Skyjacker I-D4519 Dodge-RAM Instructions

09-11 Dodge 2500 / 3500 4WD

5” Suspension Lift

Installation Instructions

www.skyjacker.com

RequIReD TooL LIST:

* Safety Glasses

* Metric / Standard Wrenches & Sockets

* Drill & Assorted Drill Bits

* Floor Jack

* Jack Stands

* Measuring Tape

* Torque Wrench

* Pitman Arm Puller

Before beginning the installation, thoroughly & completely read these instructions & the enclosed driver’s WARNING NOTICE. Affix the WARNING decal in the passenger compartment in clear view of all occupants. Please refer to the Parts List to insure that all parts & hardware are received prior to the disassembly of the vehicle. If any parts are found to be missing, contact SKYJACKER®

Customer Service at 318-388-0816 to obtain the needed items. If you have any questions or reservations about installing this lift kit, call SKYJACKER® Technical Assistance at 318-388-0816.

Make sure you park the vehicle on a level concrete or asphalt surface. Many times a vehicle is not level (side-to-side) from the factory & is usually not noticed until a lift kit has been installed, which makes the difference more visible. Using a measuring tape, measure the front & rear (both sides) from the ground up to the center of the fender opening above the axle. Record this information below for future reference.

Driver Side Front:

Driver Side Rear:

Passenger Side Front:

Passenger Side Rear:

IMPoRTANT NoTeS:

• This lift is determined from the amount of lift to the front of the vehicle, while only lifting the rear to a position level with the front.

• If larger tires (10% more than the stock diameter) are installed, speedometer recalibration will be necessary. Contact your local Dodge dealer or an authorized dealer for details.

• After installation a qualified alignment facility is required to align the vehicle to factory specifications.

• If after installation a front driveline vibration occurs, Part # IXR20K must be ordered. It is an indexing ring that rotates the transfer case to improve the driveline angle.

I-D4519 REV2 12-10 Pg 1

• Some models will come equipped with a larger Sterling rear axle. These models will require a larger rear U-bolt. Order rear U-bolt kit Part # U9B12R.

• Under no circumstances are SKYJACKER® coil springs to be used in conjunction with any type of coil spring tower, block, or spacer. The use of a coil spring tower, block, or spacer will allow the coil spring to exceed its designed stress & travel load allowing it to be

overstressed, oversprung, fatigued, & possibly broken. The SKYJACKER® warranty is void under any such application.

• For vehicles with a carrier bearing on the rear driveshaft, lowering brackets are available if a rear driveline vibration occurs. (Part # CBL3401 = 1" Drop & Part # CBL214 = 2 1/4" Drop)

Kit Box Breakdown :

Part #: D45510 / D45529

ITEM# DESCRIPTION QTY

DUL253-L

DLL45-L

DULRB3-B

DTB50-B (D45510 Box)

DTB53-B (D45529 Box)

SBL20-L

SBL20-R

DA309

BP60S

HB-D45510-LK

HB-D4510-LK

HB-D4552-LK

HB-DTB53-TB

I-D4519

(D45510 Box)

(D45529 Box)

(D45529 Box)

(D45529 Box)

03 DGE UPPER LINK 2-5"LIFT

DODGE LWR LINK 4-5"

03 DGE UPPER LINK RELOC BRK

10 DGE TRK BAR DROP BRKT,5"

03 DGE TRK BAR DROP BRKT,5"

2.5" SWAY BAR LWG BRKT-LEFT

2.5"SWAY BAR LWG BRKT-RIGHT

2009 DODGE DROP PITMAN ARM

BUMP STOP DODGE RAM 4-5"

HDWR BAG:5"2010 DGE LWR LKS

HDWR BAG: 5" DGE LWR LK

HDWR BAG/4-5" 2000 DODGE L

HB-D4513-ULB

HB-D4513-BL 1

HB-DTB50-TB (D45510 Box) HDWR BAG: DTB50 TRK BAR BRK 1

1

1

1

1

2

1

2

2

HDWR BAG:UPR LK BRKTS/SBL20 1

HDWR BAG/BRAKE LINE BRKTS

HDWR BAG FOR DTB53

INSTRUCTION SHEET: D45529

1

1

1

1

2

1

Hardware Bag Breakdown:

