K869 Instructions

K869 Instructions
FORM #3320.06-031711
PRINTED IN U.S.A.
PAGE 1 OF 18
Superlift 6” lift system for 2001 and newer
Chevrolet Silverado / GMC Sierra 3/4-ton and 1-ton HD 4WD
INSTALLATION INSTRUCTIONS
INTRODUCTION
Installation requires a professional mechanic. Prior to beginning, inspect the vehicles steering,
driveline, and brake systems, paying close attention to the suspension link arms and bushings,
anti-sway bars and bushings, tie rod ends, pitman arm, ball joints and wheel bearings. Also check
the steering sector-to-frame and all suspension-to-frame attaching points for stress cracks. The
overall vehicle must be in excellent working condition; repair or replace all worn parts.
Read instructions several times before starting. Be sure you have all needed parts and
know where they install. Read each step completely as you go.
NOTES:
• Prior to beginning the installation, check all parts and hardware in the box with the
parts list below. If you find a packaging error, contact Superlift directly. Do not
contact the dealer where the system was originally purchased. You will need the
control number from each box when calling; this number is located at the bottom of
the part number label and to the right of the bar code.
•
Exhaust modifications are required on vehicles equipped with a gas engine; vehicles with a
diesel engine do not require exhaust modifications.
•
The factory wheels cannot be used with larger-than-stock tires. The factory spare tire and
wheel can be used in emergency situations.
•
This system requires the use of wheels with a minimum of 4-5/8” of backspacing, and a
maximum of 5”.
•
The factory steering stabilizer can be re-used with this lift system; order part #92050 as an
optional replacement.
•
Rear lift is sold separately and includes separate 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 re-alignment is necessary.
•
This system utilizes the stock torsion bars, which 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.
FORM #3320.06-031711
PRINTED IN U.S.A.
PAGE 2 OF 18
•
A foot-pound torque reading is given in parenthesis ( ) after each appropriate fastener.
•
Do not fabricate any components to gain additional suspension height.
•
Prior to drilling or cutting, check behind the surface being worked on for any wires, lines, or
hoses that could be damaged.
•
After drilling, file smooth any burrs and sharp edges.
•
Prior to operating a torch or saw, protect any heat-sensitive components located in the
immediate area by covering them with a water-saturated cloth. Most undercoating are
flammable but can be extinguished using a water-filled spray bottle. Have a spray bottle
and an ABC rated fire extinguisher on hand.
•
Paint or undercoat all exposed metal surfaces.
•
Prior to attaching components, be sure all mating surfaces are free of grit, grease,
undercoating, etc.
•
A factory service manual should be on hand for reference.
•
Use the check-off box “” found at each step to help you keep your place. Two “”
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
(Qty.- if more than one)
(Qty.- if more than one)
01-3320 ...................... driver side knuckle ....................... (2) 1/4” x 1/2” self-tapping bolt
(2) wire retaining clamps
02-3320 ...................... passenger side knuckle................ (2) 1/4” x 1/2” self-tapping bolt
(2) wire retaining clamps
55-03-3320 ................. differential bracket, ....................... (1) 9/16” x 4-1/2” bolt
driver side
(2) 9/16” SAE flat washer
(1) 9/16” nyloc nut
(2) bushing half
(1) 1” OD x 2-7/16” sleeve
(1) vent hose extension
55-04-3320 ................. differential drop bracket, ............... (2) 9/16” x 1-1/2” bolt
passenger side
(2) 9/16” extra-thick flat washer
(2) 9/16” USS washer
(2) 9/16” nyloc nut
1-07-3320 .................... frame reinforcement plate
55-05-3320 ................. front crossmember ....................... (2) 5/8” x 4-1/2” bolt
(4) 5/8” USS washer
(2) 5/8” nyloc nut
55-06-3320 ................. rear crossmember ........................ (2) 5/8” x 5-1/2” bolt
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PRINTED IN U.S.A.
PAGE 3 OF 18
(4) 5/8” USS washer
(2) 5/8” nyloc nut
(1) 9/16” x 3-1/2” bolt
(1) 9/16” SAE washer
(1) 9/16” nyloc nut
55-08-3320 ................. anti-sway bar drop bracket, .......... (2) 3/8” x 1-1/4” bolt
passenger side
(4) 3/8” USS washer
(2) 3/8” nyloc nut
55-09-3320 ................. anti-sway bar drop bracket, .......... (2) 3/8” x 1-1/4” bolt
driver side
(4) 3/8” USS washer
(2) 3/8” nyloc nut
55-11-3320 ................. front skid plate .............................. (2) 5-16” x 1” stainless allen bolt
(2) 5/16” SAE washer
66-22-3322 ................. (2) CV axle spacer ....................... (12) 10mm x 70mm bolt
(12) 10mm flat washer
55-15-3292 ................. torsion bar drop bracket, .............. (6) 7/16” x 1-1/4” bolt
driver side
(12) 7/16” USS washer
(6) 7/16” nyloc nut
(2) bushing half
(1) 3/4” OD x 1-3/4” sleeve
55-16-3292 ................. torsion bar drop bracket, .............. (6) 7/16” x 1-1/4” bolt
passenger side
(12) 7/16” USS washer
(6) 7/16” nyloc nut
(2) bushing half
(1) 3/4” OD x 1-3/4” sleeve
55-10-3370 ................. (2) kicker brace bracket ................ (2) 7/16” x 1-1/4” bolt
(2) 7/16” SAE washer
(2) 7/16” tab nut
55-29-3480 ................. (2) kicker brace ............................ (4) 7/16” x 4” bolt
(4) 7/16” SAE washer
(4) 7/16” nyloc nut
(8) bushing half
(4) 3/4” OD x 2-5/8” sleeve
44-18-3290 .................. (2) lower shock bracket
55-19-3290 .................. (2) compression stop.................... (4) 7/16” x 1-1/4” bolt
extension, rear
(4) 7/16” nyloc nut
55-26-3280 .................. rear emergency brake cable ........ (1) 5/16” x 1” bolt
drop bracket
(2) 5/16” flat washer
(1) 5/16” nyloc nut
stock rear brake line bracket ........ (2) 1/4” x 1” bolt
(2) 1/4” nyloc nut
55-30-3290 ................. carrier bearing drop bracket ......... (2) 7/16” x 2-3/4” bolt
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PRINTED IN U.S.A.
PAGE 4 OF 18
(2) 7/16” USS washer
(2) 7/16” nyloc nut
058 .............................. (2) 5” non-tapered blocks
11122........................... (4) U-bolts .................................... (8) 5/8” extra thick flat washer
(8) 5/8” nyloc nut
(2) shock absorber, front .............. (2) shock boot*, yellow
(2) hardware pack and cable tie
*(NOTE: Shock boots, if desired, purchased separately)
(2) shock absorber, rear ............... (2) shock boot*, yellow
(2) hardware pack and cable tie
*(NOTE: Shock boots, if desired, purchased separately)
00461........................... decal, "Warning To Driver"
FRONT DISASSEMBLY
1)

