K271 Instructions
Contents
1. 1 7 16 thick flat washer 55 04 3205 bracket lower control arm s SAME AS ADOVE cecce 77 0005 front leg passenger side 55 05 3205 bracket upper lower control arm s rear legs driver side 2 5 8 x 5A bolt sresersicccisdscarses 77 0004 2 5 8 Nyloc nut 1 9 16 x 3 bolt 1 9 16 Nyloc nut 2 9 16 USS flat washer 4 5 8 ID 1 16 thick shim 77 0005 55 06 3205 bracket upper lower control SAME AS above 2 cceeeeeeeeeeees 77 0004 arm s rear legs passenger side 77 0005 55 03 3260 crossmember differential front 2 9 16 x 4 bolt cceeeeeeee 77 0002 2 9 16 Nyloc nut 55 04 3260 crossmember differential reaf cece cceeccceeeeseeeeeesueeeeseeeeeueeeees included FORM 3260 04 110209 PART NO DESCRIPTION Qty if more than one 55 05 3260 kicker brace driver side 55 06 3260 kicker brace passenger side 55 11 3205 Cente rlink eeeeeeeeeeeeeeeeeeeees 55 01 3213 crossmember CSS 00 55 03 3214 stabilizer link CSS driver side 55 04 3214 stabilizer link CSS passenger side 55 12 3215 wan skid Plates a osce cece ietesceai eters ieteade 55 10 3260 2 front brake hose bracket differential vent hose extension extension travel limiting2. With the control arm assembly on a floor jack raise it into position Install 5 8 x 5 4 bolt and Nyloc nut at the lower control arm rear leg attaching point This bolt points rearward and will also capture the bottom hole of the diffrential s rear crossmember Use a 5 8 x 4 7 bolt pointing forward to connect front leg of lower control arm Now mate the upper control arm to the Superlift bracket with the factory eccentric cam bolts In applications with the two bolt idler the eccentric cam bolts are supplied Be sure that the anti sway bar body is pivoted down so it is below the upper control arm s front leg NOTE 4 wheel anti lock brakes Diagram 4 The wiring harness disconnected in Step 8 must be relocated lower on the frame Drill one new hole as shown and reconnect harness FORM 3260 04 110209 PRINTED IN U S A PAGE 13 OF 20 31 QU 32 QU 33 ou 34 QU QU QU QU 35 ou AXLE SHAFTS Attach CV axle flange to differential LC 60 TORQUE BOLTS IN THIS SEQUENCE 1 OU differentials front crossmember to frame 0c0ee 2 bolts 112 2 OO diferential to front crossmembet c eceeee cece ee ee tees 2 bolts 82 3 OO differential to rear crossmembe 0ccceeeeeeeeeeeee teens 2 bolts 82 4 OU rear crossmember s top bolts to 05 and 06 brackets 2 bolts 112 5 00 rear lower control arm legs to Superlif
3. cycle the tire and hose come within one inch or closer of each other you must modify these accordingly To achieve desired clearance first bend the hose s metal leader at the FORM 3260 04 110209 PRINTED IN U S A PAGE 17 OF 20 caliper end inboard slightly If more clearance is needed locate the DIAGRAM 19 BRAKE HOSE CLEARANCE i DRIVER SIDE VIEW FROM FRONT OF VEHICLE On both sides mounting tab where the upper end of check for clearance between hose and tire wheel throughout full turning the hose mates to the hard metal line cycle with suspension laden and unladen Some tire wheel combina and carefully bend the tab downward tions will require both top and bottom of hose to be re formed as shown l Recheck brake hose fittings for leaks 47 VEHICLE SPEED SENSOR QO When different height tires are installed the speedometer must be recalibrated Consult your Superlift distributor or Superlift catalog for appropriate reprogramming device The device is sold separately and includes separate installation instructions on roy ay waa AS i7 b BEND METAL TIRE WHEEL LEADER INWARD SECTION AS NEEDED 7 ay Lael Dinim UIK ES 48 Activate four wheel drive system and check front hubs for engagement a 49 HEADLIGHTS Q Readjust headlights to proper setting 50 FRONT DRIVESHAFT NOTE Driveshaft will not clear exhaust crossover pipe Punimi QO Reroute a new section of pip
4. strap kit rear axle 85113 anenai 2 shock absorber front 85156 aaaaan 2 shock absorber rear PRINTED IN U S A PAGE 3 OF 20 NEW ATTACHING HARDWARE FOUND IN Qty HDWE PACK 1 7 10 x 1 2 bolt 77 0002 1 7 16 Nyloc nut 1 7 16 flat washer 2 3 8 Nyloc nut SAME AS ADOVE eeeceecceeeeeceeees 77 0002 2 12mm Stover nut Gd 8 8 77 0005 2 14mm Stover nut Gd 8 8 tube thread lock compound 2 9 16 X 1 Y bolticsutienesstned 77 0003 2 9 16 Nyloc nut 2 9 10 x 3 bolt 77 0003 2 9 16 Nyloc nut 2 9 16 USS flat washer 4 half bushing 2 sleeve same as ADOVE ececeeeceeeceeeeees 77 0003 4 T110 x 1 Ya bolt 77 0004 4 7 16 Stover nut 8 7 16 thick flat washer 1 3 8 x 1 DOIG isn ctactiinccnes occas 77 0025 1 3 8 Nyloc nut 1 3 8 SAE washer 1 5 16 x 3 4 bolt 1 5 16 SAE washer 1 5 16 Stover nut 3 long vent hose with coupler 77 0005 2 01 99265 strap ee 77 0021 2 2 X 1 bolt 2 2 Nyloc nut 2 2 thick flat washer 2 cable tie FORM 3260 04 110209 PART NO DESCRIPTION Qty if more than one PRINTED IN U S A Qty PAGE 4 OF 20 NEW ATTACHING HARDWARE FOUND IN HDWE PACK NOTE Your application will include only the 55 10 3205 OR 55 10 3210 not both 55 10 3205 55 10 3210 bracket 2 bolt idler arm all 1988 t
