K776 Instructions
Contents
1. a portable band saw or cut off wheel remove the driver side upper mounting ear on the differential housing as shown It is also necessary to slightly trim the metal plate on the side of the differential as indicated Using the same cutting tool trim approximately 1 4 off of the ribbing on the driver side of the differential as indicated in Diagram 4 DIFFERENTIAL DIAGRAM 5 INSTALLING THE 55 01 3140 DIFFERENTIAL INSTALLATION BRACKET View is from the passenger side of the differential DIAGRAM 5 Install the factory ear was supplied bushings and _ __ A removed here sleeve in the driver side AO SS OR i upper differential bracket s i KS 55 01 3140 Install the i oes lt gt Ye bracket on the differential BE housing as shown using the factory hardware Tighten 35 WARNING Failure to use a torque wrench when tightening the differential housing bolts may result in warping or cracking the housing Position the passenger side differential bracket 55 02 3140 against the factory mount on the frame with the tall end facing the front of the vehicle and the open side facing the center of the vehicle Attach it to the factory mount using the supplied 1 2 x 1 1 2 bolt in the forward hole and the 1 2 x 1 1 4 bolt in the rearward hole The bolts should be installed front the top and the supplied 1 2 USS flat washers should be positioned under the 1 2 nyloc nuts Do not tig2. 55 06 3140 and loosely REMOVING THE EXTENSION STOPS attach it to the factory front lower control arm mounts as shown Using the crossmember as a template mark the area on the frame to be trimmed flush with the crossmember do not remove the welded portion of the frame Remove the crossmember and use a torch or plasma DRIVER SIDE cutter to trim off the marked areas FRAME RAIL DIAGRAM 1 Remove the extension 3 IS stops from the frame brackets for the yy r ayy upper control arms 4 A Grind any rough areas smooth and paint any exposed metal surfaces Temporarily install the centerlink 55 03 3140 on the pitman and idler arms and cycle the steering lock to lock in order to check tor adequate csaranes bereen DIAGRAM 2 TRIMMING THE DRIVER SIDE LOWER DIFF the centerlink and the frame MOUNT Follow the steps to weld in the 55 13 3140 reinforcement Additional trimming may be necessary plate but do not perform final welding until differential has been to gain adequate clearance aE OR alec a DIAGRAM 2 Following the cut lines shown remove the driver side lower PA i ow differential mount located on the frame priversipe mount for the lower control arm s rear FRAME RAIL leg V X cut pieces Test fit the supplied reinforcement plate 55 13 3140 as shown It may be necessary to trim the plate slightly to ensure a proper fit Once the frame and plate are properly prepped for later welding
3. Detach the rubber brake hose from the metal line Plug both ends to minimize fluid loss Diagram 9 Loosely install the rotor and caliper assembly on the knuckle using the factory hardware Route the brake hose under the upper control arm but above the CV axle as shown FORM 3145 03 110209 PRINTED IN U S A PAGE 15 OF 23 QU QU QU QU QU QU QU QU QU QU 24 NOTE Using a line DIAGRAM 9 BRAKE LINE EXTENSION INSTALLATION wrench is recommended BRAKE HOSE AND ABS WIRE ROUTING for all brake line connections Unclip the brake line from the bracket securing it to the side of the frame and unbolt the bracket from the frame brake line ABS attachment Attach a brake line bracket 55 28 3120 to the frame in the same location as the factory bracket that was just removed and as shown in Diagram 9 Use the note brake line routing factory hardware and l under upper control arm tighten 10 Install the appropriate female female adapter fitting 47 3120 or 48 3120 on one end of each brake line extension 45 3120 or 46 3120 Tighten using a line wrench Connect the female end of the 45 or 46 brake line extension to the metal brake line at the frame Verify that the rubber brake hose is still routed under the upper control arm then connect the male end of the extension to the rubber brake hose and tighten both connections Secure the factory brake line support bracket to th
4. tack weld the reinforcement bracket in place Do not completely weld the reinforcement plate at this time The differential must be test fit first and final welding will occur in a straighten flared edge later step FORM 3145 03 110209 PRINTED IN U S A PAGE 9 OF 23 12 FRONT CROSSMEMBER C S S AND CENTERLINK NOTE These components must be installed on the vehicle as an assembly CAUTION Prior to beginning assembly check the idler and pitman arms for signs of wear or excessive play If it is possible to spin the studs with your fingers or there is play evident in the idler pivot arm replace the worn components before proceeding It has been noted that excessive idler arm wear is common on these vehicles even if they show relatively low miles Superlift recommends replacing the idler arm if any play is evident and or if the vehicle shows in excess of 50 000 miles Failure to replace worn steering components will result in undesirable and dangerous steering characteristics QO Lubricate and install the bushing halves and sleeves for the C S S link 55 04 3140 Also install the knock in grease fittings in each of the link s ends DIAGRAM 3 THE CROSSMEMBER C S S AND UO DIAGRAM 3 Attach the C S S GENTERLINK ASSEMBLY These components must link to the front crossmember be installed on the vehicle as an assembly View is from 55 05 3140 using the supplied the front 1 2 x 3 hex head bolt 1 2 washer
