save the rubber insulators for reuse NOTE Use caution when lowering the front axlehousing to avoid damaging the brake lines vacuum lines and front driveshaft Pry the factory bumpstops from their mounts on the frame using a large screwdriver or pliers and discard SUSPENSION LINKS Cam bolts attach the lower suspension links to the front axle housing Paint or scribe alignment marks on each cam bolt and axle bracket so the bolts can later be returned to their original position Detach the upper and lower suspension links from the axle and the frame Save all hardware for reuse FRONT ASSEMBLY 7 a QU 8 LOWER LINKS Lubricate the supplied bushing halves and sleeves and install them in the Superlift lower links 55 02 4530 DIAGRAM 1 DRILLING THE AXLE BRACKETS Connect a lower link 55 02 4530 to On each side drill out the existing holes indicated the axle using the factory cam bolts then to the frame using the factory hardware These bolts should be installed from the outside Be sure to position the link so that the zerk fittings are easily accessible for vehicle service Do not fully tighten at this time LINK ARM DROP BRACKETS DIAGRAM 2 Test fit the link arm drop brackets 55 03 4530 driver side and 55 04 4530 passenger side on the axlehousing Take one of the supplied 12mm bolts and check to see if th
19. to the axle bracket to start the rear eye in the factory frame mount Be sure to position each link so that passenger side the zerk fittings can be easily frame rail accessed for service Attach the rear eye using the factory hardware but do not tighten at this time Line up the front link eye in the 03 and 04 brackets Position one end of a supplied limiting strap on vacuum line each factory upper link bolt then install the bolt from the outside Do not tighten at this time FORM 4530 03 090402 PRINTED IN U S A PAGE 6 OF 13 10 VACUUM HOSE AND ELECTRICAL PLUG RELOCATION QOH DIAGRAM 3 Locate the metal vacuum line that runs along the passenger side frame rail This line is attached to a rubber hose that connects to the vacuum actuator valve on the differential Remove the metal line s retaining screws and attach one end of the furnished vacuum line drop bracket 55 09 4530 to the frame rail using one of the original screws Carefully reform the metal line as necessary and attach it to the lower end of the 09 bracket using the supplied 1 4 x 1 bolt washer and nyloc nut 8 er EH DIAGRAM 4 DRILLING THE CROSSMEMBER FOR Q Unplug the electrical line at the vacuum THE 05 BRACKET actuator valve and release the line s plastic retaining clip on the valve bracket Reconnect the electrical line to the valve NOTE If additional slack is needed for the electrical line when the installation is
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