PREPARE VEHICLE...
Place the vehicle in neutral. Raise the 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 the front
tires.

Disconnect the battery.
2)
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 driver and passenger side.
 A special torsion bar puller tool is required to unload the torsion bars. Use the tool to load
the torsion bar, then remove the adjusting bolt and nut block. Unload the bar.
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 found 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).
 Once unloaded, scribe an alignment mark on each bar to indicate its indexing in relation to
the adjuster arm and the lower control arm.
 Slide the torsion bar forward (into the lower control arm) and remove the adjusting arm.

Remove the torsion bar crossmember. Slide the torsion bars out of the lower control arms
and set these parts aside.
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PRINTED IN U.S.A.
PAGE 5 OF 18
3)
BRAKE HOSE AND CALIPER…
 Unbolt the brake hose from the upper control arm, then unbolt the caliper bracket from the
knuckle and hang it out of the way using mechanic’s wire. Be sure the brake hose isn’t
stretched or pinched. Retain all the factory hardware.
4)
AXLE SHAFT…
 Remove the six bolts that hold the CV axle flange to the differential.
5)
TIE ROD ENDS…
 Using a special puller tool (refer to the factory service manual), detach the tie rod end from
the knuckle. Leave the tie rods attached to the centerlink.
6)

SWAY BAR AND COMPRESSION STOPS…
Unbolt the sway bar links from the lower control arms, then detach the sway bar from the
frame. Retain all the factory hardware and bushings.

Unbolt the factory compression stops from the frame. Save the stops and hardware for reuse.
7)
CONTROL ARM / HUB ASSEMBLY…
 Remove and discard the front shocks. Save the lower shock hardware for re-use.
 Mark the axleshafts’ respective positions (Driver and Passenger).
 Remove the dust cap in the center of the wheel bearing assembly in order to gain access to
the axleshaft nut. Remove the axleshaft nut, then remove the axleshaft from the vehicle.
Save all hardware for re-use.
 Support the control arm / hub assembly with a jack. Remove the upper ball joint nut securing
the knuckle to the upper control arm. Using the appropriate puller tool, separate the upper
ball joint from the knuckle. Save all hardware for re-use.
 Remove the lower ball joint nut and, using the appropriate puller tool, separate the ball joint
from the knuckle. Set the knuckle (with the wheel bearing assembly still attached) aside.
 Remove the bolts that hold the lower control arm to the frame and set the lower control arm
aside. Save all hardware for re-use.
8)