5. 4 nyloc nut 2 1 1 1 1 1 shock mount spacer 55 20 3140 2 oe lower front shock bracket rear passenger side 55 21 3140 oe anti sway bar drop bracket 2 3 8 x 1 bolt front driver side 4 USS flat washer 2 3 8 nyloc nut 55 22 3140 ee eee anti sway bar drop bracket 2 3 8 x 1 bolt front passenger side 4 USS flat washer 2 3 8 nyloc nut 55 28 31 20 2 0 2 brake line bracket front 4 1 4 x 1 1 4 bolt 8 1 4 flat washer 4 1 4 nyloc nut 45 3120 eenn 2 brake line extensions front 3 8 fittings 1995 1997 46 3120 2 brake line extensions front 7 16 fittings 1998 2001 47 3120 2 3 8 female female adapter 48 3120 2 7 16 female female adapter differential vacuum solenoid 2 5 16 x 1 self tapping bolt relocation hardware 3 zip tie 55 23 3140 csiscecescctecige 2 rear spring pad bracket 55 24 3140 oo 2 rear U bolt plate 55 30 3140 oe rear brake hose junction block keeper FORM 3145 03 110209 PRINTED IN U S A PART NO DESCRIPTION Qty if more than one 55 23 3120 oes lower shock bracket 0 driver side rear 55 24 3120 eeee lower shock bracket 00 passenger side rear 55 21 7055 iain emergency brake cable extension bracket 55 35 3120 es aes 2 rear brake line bracket B9400 E T rear br
6. DIAGRAM 11 Position the gt os i a a arm in the TTE 5 OSETIA samm pee adjuster arm torsion bar crossmember JD oe or r AX adjuster re x boet bot Line up the marks made during removal for the torsion FORM 3145 03 110209 PRINTED IN U S A PAGE 17 OF 23 QU 26 QU bar lower control arm and adjuster arm then torsion bar rearward into the adjuster arm Position the special puller tool used during disassembly Load the puller bar and install the adjusting bolt and nut block Use extreme caution while the bar is under load Unload and remove the puller then thread the adjuster bolt into the nut until the arm is raised approximately 1 4 off of the nut Final ride height adjustments are made after the installation is complete VACUUM SOLENOID RELOCATION DIAGRAM 12 Position the vacuum solenoid on the inside of the passenger veciumeciangia DIAGRAM 12 RELOCATING THE VACUUM SOLENOID 5 16 x 3 4 frame rail just in front of the idler arm as A QTV cetttanping Ear IN Ne indicated Mark and drill two 9 32 holes in the frame then secure the solenoid using the supplied 5 16 x 3 4 self tapping bolts Use caution to avoid overtightening the bolts 10 idler arm Reconnect the vacuum hose and actuating cable to the solenoid Use the supplied zip PASSENGER SIDE ties to secure the cable away from any heat ee eee sources or moving parts eee Reconnect the electrical plug to th
7. NOTICE TO DEALER AND VEHICLE OWNER section below 43 ALIGNMENT Q 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 e Alteration 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
8. and nyloc nut The bolt 55 03 3140 should be installed from the top Sih cs Do not tighten at this time carriage R gt QO Attach the other end of the 3 4 OD x C S S link to the centerlink 55 1 3 4 03 3140 using the supplied 1 2 x 3 carriage bolt 1 2 washer and nyloc nut as shown in Diagram 3 The bolt must be installed from the top Do not tighten at this time Q With the help of an assistant raise the crossmember C S S and centerlink assembly into place Attach the centerlink to the pitman and idler arms using the factory hardware Attach the crossmember to the factory front lower control arm mounts using the factory LCA hardware which is installed from front to rear Install the two supplied 10mm x 20mm bolts through the bottom of the 05 crossmember and into the threaded factory holes in the bottom of the frame Do not tighten any hardware at this time 55 05 3140 Q Tighten the factory nuts on the pitman and idler arms 45 Install the supplied cotter pins if the factory nuts are castellated Q Cycle the steering once more to ensure the centerlink has adequate clearance from the frame FORM 3145 03 110209 PRINTED IN U S A PAGE 10 OF 23 13 QU QU 14 QU QU QU DIFFERENTIAL DIAGRAM 4 DIFFERENTIAL MODIFICATIONS Trim the MODIFICATIONS e i differential housing upper mount and ribbing using a cut off wheel DIAGRAM 4 Using or similar tool none j
9. between the 07 bracket and the frame where the hole was drilled in order for the bracket to sit properly on the frame Install the supplied 7 16 x 1 1 4 bolt washer FORM 3145 03 110209 PRINTED IN U S A PAGE 12 OF 23 16 17 18 and 7 16 tab nut through the 07 bracket 1 2 USS washer if necessary and frame Do not tighten at this time Attach the passenger side UCA drop bracket 55 08 3140 using the same hardware specified for the driver side bracket However note there is a recess in the frame where the 7 16 hole must be drilled Insert the supplied 1 OD x 5 8 long spacer sleeve between the frame and 08 bracket to fill this recess Once the hole is drilled install the supplied 7 16 x 1 3 4 bolt with a washer through the 08 bracket sleeve and frame and secure with the supplied 7 16 tab nut Do not tighten at this time UPPER CONTROL ARM BRACKET CROSSMEMBER Position the upper control arm bracket crossmember 55 10 3140 between the 07 and 08 UCA drop brackets Attach the crossmember to the 08 passenger side bracket using the supplied 3 8 x 1 bolts washers and nyloc nuts DIAGRAM 7 Position the DIAGRAM 7 INSTALLING THE 55 10 3140 Position the supplied spacer plate between spacer plate between the UCA bracket and 10 bracket then the crossmember and 07 secure using 3 8 x 1 1 4 bolts driver side UCA bracket and install t