5. FORM 3260 04 110209 PRINTED IN U S A PAGE 1 OF 20 SUPERLIFT SUSPENS Superlift 4 to 6 lift system for 1988 Newer GENERAL MOTORS FULL SIZE 1 2 TON 4WD Trucks With 6 Hole Wheels up to 7300 Ib GVWR 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 Rear lift is performed first The rear lift is sold separately and includes separate installation instructions Speedometer reprogramming is necessary refer to step 47 The device is sold separately and includes separate installation instructions A special tool is required to load unload the torsion bars step 2 Other special tools are recommended to detach attach the pitman idler studs Refer to the factory service manual Front end realignment is necessary Exhaust modification is necessary refer to step 50 This system utilizes the stock torsion bars wh
6. RM BRACKETS the plugs have already been removed BRACKETS UPPER en CONTROL ARM FRONT LEG j omwe A DRIVER SIDE 55 01 3260 71 s cance UPPER CONTROL ARM Bit ee FRONT LEG PASSENGER FA lt n SIDE 55 02 3260 DIFFERENTIAL CROSSMEMBER FRONT 55 03 3260 Diagram 11 With brackets laying on the floor loosely attach the 01 and 02 bracket to the 03 front differential crossmember using 7 16 x 1 7 bolts and hardware Be sure to E diab ute A have the attaching flanges of the flange is mated to front side of STEP 24 55 02 3260 01 and 02 bracket 55 03 3260 FORM 3260 04 110209 PRINTED IN U S A PAGE 11 OF 20 25 26 QU crossmember to the front side of the 01 and 02 brackets do not tighten the 7 16 bolts at this time DIAGRAM 12 DIFFERENTIAL CROSSMEMBER Position the 3 piece crossmember bracket assembly up to the frame as shown and align the 01 and 02 brackets into the strock upper control arm mounts Connect the two using 9 16 x 3 bolts and Nyloc nuts with 1 7 8 square washers positioned on both sides of the 9 16 bolts The square washers are used to center the bolts in their slotted holes Insert factory bolts through the crossmember s upper tabs where they mate to the stock differential mounts These will be tightened later DIFFERENTIAL TO FRONT CROSSMEMBER Diagram 12 Raise the dif
7. UKON Lubricate adjuster bolt and puller threads prior to installation Position the two 55 07 3205 brackets in between the bottom of the frame rails and top of the crossmember Invert as shown the stamped steel straps that cap the rubber insulators Tighten the 7 16 x 5 1 2 center bolts and Stover nuts 18 then the outer edge 7 16 x 4 bolts 57 Bar loading sequence is the reverseof Step 2 again be careful Tighten until arms are just clearing nut blocks OR TORSION BAR CROSSMEMBER TO FRAME LINK 55 01 3265 m Diagram 18 1995 4 DOOR YUKON Insert bushing halves and sleeves into each end of the 55 01 3265 link Attach the links to the crossmember with the factory bolts but do not fully tighten yet Attach the crossmember to the links using the stock bolts pointing forward the nuts are not installed until the support cables are attached The support cables have a mounting bracket on each end On the driver side slip one of the cable s mounting brackets either end will do onto the bolt Position the mounting bracket so it points towards the front of the vehicle and is angled upwards Now torque both bottom and top link bolts 82 The other end of the cable mounts to the bottom side of the frame rail Pull the cable tight locate the mounting bracket and mark the frame Measure back 3 8 to allow some cable slack and drill a 15 32 hole for the new 7 16 x 1 1 bolt torque to 41 Install the cable on the
8. a These are trimmed second in Step 14 AFTER This piece is trimmed first in Step 12 with differential differential is removed i pivoted up and out of the way 12 TRIM FRAME 4 Diagram 5 Place a jack under the differential Remove the bolts 2 total that attach the rear of the differential to the lower control arm differential mounts on the driver and passenger sides With the two front upper differential bolts still attached raise the jack to pivot the differential upward and out of the way With a torch trim off the driver side mounting bracket shown as Section A This allows the differential to be lowered 13 REMOVE DIFFERENTIAL ASSEMBLY Q Now remove the reamaining bolts 1 bolt at top of differential on driver side 1 bolt upper axle mount to frame at passenger side Ob Now lower assembly to the floor 14 TRIM FRAME QO Diagram 5 On both sides use a torh to trim Section B from the stock lower control arm differential mount as shown represented as dotted lines This allows clearance for the differential in the relocated DIAGRAM 6 TRAVEL STOP REMOVAL and A SLOTTED HOLES position 15 TRAVEL STOPS Step 23 Some vehicles have round Q Diagram 6 On both sides unbolt the rubber compression travel stops from their stock position These stops will be reused With a torch carefully trim the steel frame mounted brackets from the frame as shown Care must be taken to cu