FRONT DRIVESHAFT…
Mark the driveshaft in relation to the differential yoke for reference during re-assembly.
Detach the front driveshaft from the differential and retain the factory bolts and clamps.
Leave the driveshaft attached to the transfer case and tie it up out of the way.
9)

SKID PLATE…
Remove the differential skid plate and splash shield if so equipped.
10) DIFFERENTIAL WIRING…
 Disconnect the differential wiring and vent hose.
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PRINTED IN U.S.A.
PAGE 6 OF 18
11) DIFFERENTIAL
ASSEMBLY…
 Remove the factory rear
crossmember.

Support the differential
with a floor jack. Remove
the bolt that attaches the
rear of the differential to
the driver side lower
control arm frame mount.
Save this bolt for re-use.

Remove the two bolts that
hold the differential on the
passenger side.

Remove the last bolt on
the top of the differential
on the driver side and carefully lower the differential assembly to the floor.
12) TRIMMING THE FRAME…

[DIAGRAM 1] Trim the driver side differential mount as shown. Measure over 1-1/2” over
from the center of the factory LCA mounting hole and mark a vertical cut line. Use a plasma
cutter, torch, or similar tool to perform the trimming.

Test-fit the supplied
reinforcement plate (#07-3320)
as shown in Diagram 1. It may
be necessary to trim the plate or
the frame for a proper fit, but
care should be taken to be sure
the plate fits properly to ensure a
proper weld and a clean-looking
finished product. Tack-weld the
reinforcement plate in place.

Test-fit the rear crossmember
(#55-06-3320) to ensure proper
clearance with the reinforcement
plate. Remove the crossmember
and weld the plate completely.
Allow the welds to cool and then
paint the affected area.
 [DIAGRAM 2] Trim the forward lip on both the driver and passenger side lower control arm
mounts as shown for proper differential flange clearance.
FORM #3320.06-031711
PRINTED IN U.S.A.
PAGE 7 OF 18
FRONT ASSEMBLY
13) FRONT CROSSMEMBER…
NOTE: If the optional replacement steering stabilizer #92050 has been purchased, install
now per separate instructions.

Attach the front crossmember (#55-05-3320) to the factory lower control arm mounts on the
frame and loosely secure using the supplied 5/8” x 4-1/2” bolts, washers, and nyloc nuts.
The bolts should be installed from the front. Note that it is necessary to angle the
crossmember and slide it into one mount first, then straighten the crossmember and shift it
slightly to install it in the remaining mount. Do not tighten the hardware at this time.
14) DIFFERENTIAL
MODIFICATIONS…

[DIAGRAM 3] Using a hacksaw,
cut-off wheel, or similar tool, trim off
the upper mounting ear on the
differential housing as shown.
WARNING: Do not use a torch or
similar tool that generates extreme
heat to make the necessary cuts to
the differential. Excessive heat will
warp the differential housing and
irrevocably damage it.

Trim the corner off of the passenger
side mounting pad as shown in
Diagram 3.

Lubricate and installed the supplied
bushings and sleeve in the driver
side upper differential mount (#5503-3320).

[DIAGRAM 3] Remove the factory bolts on the differential and attach the “03” bracket to the
housing as shown. Re-install the bolts and tighten (35).
NOTE: On some housings there is a notch present that prevents the "03" bracket from
seating flat against the housing. If necessary grind down this notch until the bracket fits
properly.
15) DIFFERENTIAL AND REAR CROSSMEMBER INSTALLATION…

Look at the passenger side differential drop bracket (#55-04-3320). You will notice it has a
taper in it. Position the bracket on the factory mount so that the tall end of the taper faces
forward, while the short end of the taper faces rearward. Attach the “04” bracket to the
factory mount using the factory hardware. Do not tighten at this time.
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PRINTED IN U.S.A.
PAGE 8 OF 18

Using a jack and an assistant, raise the differential housing into position. Attach it to the “04”
passenger side mount using the supplied 9/16” x 1-1/2” bolts, extra-thick flat washers, and
nyloc nuts. The bolts should be installed from the top, and the thick flat washers should be
positioned under the nuts. Do not tighten at this time.

Line up the driver side front mount with the tabs on the front crossmember and secure using
the supplied 9/16” x 4-1/2” bolt. Do not install the washer or nut at this time.

Raise the rear crossmember (#55-06-3320) into position and attach it the factory LCA rear
leg mounts using the supplied 5/8” x 5-1/2” bolts, washers, and nyloc nuts. The bolts must
be installed from the front. Do not tighten at this time.