10. 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 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 FORM 3145 03 110209 PRINTED IN U S A PAGE 23 OF 23 or for any incidental consequential or other damages you may have e This Limited Warranty gives you specific rights You may also have other rights that vary from state to state For example while all implied warranties are disclaimed herein any implied warranty required by law is limited
11. the leaf pack together SA es fear epring then carefully remove the center bolt a5 7 16 x 3 1 4 NOTE Verify the spring pack is fully compressed before installing the new bolt Insert the supplied tie bolt through the spring pack The bolt should be installed so that the head is at the bottom of the spring pack Install and tighten the supplied 3 8 fine thread nut 23 Remove the C clamps and trim the i ii excess length of the tie bolt using a b 55 35 3120 hacksaw or cutoff wheel On each side loosen the front spring FONT hanger bolt and remove the spring to shackle bolt Swing the leaf springs down and let them hang from the front hanger Lower the rear axle to facilitate reinstalling the springs above the axle Reinstall the springs in the shackles using the factory hardware but do not fully tighten at this time SPRING PADS NOTE The Superlift spring pads 55 29 3120 are indexed off the factory pads attached to the axle Be sure the underside of the factory pads opposite where the springs were attached are free from dirt and other debris before continuing Also be sure the areas on the axle tubes are prepped for later welding DIAGRAM 13 Examine the supplied rear spring pads 55 23 3140 You will note that one end of each pad is taller than another Index the 23 spring pads on the axle tubes and inside the factory pads so that the tall end faces the rear of the vehicle as shown NO
12. 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 vehicles equipped with an electronic speedometer the speed signal impacts other important functions as well Speedometer recalibration for both mechan
13. tray in place and remove the tray Save all hardware for reuse FORM 3145 03 110209 PRINTED IN U S A PAGE 6 OF 23 E 3 QU QU QU 5 aa QU QU 6 QU 7 aa 8 Locate the vacuum solenoid that actuates the front differential Carefully disconnect the cable from the solenoid as well as its mounting bracket and remove the screws holding the solenoid and bracket to the inner fenderwell Save all components and hardware for reuse UNLOADING THE TORSION BARS WARNING Be extremely careful when loading and unloading the torsion bars there is a tremendous amount of energy stored in them Keep your hands and body clear of the adjuster arm assembly and the puller tool in case anything slips or breaks Mark the torsion bars to indicate their indexing in relation to the lower control arms and the adjuster arms A special torsion bar puller tool is required to unload the torsion bars refer to Diagram 11 Use the tool to load the torsion bar then remove the adjusting bolt and nut block Unload the bar slide the adjuster arms out of the crossmember then slide the torsion bars forward into the lower control arms NOTE Because of the extreme loads generated by the torsion bars on these vehicles a standard two jaw puller tool tends to bend the lips of the crossmember which it uses for attachment and may pop out of place We have had the best results using a C clamp type puller tool If one cannot be fou
14. 19 ANTI SWAY BAR DROP BRACKETS n Attach the anti sway bar drop brackets 55 21 3140 driver side and 55 22 3140 passenger side to the factory anti sway bar attachment points on the frame using the supplied 3 8 x 1 bolts washers and nyloc nuts Do not tighten at this time 20 LOWER SHOCK BRACKETS NOTE Perform the following steps one side at a time Start on the driver side QW Diagram 8 Position the front lower shock bracket DIAGRAM 8 LOWER SHOCK MOUNT ASSEMBLY 55 19 3140 1 and rear View is of the Driver Side lower shock bracket 55 19 3140 2 against the factory l 85070 mount on the lower control arm as shown using the supplied 1 2 x 2 1 2 bolt 3 4 OD x 1 1 4 long sleeve 55 19 3140 2 and 1 2 stover nut Do not 1 2 X 2 1 4 QD n ji tighten at this time laa bS nen eer al piate edt V QO The 1 4 hole in the 19 1 sy ee rme and 19 2 brackets should q _ 55 19 3140 1 gt 7 be lined up Using the brackets as a template drill a 1 4 hole in the factory LCA shock mount Insert the supplied 1 4 x 1 bolt washer and nyloc nut and tighten 13 3 4 OD x 1 1 4 Q Repeat these steps with the 55 20 3140 1 and 55 20 3140 2 brackets on the passenger side 21 CONTROL ARM ASSEMBLY NOTE If the optional stainless steel brushguard has been purchased the 55 16 3140 brush guard crossmember will be needed for installati