9. agram 13 Due to manufacturing tolerances there may be slight gaps between the bracket and the stock upper control arm mounting ears If gaps exist bridge gaps with the shims Hradware Pack 77 0005 contains 16 thin shims There should be enough shims to cover all four of the Superlift bracket to stock upper control arms attaching points BUMP STOP Diagram 14 In order to clear the shock DIAGRAM 14 Sante HOS EON absorber grind the front outside corner of the TER stock rubber compression travel bump stop to G oe match the radius of its mounting pad on 55 05 O a 3205 Then attach bump stop as shown Ji pe FRAME SIDE Repeat steps 26 through 28 on the passenger lt side J DIFFERENTIAL CROSSMEMBER REAR 55 04 3260 p Diagram 12 Reposition the jack to under the rear end of the differential Raise the jack to J 55 05 3205 rotate the differential upward as high as it will go lt lt FRT RK Position the rear crossmember by mating it onto a the two 5 8 bolts protruding through the stock rear control arm mounts as shown Once the crossmember is in place install the two 5 8 Nyloc Wore step 28 cand nuts hand tighten only Lower the jack and bump stop here for clearance differential until the rear attachment points align s0P then install the original mounting bolts 112 Cf Sf Steps 30 through 37 are performed one side at a time Start at the driver side REHANGING CONTROL ARMS
10. ap to the shock body with another cable tie This keeps the strap away from the tire wheel exhaust etc Q Diagram 21 PASSENGER SIDE As DIAGRAM 21 LIMITING STRAP PASSENGER SIDE per the diagram the new hole in the shock tower is in line with the shock centerline there is no offset The remainder of the installation is identical to the driver side refer to the steps above 52 SUPERLIFT NAME BADGE AND WARNING DECAL The system includes one 2 x 5 name badge 0034 Additional and or LIMITING STRAP A larger badges are available from Note buckle offset_ Superlift or a Superlift dealer We DN 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 QO 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 Oh Remove mounting tape backing line up badge and press in place Do not touch mounting tape or allow tape to get dirty Q 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
11. ause damage may occur 7 ANTI SWAY BAR QW Remove both anti sway bar drop links which connect bar body to lower control arms the link nuts accessed through the bottom of the arms are somewhat restricted It may be necessary to detach bar at frame first 8 CONTROL ARM HUB ASEMBLY REMOVAL QW Position a floor jack under the hub assembly Remove upper and lower control assembly to floor NOTE Vehicles equipped with 4 DIAGRAM 4 RELOCATION OF 4WAL BRAKE S wheel anti lock brakes have a wiring FRONT WHEEL WIRING HARNESS harness at each front wheel that runs On each side move bracket down approximately 3 1 4 and drill a from the frame along the control arm 9 32 hole for the mounting bracket s self tapping screw The and down to the outer axle Remove electrical connector stem now plugs into the bracket s stock hole mounting bolt then unplug connector as shown Diagram 4 A new mounting hole is drilled in step 30 Perform Steps 4 through 8 on passenger side 9 DRIVESHAFT p Detach front driveshaft at differential 3 ERNS uE and secure it out of the way STEP 30 NEW HOLE FOR BRACKET A 10 SKID PLATE A Remove differential skid plate if so oe equipped x 11 DIFFERENTIAL WIRING HOSE Q Unplug differential wiring harness and vent hose FORM 3260 04 110209 PRINTED IN U S A PAGE 7 OF 20 DIAGRAM 5 TRIMMING FRAME i ad st go S Le o ME CROSSMEMBER a a eS me
12. cles equipped with an electronic speedometer the speed signal impacts other important functions as well Speedometer recalibration for both mechanical and electronic types is highly recommended FORM 3260 04 110209 PRINTED IN U S A PAGE 20 OF 20 Do not add alter or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the Superlift product purchased Mixing component brands is not recommended All Superlift material is copyrighted All images found in this catalog and in any Superlift marketing forums are the sole property of or licensed to Superlift Any reproduction of said materials in part or in whole with out the express written permission of Superlift is strictly forbidden Superiift Rockrunner Swamprunner Superide Superide SS and SSR Black Diamond XCL X2 Super Trac Torque Max Torque Max SS eXtreme Ring Rail Wrap Bullet Proof Brake Hose TruSpeed Frame Integrated Technology F I T Series and Rock Fink are registered trademarks of Superlift Suspension Systems Superlift Suspension Systems is a Division of Bret Lovett s Lift Kits Incorporated SUPERLIFT SUSPENSION SYSTEMS 300 Huey Lenard Loop Rd West Monroe Louisiana 71292 Phone 318 397 3000 Sales Tech 1 800 551 4955 FAX 318 397 3040 www superlift com