HB-D45510-LK HARDWARE BAG

ITEM# DESCRIPTION QTY

2617

2618

LS20DL

LS20DU

LS2650

SP3643

ZF316

BUSHING DGE RAM LWR LNK

BUSHING DGE RAM UPPR LNK

LINK SLEEVE,2K LOWER DODGE

LINK SLEEVE,2K UPPER DODGE

LINK SLEEVE 2.65" LOWER

LINK BUSHING DODGE / FORD

ZERK FITTING ALEMITE, 3/16"

4

8

2

4

2

4

8

I-D4519 Pg 2

Hardware Bag Breakdown:

HB-D4510-LK HARDWARE BAG

ITEM# DESCRIPTION QTY

SP3643

LS2650

LINK BUSHING,LOWER

LINK SLEEVE 2.65" LOWER

4

2

Hardware Bag Breakdown:

HB-D4552-LK HARDWARE BAG

ITEM# DESCRIPTION QTY

2617

2618

LS20DU

LS20DL

ZF316

BUSHING DGE RAM LWR LNK

BUSHING DGE RAM UPPR LNK

LINK SLEEVE,2K UPPER DODGE

LINK SLEEVE,2K LOWER DODGE

ZERK FITTING ALEMITE, 3/16"

8

8

4

4

8

Hardware Bag Breakdown:

HB-D4513-uLB HARDWARe BAG

ITEM# DESCRIPTION QTY

916X5FTB

716X112FTB

LS20DU

916FTN

716FTN

916SAEW

716SAEW

916X6FTB

12USSW

916STVFTN

9/16 X 5 FINE THRD BOLT

7/16 X 1 1/2 FINE THRD BOLT

LINK SLEEVE,2K UPPER DODGE

9/16-18 NYLON INSERT LOCKNU

7/16-20 FINE N/I LOCK NUT

9/16 SAE WASHERS

7/16 SAE WASHER

9/16 X 6 FINE THRD BOLT

1/2 USS WASHER

9/16-18 STOVER NUT,GRADE C

2

12

2

2

12

5

24

1

1

1

Hardware Bag Breakdown:

HB-D4513-BL HARDWARe BAG

ITEM# DESCRIPTION QTY

DBE23

516X1FTB

516FTN

516SAEW

BRAKE LINE BRKT,03 2500 DGE

5/16 X 1 FINE THRD BOLT

5/16" FINE THRD N/I LOCKNUT

5/16 SAE WASHER

2

2

2

4

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Hardware Bag Breakdown:

HB-DTB50-TB HARDWARe BAG

ITEM# DESCRIPTION QTY

12X412FTB

12SAEW

12STVFTN

58X312FTB

58FTN

58SAEW

1/2 X 4 1/2 FINE THD GRD. 8

1/2 SAE WASHER

1/2" STOVER LKNUT, FINE THD

5/8 X 3 1/2 FINE THD BLT,G8

5/8-18 NYLON INSERT LOCKNUT

5/8 SAE WASHERS

1

2

1

1

1

2

Hardware Bag Breakdown:

HB-DTB53-TB HARDWARe BAG

ITEM# DESCRIPTION QTY

916X3FTB

12X412FTB

916SAEW

12SAEW

916FTN

12STVFTN

9/16 X 3 FINE THREAD BOLT

1/2 X 4 1/2 FINE THD GRD. 8

9/16 SAE WASHERS

1/2 SAE WASHER

9/16-18 NYLON INSERT LOCKNU

1/2" STOVER LKNUT, FINE THD

1

1

2

2

1

1

Part #: D4513 (Kit Box)

ITEM# DESCRIPTION QTY

R334S

H-BOX D4513

ADD-A-LEAF,2003 DGE 3/4 4"

HDWR BOX: D4513 COMP BOX

2

1

Hardware Box Breakdown:

H-BOX D4513 HARDWARE BOX

ITEM# DESCRIPTION QTY

WSP334S

1206

916X312X11U

7013

HB-916

WEDGE SHIM PLATE FOR R334S

1/2 X 6 TIE BOLTS PR W/NUTS

9/16 X 3 1/2 X 11 U-BOLT RD

OEM STABILIZER,03 DODGE

HDWR BAG/ 8 - 9/16" NYLON

2

2

4

1

1

Hardware Bag Breakdown:

1206 HARDWARe BAG

ITEM# DESCRIPTION QTY

1206S

12TBN

1/2 X 6 TIE BOLT

1/2" TIE BOLT NUT

2

2

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Part #: 7013

ITEM# DESCRIPTION QTY

7000WS

HB-7013

HSS

B10RS

BTIE

WHITE STEERING DAMPER

HARDWARE BAG FOR 7013

HYDRO SHOCK DECAL

RED BOOT

RED BOOT TIE

1

1

1

1

1

Hardware Bag Breakdown:

HB-7013 HARDWARe BAG

ITEM# DESCRIPTION QTY

HOURGLASS 5/8

142121

141509

58SP

12X5FTB

12FTN

81004

12SAEW

12USSW

HOURGLASS 5/8 SHOCK BUSHING

ES24 SLEEVE/402087 1.38"

ES25 SLEEVE/403646 1.50"

5/8" SPACER - 1 1/4" O.D.

1/2 X 5 FINE THREAD BOLT/G8

1/2-20 FINE N/I LOCK NUT

TAPERED SLEEVE, 1/2"I.D.

1/2 SAE WASHER

1/2 USS WASHER

2

1

1

1

1

1

1

1

1

Hardware Bag Breakdown:

HB-916 HARDWARe BAG

ITEM# DESCRIPTION QTY

916FTN 9/16-18 NYLON INSERT LOCKNU 8

Part #: D4513S (System Box)

ITEM# DESCRIPTION QTY

916X312X11U

7013

HB-916

9/16 X 3 1/2 X 11 U-BOLT RD

OEM STABILIZER,03 DODGE

HDWR BAG/ 8 - 9/16" NYLON

4

1

1

Part #: 7013

ITEM# DESCRIPTION QTY

7000WS

HB-7013

HSS

B10RS

BTIE

WHITE STEERING DAMPER

HARDWARE BAG FOR 7013

HYDRO SHOCK DECAL

RED BOOT

RED BOOT TIE

1

1

1

1

1

I-D4519 Pg 5

Hardware Bag Breakdown:

HB-7013 HARDWARe BAG

ITEM# DESCRIPTION QTY

HOURGLASS 5/8

142121

141509

58SP

12X5FTB

12FTN

81004

12SAEW

12USSW

HOURGLASS 5/8 SHOCK BUSHING

ES24 SLEEVE/402087 1.38"

ES25 SLEEVE/403646 1.50"

5/8" SPACER - 1 1/4" O.D.

1/2 X 5 FINE THREAD BOLT/G8

1/2-20 FINE N/I LOCK NUT

TAPERED SLEEVE, 1/2"I.D.

1/2 SAE WASHER

1/2 USS WASHER

2

1

1

1

1

1

1

1

1

Hardware Bag Breakdown:

HB-916 HARDWARe BAG

ITEM# DESCRIPTION QTY

916FTN 9/16-18 NYLON INSERT LOCKNU 8

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Front Installation:

1. Secure & properly block the tires of the vehicle on a level concrete

or asphalt surface.

2. Remove the upper shock nuts, retainers, & the three nuts on the

upper shock tower brackets.

3. Lift the front of the vehicle & install jack stands under the frame

behind the lower link rear brackets.

4. Remove the front tires & brakeline anchor bracket between the

upper & lower links behind the coil spring.

Photo #1

5. Loosen the trackbar at the axle housing. Remove the frame end of

the track bar from the frame mount & lower it down.

6. Remove the drag link from the pitman arm. Remove the pitman arm

from the steering sector using a pitman arm puller. (See Photo # 1)

Install the new Skyjacker drop pitman arm using the OEM lock

washer & nut. Note: Do not reinstall the drag link to the pitman

arm at this time.