15. 5 06 3140 rear crossmember 55 07 3140 aves upper control arm drop bracket driver side NEW ATTACHING HARDWARE Qty if more than one 2 bushing half bushing half 3 4 OD x 1 3 4 sleeve 1 2 x 3 carriage bolt 1 2 x 3 bolt 1 2 SAE washer 1 2 nyloc nut 3 16 knock in zerk fitting 14mm x 110mm socket head bolt 14mm lock nut 10mm x 20mm bolt 3 8 SAE flat washer 9 16 x 3 1 2 bolt 9 16 SAE washer 9 16 nyloc nut 14mm x 100 mm bolt 14mm lock nut 9 16 SAE flat washer 1 OD x 2 sleeve 12mm x 100mm bolt 12mm lock nut special square washer 7 16 x 1 1 4 bolt 7 16 flat washer 7 16 tab nut 3 8 x 1 bolt 3 8 USS washer 3 8 nyloc nut 1 2 USS washer 9 16 USS washer 1 1 2 OD x 2 1 4 sleeve zip tie cotter pin FORM 3145 03 110209 PRINTED IN U S A DESCRIPTION Qty if more than one upper control arm drop bracket passenger side upper control arm bracket crossmember belly PaM iian eae torsion bar drop bracket driver side torsion bar drop bracket passenger side lower front shock bracket front driver side PAGE 3 OF 23 NEW ATTACHING HARDWARE Qty if more than one 2 12mm x 100mm bolt special square washer 7 16 x 1 3 4 bolt 7 16 flat washer 7 16 tab nut 3 8 x 1 bolt 3 8 USS
16. FORM 3145 03 110209 PRINTED IN U S A PAGE 1 OF 23 SUPERLIFT SUSPENS Superlift 6 lift system for 1995 2003 CHEVROLET S 10 BLAZER PICKUP 4WD without ZR2 option package 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 kit fits only the standard S 10 Blazer Pickup in the years specified It will not fit vehicles equipped with the ZR2 option package Welding is required A special tool is required to load unload the torsion bars step 3 Other special tools are recommended to detach attach the pitman idler studs Refer to the factory service manual Front end realignment is necessary An arrow on diagrams indicates which direction is toward the front of the vehicle A foot pound torque reading is given in parenthesis after each appropriate fastener Do not fabricate any components to gain addit
17. Lower control arm hardware 82 OU Rear spring hardware 148 BLEED THE BRAKES Bleed the brake system following the procedure found in the factory service manual Inspect all connections for leaks REINSTALL BATTERY Reinstall the battery tray and secure using the factory hardware 23 Install and reconnect the battery using the procedure found in the factory service manual FORM 3145 03 110209 PRINTED IN U S A PAGE 21 OF 23 37 TURNING RADIUS STOPS 38 m QU QU NOTE Some deeply inset wheels when turned full lock may make slight contact with the upper control arm Even if the wheels are not making contact the close clearance may interfere with wheel balancing weights If either problem exists perform this step In some cases it may be necessary to abandon knock on weights in favor of tape ons Locate the factory turning radius stops on the rear of the lower control arms and prep the area for welding DIAGRAM 15 Weld the furnished 3 8 O D x 1 long piece of half section tubing onto both factory turning radius stops as shown After the area has cooled paint the exposed surfaces DIAGRAM 15 Turning radius stops and front height measurement weld where shown then subtract A from B to obtain the Z height Sumas lower control arm level floor ADJUSTING FRONT RIDE HEIGHT Manually bounce the front and rear of vehicle to normalize the torsion bars and leaf springs DIAGRAM 15
18. Position the vehicle on a level surface Measure from the LCA front pivot bolt center down to the floor Record this as Measurement A Now measure from the inside edge of the knuckle at the lower ball joint boss down to the floor Record this as Measurement B Subtract measurement B from A for the ride height figure Minimum ride height is 4 6 maximum is 5 2 Preferred ride height is 4 9 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 FORM 3145 03 110209 PRINTED IN U S A PAGE 22 OF 23 39 FINAL CLEARANCE and TORQUE CHECK Q 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 40 Activate four wheel drive system and check front hubs for engagement 41 HEADLIGHTS QO Readjust headlights to proper setting 42 SUPERLIFT WARNING DECAL Installthe WARNING TO DRIVER decal on the inside of the windshield or on the dash within drivers view Refer to the
19. TE If there is extra space between the Superlift spring pads and the factory pads butt the tall end of the 23 pads against the factory pads Verify that the 29 spring pads are fully seated in the factory pads and that they fit properly on the axle tube FORM 3145 03 110209 PRINTED IN U S A PAGE 19 OF 23 QU QU QU 30 31 ou QU QU QU Raise the rear axle and line up the tie bolts with the holes in the 23 spring pads Position the U bolt plates 55 36 3120 on top of the springs and reinstall the stock U bolts Snug but do not fully tighten at this time Tack weld the 29 spring pads in place Remove the U bolts then weld the pads to the axle tubes on both sides After the welds have cooled reinstall the U Bolts with the supplied U bolt plates 55 24 3140 and tighten in an X pattern to factory specifications REAR BRAKE HOSE AND BRAKE LINE BRACKETS NOTE Using a line wrench is recommended on all brake line connections Disconnect the factory rubber brake hose from the brake lines on the axle Then remove the hose from the axle and discard Attach the new rear brake hose 89400 to the mount on the axle using the supplied 5 16 x 1 bolt and nyloc nut Do not tighten at this time Remove the differential cover bolt securing the factory brake hose retaining bracket to the axle Position the 55 30 3140 brake line keeper so that the brake hose fitting where the rubb