13. e above shaft If necessary vehicle can be driven to a muffler shop with the front drive shaft completely removed Torque shaft to differential bolts 15 shaft to transfer case bolts 74 ihe eo TE 51 REAR AXLE EXTENSION TRAVEL DIAGRAM 20 LIMITING STRAP DRIVER SIDE LIMITING STRAPS and REAR SHOCK ABSORBERS Q Diagram 20 DRIVER SIDE Drill a 17 32 diameter hole in the tower as shown for the upper end of the limiting strap Locate this new hole 7 inboard of shock body centerline and 1 down from the tower s top plate x 1 BOLT Q LIL The strap s upper end bolts to the inside of X the tower with a 2 x 1 bolt thick washer LIMITING STRAP and Nyloc nut The bolt should face away Note buckleoffset from the shock Note that the strap mounting buckle has a slight offset install with offset facing away from the tower FORM 3260 04 110209 PRINTED IN U S A PAGE 18 OF 20 mating surface Do not fully tighten the bolt the buckle should be able to pivot slightly QW Bolt the upper end of the new shock to the tower using the stock bolts 20 The lower end of the limiting strap anchors to the shock mount at the axle via the stock shock bolt The strap buckle mates to the wheel outside side with the buckle offset facing away from the shock body Torque the lower shock bolt 81 QIU Pull the strap tight against the shock body so that all strap slack is above the body Anchor the str
14. e crossmember and install a 7 16 x 1 1 2 bolt flat washer and Nyloc nut position the flat washer a gt N inside the crossmember se 37 At the outboard holes install the 9 16 X 1 bolts pointing downward These outboard cossmember holes exist on most but not vehicles If drilling or reaming is necessary use a 19 32 drill bit These bolts also capture the Centerlink Stabilizing System CSS e 55 04 3205 mount so do not install nuts DIAGRAM 10 VIEW FROM DRIVER SIDE a LOWER TUBE OF CENTERLINK css CROSSMEMBER FRONT CROSSMEMBER y MOUNT 55 01 3213 9 16 X 1 1 2 Diagram 10 Mate the 01 bracket onto the 9 16 x 1 7 bolts installed in the previous step Be sure that the bracket face where the links will NOTE ultimately attach is angled ee towards the centerlink as A rear with shown Now install the 9 16 ped etches sis Stover nuts 110 The CSS pointing liks are not attached until Step outward 22 FORM 3260 04 110209 PRINTED IN U S A PAGE 10 OF 20 21 22 23 24 SUPERLIFT CENTERLINK 55 11 3205 Diagram 8 Unless a special seating tool is used refer to factory service manual the new pitman idler arm to center link nuts 40 must be initially snugged up with an impact wrench This is necessary because unless tightened rapidly the locking nuts cause the tapered studs to rotate in their sockets Use the furnished 14mm lock nuts the st
15. e floor Record this as Measurement A OO Now measure from the inside edge of 1 af BOTTOM OF DRIVER the knuckle at the lower ball joint 7 SIDE FRAME RAIL boss down to the floor Record this as Measurement B Subtract Measurement B from A for the ride height figure Minimum ride height is 3 08 maximum is 5 0 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 46 FINAL CLEARANCE and TORQUE CHECK QIU 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 n Diagram 19 If stock wheels are being used or wheels with the same or greater positive offset the distance between the tire side wall and the brake hose will be minimal and must be checked closely Normally the hose and tire will be closest to making contact when the tire wheel is in a turn Cycle the steering left to right full lock If at any point during the turning
16. ed 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 A factory service manual should be on hand for reference e Use the check off box Q found at each step to help you keep your place Two UIQ 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 FOUND IN Qty if more than one Qty HDWE PACK 55 01 3260 bracket upper control arm s 1 9 10 X32 Dolluatwasanas 77 0001 front leg driver side 1 9 16 Nyloc nut 2 1 7 8 sq washer 1 8 thick 2 7 16 x 1 bolt 2 7 16 Stover nut 4 5 8 ID 1 16 thick shim 77 0005 1998 1992 models only 2 CAMDOME es cotesiees vets cues code ceraeeriane 77 0008 55 02 3260 bracket upper control arm s SAME AS above ceceeeeeeeeeeeeeees 77 0001 front leg passenger side 77 0005 77 0008 55 03 3205 bracket lower control arm s 1 5 8 x 4 Y bolt nasses 77 0005 front leg driver side 1 5 8 Nyloc nut 1 7 16 x 1 1 2 bolt 1 7 16 Nyloc nut