Photo #2

7. Loosen the front sway bar bolts at the frame (Do not remove).

Disconnect the sway bar end link from the sway bar mount on the

axle. (See Photo # 2)

8. Remove the upper shock tower & lower shock bolt. Pull the shock

up through the coil spring under the hood.

Photo #3

9. Lower the front axle down until the coil springs become loose &

remove the coil spring, rubber isolator, & three-bolt tower ring. (See

Photo # 3)

10. Locate the front rubber bump stop mounted on the frame rail behind

the coil spring. Remove the bump stop from the pocket by using a

large flat screwdriver or similar tool to pry them out. A pair of

channel lock pliers can also be used to remove this bump stop by

working it back & forth. (See Photo # 4)

Photo #4

11. At the front lower link adjustment cams, mark (with an ink marker, or scribe a mark) the vertical line on the cam & the reinforcement bracket for reference so you can realign the marks after installation.

(See Photo # 5)

12. Install the drive-in grease fittings in each end of all the link arms by

using a 1/4" socket over the grease fitting. Tap with a hammer until

the grease fitting is flush.

Photo #5

I-D4519 Pg 7

13. Install the new Skyjacker poly bushings (Part # 2617) in each end of

the larger lower links & (Part # 2618) in the smaller upper links. Be

sure to slightly grease them prior to installation. Insert the 2.645" long

sleeve in the larger lower links & the 2.375" long sleeve in the smaller

upper links. Note: Some 2009 models & all 2010 models use a

18mm lower link bolt at the axle. If your model has this 18mm bolt,

use the larger ID poly bushings (Part # SP3643) & 2.65" sleeves

(Part # LS2650) to connect the new Skyjacker lower links to the axle.

14. Loosen & remove the upper & lower links from both sides. Replace the lower links with the new Skyjacker lower links (one side at a time).

Note: Do not tighten at this time. Note: On some models with the

Cummings Diesel the upper control arm bolt on the passenger side

at the frame will need to be cut off in order to remove. Skyjacker has provided a 9/16" x 6" fine thread replacement bolt to be used if

neccessary.

Photo #6

15. Install the new Skyjacker upper control arm relocation bracket over the OEM bracket on the axle. Install the 9/16" x 5” fine thread bolt, washers, & nut into the OEM mounting hole. Note: Be sure to install the 2.375” crush sleeve on this bolt inside of the OEM bracket. (See

Photo # 6)

Photo #7

16. Mark the two additional holes on each side of the bracket & drill

using a 15/32” drill bit. Once drilled, install the 7/16" x 1 1/2” fine

thread bolts, washers, & nuts. Note: If installing a Skyjacker Dual

Shock Kit, be sure to install the bottom dual shock bracket at this

time. (See Photo # 7)

17. When installing the new Skyjacker upper links, slide the front eye through the new Skyjacker upper relocation bracket enough to bolt the rear eye in the OEM frame mount. Position & bolt the front eye through the upper relocation bracket using OEM hardware. Note: Do not tighten at this time. Note: Install the upper links with the front eye of the link having the grease fitting pointing out the end & the rear eye of the link having the grease fitting pointing up.

Photo #8

18. Install the new Skyjacker track bar drop bracket into the OEM mount.

Attach the bracket to the OEM mounting hole using the OEM

hardware. (See Photo # 8)

Photo #9

19. Install the 1/2" x 4 1/2” fine thread bolt, washers, & nut into the

bottom of the bracket, up through the OEM mount. (See Photo # 9)

20. To begin the coil spring installation, insert the OEM three-bolt tower

ring in place inside the top of the coil spring tower. Start a couple of the nuts to hold the ring in

place. Note: Do not tighten at this time. Note: If installing a dual shock kit, it is important to see

those instructions at this time.

I-D4519 Pg 8

21. Install the new Skyjacker coil springs by placing the rubber isolator on top of the coil spring & aligning the coil spring so that the end of the bottom wraps are turned to the inside at the center of the axle. Lift up on a jack under the differential until the coil springs are securely in place & keeping a load on them to hold them in place.