20. ach the Install with the hardware indicated then use the bracket as a driver side upper control template to drill a 7 16 hole View is of the driver side arm drop bracket 55 1 1 2 OD x 07 3140 to the factory Square 2 1 4 front UCA mount as 12mm x 100mm ot eit shown using the supplied be 12mm x 100mm bolts i bt Ue f DRIVER SIDE square washers 9 16 ay j A NN FRAME RAIL USS washers and 12mm lock nuts Note that the square washers should be positioned in the ae Ot original control arm cam bolt slots Do not tighten at this time one a s E factory LCA J AN U hardware 7 16 x Sd 1 4 Attach the 07 bracket to the rear UCA frame mount using the supplied 12mm x 100mm bolt washers and 12mm lock nut The bolt should be installed front the rear Note that the supplied 1 1 2 OD x 2 1 4 long crush sleeve should be positioned in the void of the frame bracket where the UCA used to be mounted and that a 9 16 USS washer should be positioned in the recess between the 07 bracket and the rear face of the UCA frame mount as indicated in Diagram 6 Do not tighten at this time 55 06 3140 Locate the 7 16 diameter hole in the 07 bracket roughly below the factory front UCA frame mount Using the bracket as a template drill a 7 16 hole in the vehicle s frame as shown in Diagram 6 Note that due to a variance in vehicle frames it may be necessary to insert a 1 2 USS washer
21. ake NOSGC ccceeeeeeeeeees 09070 civetevenevotevenccodivs 2 shock absorber front Ool ee ee eee eee 2 shock absorber rear OO SA at yi tei woke Superlift badge ce eeeeeeeeeeeeee 00461 cece eeeeceeeee ees decal Warning To Driver PAGE 5 OF 23 NEW ATTACHING HARDWARE Qty if more than one 1 7 16 x 3 1 4 x 4 1 2 U bolt 7 16 nyloc nut 1 2 x 2 3 4 bolt 1 2 SAE washer 1 2 nyloc nut 7 16 x 3 1 4 x 4 1 2 U bolt 7 16 SAE washer 7 16 nyloc nut 1 2 x 2 3 4 bolt 1 2 SAE washer 1 2 nyloc nut 5 16 x 1 bolt 5 16 USS washer 5 16 nyloc nut FRONT DISASSEMBLY 1 a 2 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 REMOVE BATTERY NOTE The battery and battery tray must be removed in order to access the vacuum solenoid for the front differential which is relocated in a later step Open the hood and remove the positive and negative cables from the battery Remove the clamp holding the battery in place and lift the battery out of the vehicle Save all hardware for reuse Loosen the two bolts holding the battery
22. e 28 bracket as shown in Diagram 9 using the supplied 1 4 x 1 1 4 bolts washers and nyloc nuts 9 Tighten the caliper assembly to factory specifications Unclip the ABS connector located at the top of the frame Mark and drill a 1 4 hole approximately mid way down the side of the frame directly below where the connector was originally located Reroute the connector to the side of the frame and secure it in the hole drilled in the previous step If needed additional slack can be gained by unwrapping a section of the ABS wires from the rest of the wire loom in the engine compartment Route the ABS wire as shown in Diagram 9 then reattach it to the connector Secure both the factory brake hose and ABS wire guide brackets to the front leg of the upper control arm and secure using the supplied 1 4 x 1 1 4 bolt washer and nyloc nut 9 TORSION BAR DROP BRACKETS NOTE If the vehicle is equipped with the ZR5 appearance package you must remove the step bar brackets located on the frame rail outside the torsion bar mounting location FORM 3145 03 110209 PRINTED IN U S A PAGE 16 OF 23 QU QU QU QU QU QU 25 QU QU QU Position the torsion bar crossmember drop brackets 55 17 3140 on the frame under the original crossmember mounting location Use a plumb bob or level to locate the bracket directly under the original mount location then clamp the 17 bracket in place Using
23. e differential Unclip the differential breather hose from the fan shroud and relocate it to a lower point using the supplied zip ties If necessary install the front tires and wheels and lower the vehicle to the floor Final tightening of the lug nuts will occur later REAR PROCEDURE 27 oO m QU QU QU PREPARE VEHICLE Place vehicle in neutral Raise rear of vehicle with a jack and secure a jack stand beneath each frame rail in front of the rear spring hangers Ease the frame down onto the stands place transmission in low gear or park and chock front tires Remove rear tires Position the jack so that it supports but does not raise the rear axle Disconnect the axle breather tube from the axle or the frame Also detach the rear brake hose from the metal line at the frame Use a plug to minimize brake fluid loss Remove and discard rear shocks Save all hardware for reuse Disconnect the anti sway bar links if applicable from the bar body and the frame Save all hardware for reuse Remove the axle U bolts but save them for re use FORM 3145 03 110209 PRINTED IN U S A PAGE 18 OF 23 28 E QU QU QU QU QU 29 QU QU INSTALLING TIE BOLTS Raise the rear axle and secure it up and DIAGRAM 13 REAR SPRING PAD AND out of the way SHOCK BRACKET ASSEMBLY Position a C clamp approximately 3 to ee 4 inches away from the center tie bolt on i lt S a each side to hold