17. ferential into position with a floor jack Insert two 9 16 x 4 bolts into the differential to front crossmember mounts hand tighten only This differential mounting hardware is tightened later Keep the jack loaded into position The differential s rear crossmember is installed in Step 29 Steps 26 through 28 are performed one side ata time Start at driver side BRACKET UPPER LOWER CONTROL ARM S REAR LEGS DRIVER SIDE 55 05 3205 Diagram 11 Locate and check fit the bracket Now bolt the bracket to frame at the stock lower control arm mounting point Use furnished 5 8 x 5 74 bolt pointing rearward Do not install Nyloc nut at this time At the top mounting point with the slotted holes insert the furnished 9 16 x 3 bolt and Nyloc nut pointing forward Place the USS flat washers behind te bolt head and nut Hand tighten only NOTE There may be a clearance problem in the area where the travel stop was cut from the frame If so heat and dimple the frame inward to gain the needed clearance NOTE The number of shims required varies per vehicle and per side But always make sure that the number and positioning of the shims is the same for both front and rear legs FORM 3260 04 110209 PRINTED IN U S A PAGE 12 OF 20 QU 27 a0 28 QU 29 30 ou QU QU QU At the bracket s top mounting points shimming is required see next step SHIMMING BRACKETS Di
18. fits between the idler arm and its frame mounting point The arm is accessed by partially removing the passenger side inner fender NOTE On vehicles equipped with an airbag the airbag sensor is Icated on the side of the frame near the holes for the idler arm bolts USE CAUTION If struck the airbag may deploy or malfunction DIAGRAM 8 IDLER ARM SPACER 3 BOLT IDLER SPACER 2 BOLT IDLER SPACER yrs Ios IDLER ARM NOTE _ TORQUE SEQUENCE Q p TN FORM 3260 04 110209 PRINTED IN U S A PAGE 9 OF 20 For vehicles with the 3 bolt idler arm 55 10 3210 bracket installs with three 7 16 x 2 bolts thick flat washers and Stover nuts LC 57 NOTE After hand tightening nuts must be torqued in this sequence 1 rear bottom 2 front 3 rear top OR For vehicles with the 2 bolt idler arm 55 10 3205 bracket installs with two 7 16 x 2 bolts thick flat washers and Stover nuts LC 57 19 20 BRACKETS LOWER CONTROL ARM S FRONT LEG DRIVER SIDE 55 03 3205 LOWER CONTROL ARM S FRONT LEG PASSENGER SIDE 55 04 3205 Diagram 9 Each bracket attaches to the stock lower control arm s front leg mount using the stock bolt pointing rearward Each bracket attaches to the frame s front crossmember with the two bolts one inboard and one outboard At the DIAGRAM 9 LOWER CONTROL ARM BRACKET FRONT LEG PASSENGER SIDE 55 04 3205 x XY x yY inboard hole drill a 15 32 hole into th
19. hrough 1991 models some 1992 and 1993 models OR bracket 3 bolt idler arm some 1992 and 1993 models all 1994 and newer models 2 7 16 x 2 bolt 2 7 16 Stover nut 2 7 16 thick flat washer 3 7 16 x 2 bolt 3 7 16 Stover nut 3 7 16 thick flat washer NOTE Your application will include only the 55 07 3260 OR 55 01 3265 not both 2 bracket torsion bar crossmember 2 7 16 x 5 7 bolt 55 07 3260 55 01 3265 All models except 1995 4 door Yukon Tahoe Short Wheel Base OR 2 link torsion bar crossmember 1995 4 door Yukon Tahoe Short Wheel Base 4 7 16 x 4 bolt 6 7 16 Stover nut 12 7 16 thick flat washer 7 16 x 1 bolt 7 16 Nyloc nut 7 16 flat washer 7 16 x 2 bolt 7 16 Stover nut 7 16 thick flat washer support cable bushing half sleeve 2 2 2 2 2 2 2 2 2 FRONT PROCEDURE 1 a 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 and chock rear tires Remove front tires 2 UNLOADING THE TORSION BARS WARNING Be extremely careful when loading or unloading the torsion bars there is a tremendous amount of stored energy in the bars Keep your hands and body clear of the adj
20. hts that vary from state to state For example while all implied warranties are disclaimed herein any implied warranty required by law is limited to the terms of our Limited Lifetime Warranty as described above Some states do not allow limitations of how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequential damages so the limitations and exclusions herein may not apply to you Important Product Use and Safety Information Warnings As a general rule the taller a vehicle is the easier it will roll over Offset as much as possible what is lost in rollover resistance by increasing tire track width In other words go wide as you go tall Many sportsmen remove their mud tires after hunting season and install ones more appropriate for street driving always use as wide a tire and wheel combination as feasible to enhance vehicle stability We strongly recommend because of rollover possibility that the vehicle be equipped with a 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 performance and capabilities are decreased when significantly larger heavier tires and wheels are used Take this into consideration while driving Also changing axle gear ratios or using tires that are taller or shorter than factory height will cause an erroneous speedometer reading On vehi