22. Attach the new Skyjacker front brake line relocation bracket to the

OEM position using the OEM hardware. Attach the OEM brakeline to

new Skyjacker relocation bracket using the 5/16" x 1” fine thread bolt,

washer, & nut with the washer under the nut. (See Photo # 10) Photo #10

23. Remove the OEM steering stabilizer from the drag link

& axle mount. Install the new Skyjacker steering

stabilizer by inserting a poly bushing & steel sleeve

into the shaft end of the steering stabilizer. Insert a

poly bushing & the shorter sleeve into the body end of

the steering stabilizer. Attach the red boot & secure it

with the supplied plastic tie. Install the shaft end of the

steering stabilizer to the drag link using the supplied hardware.

(See Photo # 11) Insert the tapered sleeve into the tapered hole in

the tie rod placing the small 1/2" washer on the 1/2" x 5" bolt & install

through the drag link hole. Install the 5/8" spacer, the shaft end of the

steering stabilizer, the large 1/2" washer, & the 1/2" self locking nut

onto the bolt & tighten. Attach the body end of the stabilizer to the

OEM mount using the OEM hardware.

24. Take the stud ends of the front sway bar end links & swing them back

up to reattach. Remove the two bolts at the frame from each side of

the sway bar & lower the bar down. Install the new Skyjacker sway

bar lowering brackets with the offset sloping toward the front bumper

using the OEM hardware at the top & the 7/16" x 1 1/2” fine

threadbolts, washers, & nuts at the bottom. (See Photo # 12)

Photo #12

Photo #11

Front of Vehicle

25. Install the front tires & lower the vehicle to the ground. Attach the

drag link to the pitman arm.

26. Place the new Skyjacker poly bump stop in the OEM bump stop

pocket. Using leverage against the bottom of the poly bump stop,

force the bump stop into place. (See Photo # 13)

Photo #13

27. Raise the track bar & bolt it to the bottom of the new Skyjacker track

bar drop bracket using the 9/16" x 3” fine thread bolt, washers, & nut

for 2009 models or the 5/8" x 3 1/2” fine thread bolt, washers, &

nut for 2010 models . (See Photo # 14) Note: It may be necessary to

turn the steering wheel left or right in order to realign the holes when

installing the bolt. Tighten the track bar bolt on the passenger side

axle housing.

Photo #14

I-D4519 Pg 9

28. Tighten each end of the upper & lower links, being sure to realign the

marks on the eccentric cams. (See Photo # 15) Note: Thoroughly

grease all eight grease fittings.

29. Install the poly bushings & steel sleeve in the bottom eye of the new

Skyjacker front shock & place a retaining washer & stem bushing on the upper stud of the shock. From under the hood, lower the shock down through the coil spring, install & tighten the bottom bolt.

Remove the nuts on the coil spring's tower ring installed previously.

Place the OEM shock tower (that was removed earlier in Step # 7)

Photo #15 over the shock's stud & align it over the threads of the tower ring. Install & tighten the self

locking nuts on both tower rings. Install the upper shock stem bushing, retaining washer, & nut.

Note: If installing a dual shock kit, it is important to see those instructions at this time.

WARNING: On the Dodge Ram trucks, the front shock absorbers limit the extended position of the front suspension. The use of shocks other than those specified by Skyjacker, may cause coil spring disengagement, adverse steering angles, brake hose failure, driveline component failure, &/or other related component failure. The use of any other shocks will void your

Skyjacker warranty!

30. Cycle the steering to full left & right turns checking the clearance between the sway bar end link

mounts, at the front base of the coil springs & the drag link / tie rod assembly.

Rear Installation:

1. Lift the rear of the vehicle & place jack stands under the frame to support the vehicle.

2. Remove the rear tires & shock absorbers.

3. Remove the axle U-bolts & lower the axle down a few inches.

IF INSTALLING A SOFTRIDE® “SYSTEM” WITH NEW REAR SPRINGS, SKIP TO STEP # 10.

Rear Add-A-Leaf Installation:

Note: Use two large C-clamps to contain the elastic potential energy in

a leaf spring when the center tie bolts are being removed.

4. Attach & tighten a C-clamp on each end of the leaf spring to hold the

spring assembly securely together. (See Photo # 16)

Photo #16

5. Using locking pliers to hold the head of the two outer center bolts,

loosen & remove them. With care, slowly loosen & remove the

C-clamps.