24. er hose meets the junction block is between the forked end of the bracket this prevents the junction block from swiveling on the factory bracket Secure both the factory bracket and the 30 keeper bracket to the axle using the factory differential cover bolt and tighten 23 Tighten the 5 16 bolt 13 and connect the factory brake lines on the axle to the brake hose Connect the upper end of the brake hose to the metal line on the frame Secure the hose to the factory mounting bracket On each side attach the rear brake line brackets 55 35 3120 to the metal brake lines that run along the axle Attach the 35 brackets to the rear spring perches 55 29 3120 using the supplied 5 16 x 1 self tapping bolts as shown in Diagram 1 LOWER SHOCK BRACKETS Install the bushings and stickers on the rear shock absorbers 85140 Attach the rod end of the shocks to the upper shock mounts on the frame using the factory hardware Extend the shocks so that the bottom eyes are even with the middle of the axle tube DIAGRAM 13 Loosely attach the lower shock bracket 55 23 3120 driver side and 55 24 3120 passenger side to the lower eye of the shock using the supplied 1 2 x 2 3 4 bolt washer and nyloc nut Rotate the lower shock bracket so that the curved edge rests against the axle tube After verifying once again that the lower shock eye is even with the middle of the axle tube secure the bracket to the tube using t
25. er to save the extra time it takes to separate the upper ball joint and CV shaft from the knuckle This can be done with the help of an assistant and a jack If there is no help available removing the components individually is recommended NOTE Perform the following steps one side at a time Start on the driver side Remove and discard the front shocks Loosen and remove the nut securing the CV axle to the hub assembly A special tool is recommended to separate the upper ball joint from the knuckle Support the control arm assembly with a jack and remove the cotter pin if applicable and castle nut from the upper ball joint stud Using the special tool separate the upper ball joint from the knuckle Take precautions to avoid damaging the rubber dust boot as it will be reused NOTE If a ball joint tool is not available the ball joint can be separated from the knuckle by firmly hitting the side upper portion of the knuckle with a hammer Be careful not to damage any other components Loosen the cam bolts that attach the upper control arm to the frame and slide the UCA out of the frame brackets Set the UCA aside and save all hardware for reuse With the help of an assistant remove the bolts that hold the lower control arm to the frame slide the LCA and knuckle assembly away from the vehicle to separate the CV shaft from the knuckle then carefully lower the assembly to the floor Slide each CV axle out of the differential Use rags to p
26. factory hardware Tighten 37 Install a new cotter pin supplied if equipped Tighten the axle shaft nut 133 Connect the tie rods to the centerlink and knuckle secure using the factory hardware and tighten 44 Install new cotter pins supplied if equipped Install the bushings and sleeves in the front shock absorbers 85070 Attach the body of the shock to the lower shock mount using the supplied 1 2 x 2 1 4 bolt and stover nut Secure the rod end of the shock to the upper mount using the factory hardware Tighten the lower 1 2 hardware 70 and the factory upper bolt 57 ANTI SWAY BAR Attach the anti sway bar to the anti sway bar drop brackets 55 15 3120 driver side and 55 16 3120 passenger side using the supplied 3 8 x 1 bolts washers and nyloc nuts Tighten the lower and upper sway bar bracket hardware 33 Attach the factory anti sway bar links to the ends of the bar then connect the links to the to the lower control arms and tighten until the bushings swell slightly FRONT BRAKE HOSE EXTENSIONS NOTE Two sets of brake line extensions are included in the kit box One set is equipped with 3 8 flare fittings 45 3120 for 1994 1997 models and the other set is equipped with 7 16 fittings 46 3120 for 1998 2003 models Verify that you have the correct extensions for your application before continuing NOTE The following steps should be performed one side at a time Start on the driver side