21. ich normally yield the best ride quality But if the final product ride and handling seem too soft heavier Gross Vehicle Weight Rating GVWR bars can be installed Generally heavier torsion bars are only needed to compensate for the extra weight of a winch or snowplow or when the truck is subjected to extreme off road use Also wider tires and wheels proportionally increase the leverage on the bars which results in lower ride height and a spongier ride GM offers torsion bars with various rates that are heavier than stock Your vehicle s existing torsion bar rate can be identified by a 3 letter code stamped into the bars ends The code is also on an adhesive tag wrapped around the bars 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 FORM 3260 04 110209 PRINTED IN U S A PAGE 2 OF 20 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 rat
22. m straighten out the bends as needed to allow the factory brake line bracket to mate with the Superlift bracket DO NOT kink the line Attach the factory brake line bracket to the Superlift brake line bracket align the bolt hole with the upper hole and the tab with the lower hole Secure with the supplied 5 16 x 3 4 bolt washer at bolt head and Stover nut 200 In Lbs Install bolt from the top TIE ROD END INNER Attach inner tie rod end to centerlink with furnished 12mm Stover nut 40 Do not reuse the stock nut Unless a special seating tool is used refer to factory service manual the tie rod end to centerlink must be initially snugged up with an impact wrench FORM 3260 04 110209 PRINTED IN U S A PAGE 14 OF 20 36 DIFFERENTIAL WIRING DIAGRAM 16 SUPERLIFT SKID PLATE LJ Reconnect differential s electrical plug and aeie A a vent hose 37 ANTI SWAY BAR LINKS n Reinstall stock anti sway bar drop links Tighten drop link bolts only until bushings swell slightly Repeat steps 30 through 37 on passenger side 38 SKID PLATE 55 12 3215 QO Diagram 16 Skid plate attaches as shown with stock bolts 57 at the front frame crossmember and new 7 16 hardware 57 at the stock skid plate attaching points The FRONT OF STOCK SKID stock skid plate then bolts to the rear Superlift PLATE ATTACHES HERE crossmember with the supplied 7 16 hardware 57 If vehicle is not equipped with facto
23. member to frame links The four link bolts will be reused u On vehicles with stock exhaust it may be necessary to DIAGRAM 2 4 DOOR YUKON jack up exhaust to allow clearance for crossmember TORSION BAR CROSSMEMBER removal With the crossmember out of the way the bars can be dislodged from the lower control arms and T3 removed Mark the bars front rear end and driver TOP BOLT SS passenger side and keep them seperated because CROSSMEMBER A i they must be reinstalled on the same side and in the T same front rear direction as they were removed 25 TORSION E j Steps 4 through 8 are performed one side at a time BAR o gt an Start at the driver side CROSSMEMBER 4 BRAKE HOSE n At drivers side front use vise grips or a small C clamp to pinch closed the rubber brake hose which runs from caliper to frame Detach hose from caliper Plug or cover the caliper opening to prevent contamination OERE R FORM 3260 04 110209 PRINTED IN U S A PAGE 6 OF 20 5 AXLE SHAFT OO Remove the 6 bolts that attach CV axle DIAGRAM 3 CENTERLINK COMPARISON flange to differential 6 INNER TIE ROD n Diagram 3 The stock centerlink is shown Using special puller tool refer to factory T service manual detach inner tie rod ends NOTE Pitman and idler tabs point towards from centerlink rear of vehicle NOTE Do not hammer on linkage or use a STOCK pickle fork or wedge type tool to dislodge bec
24. ock nuts must not be reused CSS STABILIZER LINK DRIVER SIDE 55 03 3214 CSS STABILIZER LINK PASSENGER SIDE 55 04 3214 Diagram 10 Coat the sleeves OD with a light Lithium based grease Insert link eye bushings and sleeves into link eyes Position the centerlink installed in Step 21 so that the tires if they were on the vehicle would be pointing straight ahead Loosely connect the links to the CSS mount Do not tighten the 9 16 x 3 bolts yet Connect the passenger side link to centerlink tab first If the holes are misaligned turn the steering wheel in either direction until hole alignment is achieved Then return the centerlink to the centered position Prior to tightening be sure that the links are facing straight ahead parallel to the pitman and idler arms and that their eye bushing flanges seat flush no gaps against all mating surfaces If gaps exist slightly bend the tabs or bracket as necessary to close the gaps Torque all link eye bolts 65 Re torque all CSS hardware Lubricate eye bushings via grease fittings STOCK UPPER CONTROL ARM HANGERS Diagram 6 The hangers have slotted holes that allow them the control arms to be moved in or out to achieve front end alignment by adjusting the eccentric cam bolts On some models the slot must be opened up by knocking out a perforated plug If the vehicle has been aligned previously odds are that DIAGRAM 11 DIFFERENTIAL S FRONT CROSSMEMBER CONTROL A