6. With the tie bolts removed, remove the plastic alignment pin from the

bottom shim plate. (See Photo # 17) The new Skyjacker degree shim

is produced with an intergrated alignment pin.

Photo #17

I-D4519 Pg 10

7. Insert the new Skyjacker tie bolts through the new Skyjacker axle

wedge shim (thick end installs towards the rear bumper), two bottom

OEM shim plates, OEM bottom overload leaf, new Skyjacker

add-a-leaf, & through the OEM leaf spring pack. (See Photo # 18)

Note: Do not use the center tie bolts to draw the leaf spring leaves

together. FAILURE OF ANY COMPONENT CAN CAUSE AN

EXPLOSIVE DISASSEMBLY & POSSIBLE INJURY!

8. Place one C-clamp on each side of the center bolts & tighten evenly.

Once the C-clamps have drawn the leaves securely together, hold the center tie bolt heads with locking pliers & torque the nuts to 41 Ft.

Lbs.

Photo #18

9. Remove the C-clamps & cut off the excess length of the tie bolts. (Skip to Step # 12)

Rear Leaf Spring Installation:

10. Safely support the fuel tank & loosen the vent & fill hoses on the filler neck. Loosen (Do not remove) the front fuel tank strap bolt. Disconnect & remove the rear bolt & strap. Carefully slide the fuel tank toward the center of the vehicle to acquire sufficient room to access the driver side front spring eye bolt. Remove the spring eye bolts & OEM leaf springs from the vehicle. Note: It will be necessary on the driver side, to pry the gas tank away from the frame allowing more room to remove & reinstall the front OEM leaf spring eye bolt. Do not pry on the gas tank too much or lower it down too much because the fitting at the top may be broken off.

11. Install the new Skyjacker leaf springs with the thick end of the wedge shim towards the rear bumper. Reconnect the rear fuel tank strap & bolt. Tighten the front strap bolt & the vent & fill hoses on the filler neck.

12. Raise the rear axle, aligning the leaf spring pins with the axle housing. (See Photo # 19) Install & tighten the new Skyjacker U-bolts evenly.

13. Install the new Skyjacker rear shock absorbers & rear tires.

14. Remove the jack stands & lower the vehicle to the ground. (See

Photo # 20)

Available Accessory:

Dual Steering Stabilizer Part # 7239

Photo #19

I-D4519

Photo #20

Pg 11

FINAL NoTeS:

• After the installation is complete, double check that all nuts & bolts are tight. Refer to the

following chart below again for the proper torque specifications. (Do not retighten the nuts & bolts

where thread lock compound was used.)

• With the vehicle placed on the ground, cycle the steering lock to lock & inspect the steering,

suspension, brake lines, front & rear drivelines, fuel lines, & wiring harnesses for proper operation,

tightness, & adequate clearance.

• Rotate the driveshafts & check for interference at the differential yoke & cardan joint. If necessary, lightly dress the casting(s) &/or U-joint tabs in order to eliminate the binding.

• Have the headlights readjusted to the proper settings.

• Have a qualified alignment center realign the front end to the factory specifications.

• Retorque all the bolts after the first 100 miles.

TORQUE SPECIFICATIONS

INCH SYSTEM

Bolt Size Grade 5 Grade 8

5/16 15 FT LB 20 FT LB

3/8 30 FT LB 35 FT LB

7/16 45 FT LB 60 FT LB

1/2 65 FT LB 90 FT LB

9/16 95 FT LB

5/8 135 FT LB 175 FT LB

METRIC SYSTEM

Bolt Size Class 8.8 Class 10.9

6MM 5 FT LB 9 FT LB

8MM 18 FT LB 23 FT LB

10MM 32 FT LB 45 FT LB

12 MM 55 FT LB 75 FT LB

14MM 85 FT LB 120 FT LB

16MM 130 FT LB 165 FT LB

18MM 170 FT LB 240 FT LB

• The above specifications are not to be used when the bolt is being installed with a bushing.

Seat Belts Save Lives, Please Wear Your Seat Belt.

I-D4519 Pg 12