27. he supplied 3 8 x 1 1 4 bolts washers and nyloc nuts through the crossmember spacer plate and 07 bracket as shown in Diagram 7 Tighten 23 spacer plate If the optional steering stabilizer has been purchased install now Attach the stem end of the stabilizer to the 10 crossmember with the supplied bushings Insert the supplied sleeve in the eye end of the stabilizer and attach it to the centerlink using the supplied 7 16 x 2 1 2 bolt washer and nyloc nut The stabilizer hardware will be packaged with the stabilizer Tighten stem end until the bushings swell slightly and the 7 16 bolt 37 BELLY PAN Position the belly pan 55 11 3140 between the front and rear crossmembers Secure the pan to the rear crossmember using the supplied 5 16 x 1 tapered allen bolts and 5 16 flange nuts Secure the pan to the front crossmember using the 5 16 tapered allen bolts and two 5 16 tab nuts INITIAL TORQUE SEQUENCE Torque the following hardware in order QO 5 16 belly pan hardware 13 QW factory crossmember hardware 109 OW 10mm front crossmember hardware 25 FORM 3145 03 110209 PRINTED IN U S A PAGE 13 OF 23 Q 1 2 differential hardware 70 Q 9 16 differential hardware 114 m factory differential hardware 65 n 12mm UCA bracket hardware 107 QO 7 16 UCA bracket hardware 37 Q Tighten C S S link hardware until the bushings swell slightly
28. he supplied 7 16 x 3 1 4 x 4 1 2 U bolt washers and 7 16 nuts 41 FORM 3145 03 110209 PRINTED IN U S A PAGE 20 OF 23 QU QU 32 m 33 m Tighten the upper 27 and lower 57 shock hardware Reinstall the tires and wheels DIAGRAM14 LUG NUT TORQUE TIRES WHEELS l SEQUENCE Torque the factory lug DIAGRAM 14 Tighten the lug nuts 102 in the nuts in this sequence sequence shown WARNING When the tires wheels are installed always check for and remove any corrosion dirt or foreign material on the wheel mounting surface or anything that contacts the wheel mounting surface hub rotor etc Installing wheels without the proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion WARNING Retighten lug nuts at 500 miles after any wheel change or anytime the lug nuts are loosened Failure to do so could cause wheels to come off 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 FINAL PROCEDURES 34 HARDWARE TIGHTENING SEQUENCE Tighten the following hardware in sequence OU
29. hten at this time With the help of an assistant raise the differential into position and install the supplied 9 16 x 3 1 2 bolt through the driver side front mount at the front crossmember and the supplied 1 2 x 1 1 4 bolts washers and nyloc nuts on the passenger side mount Do not tighten at this time FORM 3145 03 110209 PRINTED IN U S A PAGE 11 OF 23 QU QU QU 15 Raise the rear crossmember 55 06 3140 into position and loosely secure using the factory lower control arm hardware Secure the driver side lower differential mount to the 06 crossmember using the factory hardware Do not tighten at this time Check to see if there is adequate clearance between the differential housing where the ribbing was removed and the 13 reinforcement plate that is currently tack welded into place If there is a sufficient amount of clearance remove the crossmember and differential housing in order to finish welding the reinforcement plate If there is not sufficient clearance trim the position of the reinforcement plate and test fit once again until adequate clearance is achieved Once the 13 reinforcement plate has been completely welded cooled and painted reinstall the differential and rear crossmember by repeating this step Do not tighten any hardware at this time unless otherwise specified UPPER CONTROL ARM DROP BRACKETS DIAGRAM 6 INSTALLING THE 55 07 3140 U C A MOUNT DIAGRAM 6 Att
30. ical and electronic types is highly recommended 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 Superlift 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
31. ional 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 area by covering them with a water saturated cloth Most undercoatings 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 3145 03 110209 PRINTED IN U S A PAGE 2 OF 23 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 Qty if more than one 55 01 3140 differential drop bracket upper driver side 55 02 3140 differential drop bracket passenger side 55 03 3140 centerlink a a 55 04 3140 CSS VINK sree cree 55 05 3140 oo front crossmember 5
32. lug the holes in the differential to avoid loosing any differential fluid Mark which side each shaft came from for reassembly COMPRESSION STOPS AND CENTERLINK Loosen and remove the nut holding the compression travel stop cup to the frame Save all components for re use Remove the nuts on the pitman and idler arms and using the appropriate puller tool remove the factory centerlink assembly Retain all the factory hardware DIFFERENTIAL Disconnect the electrical plug and breather tube from the differential Snake the actuator cable disconnected in step 2 out and away from all other undercarriage components so that the cable will not interfere with differential removal Position a jack underneath the differential housing and place just enough pressure on the jack to support the differential s weight Unbolt the driveshaft from the differential yoke and tie the driveshaft out of the way Retain all the factory hardware Remove and discard the factory rear crossmember FORM 3145 03 110209 PRINTED IN U S A PAGE 8 OF 23 m Remove the driver side lower differential bolt and the two differential bolts on the passenger side followed by driver side upper differential bolt Carefully lower the differential to the floor Save the driver side lower differential bolt for reuse FRONT ASSEMBLY 11 Q QU QU TRIMMING THE FRAME DIAGRAM 1 Temporarily install the front DIAGRAM 1 TRIMMING THE FRAME AND crossmember