25. on modification or failure to maintain e Normal wear and tear bushings tie rod ends etc Scratches or defects in product finishes powdercoating plating etc e Damage to or resulting from vehicle s electronic stability system related components or other vehicle systems e Racing or other vehicle competitions or contests Accidents impact by rocks trees obstacles or other aspects of the environment e Theft vandalism or other intentional damage Remedy Limited to Repair Replacement The exclusive remedy provided hereunder shall upon Superlift s inspection and at Superlift s option be either repair or replacement of product or parts covered under this Limited Warranty Customers requesting warranty consideration should contact Superlift by phone 1 800 551 4955 to obtain a Returned Goods Authorization number All removal shipping and installation costs are customer s responsibility If a replacement part is needed before the Superlift part in question can be returned you must first purchase the replacement part Then if the part in question is deemed warrantable you will be credited refunded Other Limitations Exclusion of Damages Your Rights Under State Law e Neither Superlift nor your independent Superlift dealer are responsible for any time loss rental costs or for any incidental consequential or other damages you may have e This Limited Warranty gives you specific rights You may also have other rig
26. passenger side Lubricate adjuster bolt and puller threads prior to installation Bar loading sequence is the reverse of Step 2 again be careful Tighten until arms are just clearing nut blocks 43 TIRES WHEELS DIAGRAM 17 TORSION BAR CROSSMEMBER factory specifications WARNING When the tires wheels are installed always check for and remove any A RUBBER y corrosion dirt or INSULATOR ee foreign material on the i 0 T wheel mounting see Sy S surface or anything 4 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 FORM 3260 04 110209 PRINTED IN U S A PAGE 16 OF 20 WARNING Retighten lug nuts at 500 m DIAGRAM 18 4 DOOR YUKON TORSION BAR are loosened Failure to do so could cau CROSS MEMBER een VAN Q Lower vehicle to the floor 44 REAR LIFT Q The rear lift is purchased separately and has separate instructions Install now 45 ADJUSTING FRONT RIDE mer 4 D 4 HEIGHT La A A SUPPORT QO Manually bounce the front and rear of a RY J Ei vehicle to normalize the torsion bars wars F and leaf springs l On each side fully tighten the LCA to crossmember bolts 156 QIU Position the vehicle on a level surface Measure from the LCA front pivot bolt center down to th
27. ry skid plate order GM Part 15538494 from your local GM dealer 39 CLEARANCE CHECK Q With vehicle still on jack stands and suspension hanging at full extension travel cycle steering lock to lock and check all components for proper operation clearances Diagram 15 shows the work completed so far 40 BRAKES Q Thoroughly bleed air from brake system as per the GM Service Manual 41 KICKER BRACE DRIVER SIDE 55 05 3260 KICKER BRACE PASSENGER SIDE 55 06 3260 Q Install the kicker brace at the rear Superlift crossmember using the supplied 5 16 Nyloc nuts do not tighten at this time The rear of the brace is then attached to the existing holes in the transmission crossmember with the supplied 7 16 hardware Tighten the Superlift crossmember end first 57 then the transmission crossmember end 57 42 TORSION BARS CROSSMEMBER LJ Insert the front end of the torsion bars into the lower control arms Be sure the bars are positioned front rear end driver passenger side in their original configuration The rear of the bar ends are now hanging Q This step is a 2 man operation With the crossmember balanced on a floor jack raise it to mate with the hanging bar ends Now locate the adjuster arms inside the crossmember and onto the bar ends FORM 3260 04 110209 PRINTED IN U S A PAGE 15 OF 20 TORSION BAR CROSSMEMBER BRACKET 55 07 3205 m Diagram 17 ALL MODELS EXCEPT 1995 4 DOOR Y