33. nd locally this tool PN J 22517 C is available from the Kent Moore Tool Group in Roseville Michigan 800 345 2233 or 313 774 9500 TORSION BAR CROSSMEMBER Remove the two bolts that attach the crossmember to the frame and set the crossmember aside Slide the torsion bars out of the lower control arms and save for reuse BRAKE CALIPERS Unclip the brake hose from the upper control arm Remove the two bolts securing the caliper assembly to the knuckle Leave the brake hose attached to the caliper and using mechanic s wire hang the calipers out of the way Take precautions to ensure the brake hose isn t stretched or pinched Unplug the ABS wire from the connector located at the top of the frame rail and unclip the wire from the upper control arm SWAY BAR Loosen the threaded rod inside the sway bar end links and remove the bushings rod and tube Set these parts aside Unbolt the sway bar from the frame and retain all factory hardware TIE RODS Remove the cotter pins if applicable and nuts securing the tie rod to the centerlink and to the knuckle Using a tie rod separating tool separate the ends from the centerlink and knuckle Set these components aside for re use CONTROL ARM HUB ASSEMBLY FORM 3145 03 110209 PRINTED IN U S A PAGE 7 OF 23 QU QU QU QU QU QU 9 oO 10 NOTE Many installers prefer to remove the control arms knuckle and CV shaft as one large assembly in ord
34. on at this time QW Slide the CV shafts in to the differential housing according to the marks made during removal Raise the control arm hub assembly into position Insert the axle shaft in the hub as the assembly is maneuvered in place and loosely secure the axle nut Secure the rear leg of the lower control arm to the rear crossmember using the supplied 14mm x 100 mm hex head FORM 3145 03 110209 PRINTED IN U S A PAGE 14 OF 23 QU QU QU QU QU QU QU 22 QU 23 QU QU bolt The bolt should be installed from the front Loosely secure using the supplied 14mm nut but do not tighten at this time If installing the optional stainless steel brush guard line up the brush guard mounting crossmember 55 16 3140 with the mounting holes for the lower control arms on the front crossmember Install the supplied 14mm x 110mm socket head bolt through the 16 brush guard crossmember 21 or 22 anti sway bar brackets crossmember and lower control arm The bolt should be installed from the front Loosely secure using the supplied 14mm nut but do not tighten at this time Attach the upper control arm to the 07 or 08 UCA drop bracket using the factory cam bolts Rotate the cams so that the alignment pins are centered in the cam bolt slots Snug but do not fully tighten at this time Raise the control arm hub assembly and reattach the upper ball joint to the knuckle using the
35. the 17 bracket as a template drill the mounting holes four per side to 5 16 Install the supplied 3 8 x 1 self tapping bolts in the holes just drilled Tighten 24 WARNING Use extreme care to not overtighten the 3 8 self tapping bolts a alea E DIAGRAM 10 TORSION BAR CROSSMEMBER perlift badges on the 17 ASSEMBLY torsion bar drop brackets using DRIVER SIDE the supplied 1 8 x 1 2 rivets seat INNER FRAME RAIL and an ordinary rivet gun DIAGRAM 10 Mount the factory torsion bar 1 2 stover crossmember with the torsion bar holes facing forward to the 17 drop brackets using the combination of bushings and hardware detailed in the Diagram Note that there is a special 2 diameter x 3 16 thick 1 2 USS special supplied washer supplied and that the 55 17 3140 1 2 x 3 bolts should be n torsion bar installed from the bottom Once factory bushing crossmember assembled as shown tighten the 1 2 bolt 76 a factory bushing Lubricate both ends of the FRONT a skeet er ne oe factory torsion bars with grease A 1 2 X 3 then slide the torsion bars into the lower control arms Be sure to line up the indexing marks made during removal L7 B DIAGRAM 11 REMOVING INSTALLING THE TORSION BARS AND TORSION BARS ADJUSTER ARMS pen Clean the hex splines on the torsion Piller tool torsion bar and apply a light har lubricating grease tae
36. washer 3 8 nyloc nut 1 2 USS washer 9 16 USS washer 1 OD x 5 8 sleeve 1 1 2 OD x 2 1 4 sleeve zip tie cotter pin 3 8 x 1 bolt 3 8 x 1 1 4 bolt 3 8 SAE washer 3 8 nyloc nut spacer plate 5 16 x 1 tapered allen bolt 5 16 flange nut 5 16 tab nut 3 8 x 1 self tapping bolt 1 2 x 3 bolt 1 2 USS washer 1 2 stover nut 2 OD x 3 16 thick washer stainless steel badge 1 8 x 1 2 aluminum rivets 3 8 x 1 self tapping bolt 1 2 x 3 bolt 1 2 USS washer 1 2 stover nut 2 OD x 3 16 thick washer stainless steel badge 1 8 x 1 2 aluminum rivets 1 2 x 2 1 2 bolt 1 2 x 2 1 4 bolt 1 2 stover nut 3 4 x 1 1 4 sleeve 1 4 x 1 bolt 1 4 SAE washer 1 4 nyloc nut shock mount spacer FORM 3145 03 110209 PRINTED IN U S A PAGE 4 OF 23 PART NO DESCRIPTION NEW ATTACHING HARDWARE Qty if more than one Qty if more than one 55 13 3140 cic frame reinforcement plate 55 19 3140 2 oo lower front shock bracket rear driver side 55 20 3140 1 wo lower front shock bracket front passenger side 1 2 x 2 1 2 bolt 1 2 x 2 1 4 bolt 1 2 stover nut 3 4 x 1 1 4 sleeve 1 4 x 1 bolt 1 4 SAE washer 1
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