28. t brackets 2 bolts 112 These bolts also capture the two bottom holes on the differential s rear crossmember 6 OQ front lower control arm legs to Superlift brackets 2 bolts 112 7 QU Superlift brackets to stock upper control arm mounts 4 bolts 82 8 OU front crossmember to 01 and 02 brackets 0608 4 bolts 57 9 00 cam bolts at upper control arm to Superlift brackets 4 bolts 75 90 NOTE Before tightening adjust cams to a neutral or centered position Check axle flange centerlink and diferential clearances SHOCK ABSORBER FRONT 85101 Torque upper and lower bolts 48 Cycle suspension through full travel cycle and check for adequate clearance between shock bump stop and brake hose BRAKE HOSE BRACKET Diagram 15 Locate the brake hose retainer on the frame rail and diconnect the brake hose from the clip Remove the brake hose bracket from its ave ai attachment point on top of the factory front upper ee 10260 control arm leg mounting bracket i yi y i Position the short side one hole of the Superlift brake hose bracket SL 55 10 3260 to the bottom side of the factory upper control arm mount and align so that it is parallel with the center of the upper control arm Secure the bracket with the supplied 3 8 x 1 bolt washer at bolt head and Nyloc nut 30 Install the bolt from the top Carefully re for
29. t these brackets as close to the frame as possible to allow clearance for the Superlift relocation hardware that is installed later Grind clean all cutting slag from the trimming performed in steps 12 14 and 15 and lightly coat all holes here with perforations that knock out to form slots STOCK UPPER CONTROL ARM MOUNTS DRIVER SIDE FRAME RAIL _S Step 15 Cut travel stop from frame STOCK LOWER CONTROL ARM REAR LEG MOUNT FORM 3260 04 110209 PRINTED IN U S A PAGE 8 OF 20 bare metal surfaces with a spray on rust inhibitor 16 CENTERLINK REMOVAL Q Using special puller tool refer to factory service manual detach center link from pitman and idler arm studs NOTE Do not use a pickle fork or wedge type tool because seal or bushing damage may occur Also do not hammer on pitman arm shaft or puller because damage to arm steering gear may result 17 ANTI SWAY BAR DIAGRAM 7 ANTI BAR Remove the bar body from the frame and re install with ee the ends switched and flipped from side to side so E Diagram 7 Detach anti that the bar steps DOWN instead of of up egi Ty PASSENGER SIDE FRAME RAIL sway bar body from frame Reinstall with ends inverted or switched so that the bar body steps down instead of up Tighten sway bar to frame bolts 12 ah ae HIDDEN LINES SHOW STOCK _ 18 IDLER ARM SPACER Se E R er ce u Diagram 8 The spacer ia gla INVERTED POSITION
30. uster arm assembly and puller tool in case anything slips or breaks NOTE For safe removal installation of the adjuster arms a special puller tool is required Because of the tremendous loads generated a standard 2 jaw gear puller tool tends to bend down te crossmember lips where it attaches and pops out of place If not found locally this special puller tool is available from Kent Moore Tool Group Roseville MI PH 800 345 2233 or 313 774 9500 J 22517 C Diagram1 On either side remove the torsion bar aligning screw Apply light lubricating grease to the puller threads and the puller shaft to adjuster arm contact point Position puller FORM 3260 04 110209 PRINTED IN U S A PAGE 5 OF 20 and load adjuster arm so the adjuster nut can be removed from crossmember With the bar unloaded slide it forward onto the lower control arm If the bar seems lodged use a hammer and punch routed through the hole in the back of the crossmember to drive it forward When the bar shifts forward the adjuster arm will fall free DIAGRAM 1 TORSION BAR LOADING i e n e M A FRAME RAIL Z meee i 7N q RIVER SIDE TORSION BAR CROSSMEMBER D driver side 3 TORSION BAR CROSSMEMBER Q All models except 1995 4 door Yukon The crossmember connects to the frame with three bolts per side Remove and discard these bolts OR QO 1995 4 door Yukon Diagram 2 Remove the two stock cross
31. with any glass cleaner Installthe 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 FORM 3260 04 110209 PRINTED IN U S A PAGE 19 OF 20 53 ALIGNMENT Realign vehicle to factory specifications 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 Limited Lifetime Warranty Warnings Your Superlift product is covered by the Limited Warranty explained below that gives you specific legal rights This limited warranty is the only warranty Superlift makes in connection with your product purchase Superlift neither assumes nor authorizes any retailer or other person or entity to assume for it any other obligation or liability in connection with this product or limited warranty What is covered Subject to the terms below Superlift will repair or replace its products found defective in materials or workmanship for so long as the original purchaser owns the vehicle on which the product was originally installed Your warrantor is LKI Enterprises Inc d b a Superlift Suspension Systems Superlift What is not covered Your Superlift Limited Warranty does not cover products parts or vehicles Superlift determines to have been damaged by or subjected to Alterati
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