Secure the driver side rear mount of the differential to the “06” rear crossmember using the
factory hardware. Do not tighten at this time.
 Attach the factory compression travel stops to the tabs on the rear crossmember using the
factory hardware. Tighten (23).
16) SKID PLATE…

Support the differential and remove the 9/16” x 4-1/2” bolt securing the differential to the front
crossmember on the driver side. Line up the front skid plate (#55-11-3320) with the
differential mounting tabs on the front crossmember and re-install the 9/16” x 4-1/2” bolt
through the skid plate, crossmember tabs, and differential. Secure using the supplied
washer and nyloc nut. Do not tighten at this time.

Attach the skid plate to the rear crossmember using the supplied 5/16” x 1” stainless allen
bolts with washers in the threaded holes present in the crossmember. Do not tighten at this
time.
17) FASTENER TIGHTENING SEQUENCE…
 Torque the following hardware in sequence:
 All 5/8” hardware (154)
 All 9/16” hardware (119)
 Factory differential hardware (82)
 5/16” skid plate hardware (19)
 On each side, check for adequate clearance between the differential drive flanges and the
factory lower control arm mounts. Also cycle the steering and check for adequate clearance
between the centerlink and the differential housing.
18) FRONT DRIVESHAFT…
NOTE: If the vehicle is equipped with a gasoline engine, exhaust modifications are required
for front driveshaft clearance. If necessary, remove the front driveshaft from the vehicle.
The vehicle can be driven to an exhaust shop to have the necessary modifications
performed once the lift installation is complete.

Attach the front driveshaft to the differential according to the marks made during removal.
Use the factory hardware and tighten (24).
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PRINTED IN U.S.A.
PAGE 9 OF 18
Reconnect the differential wiring and use the supplied vent hose extension to reconnect the
differential vent hose.
19) KICKER BRACES…

Remove the transfer case skid plate if equipped. Save all hardware for re-use.
 Lubricate and install the supplied bushings and sleeves in both ends of the kicker braces
(#55-29-3480).
 Attach the kicker braces to the mounting tabs on the rear crossmember using the supplied
7/16” x 4” bolts, washers, and nyloc nuts. Do not tighten at this time.
 Attach the supplied kicker brace attachment brackets (#55-10-3370) to the other end of the
kicker braces using the supplied 7/16” x 4” bolts, washers, and nyloc nuts. Do not tighten at
this time.
 Swing the kicker brace assembly up against the transmission crossmember. Mark the
location of the mounting holes to be drilled in the crossmember. Lower the kicker braces
and drill at the marked locations using a 15/32” bit.
 Attach the kicker brace assembly to the transmission crossmember using the supplied 7/16”
x 1-1/4” bolts, washers, and tab nuts.
 Tighten all of the 7/16” hardware (54).

Notch the corner of the factory skid plate to clear the kicker brace bracket, then attach the
skid plate to the transmission crossmember using the factory hardware and tighten (23).
20) KNUCKLE ASSEMBLY…
NOTE: Perform the following steps one side at a time.
 Place the factory knuckle assembly on a table with the lugs facing downward. Remove the
three bolts securing the wheel bearing assembly to the knuckle and remove the knuckle.
Discard the factory dust shield.
 Note that the ABS sensor on the hub assembly points upward when the knuckle is
positioned as it would be installed on the truck. Position the replacement knuckle (#013320 driver side and #02-3320 passenger side) on the hub assembly with the ABS
sensor pointing forward when the knuckle is positioned as it would be installed on the
vehicle (90 degrees from the original orientation). Secure the hub assembly to the
knuckle using the factory hardware and be sure to apply the supplied thread-locking
compound. Tighten (133).
21) KNUCKLE INSTALLATION…
NOTE: Perform the following steps one side at a time.
 Attach the lower control arms to the front and rear crossmembers using the factory
hardware. Do not tighten at this time.
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PRINTED IN U.S.A.
PAGE 10 OF 18
 Line up the knuckle assembly with the upper and lower ball joints. Secure the knuckle using
the factory hardware. Tighten the upper ball joint (37) and lower ball joint (94).
NOTE: The lower control arms will be tightened once the vehicle is on the ground with the
suspension supporting the vehicles weight.
NOTE: Verify that the ABS sensor (with its related wiring) is pointing forward instead of up
as it was stock.
22) CV AXLE SPACERS…
 Turn the knuckle so that the tie rod
boss is pointing outward. Install the
CV axleshaft by first passing the end
of the axleshaft in front of the
differential and then sliding the
axleshaft into the hub assembly.
Secure the CV axleshaft at the hub
using the factory nut and tighten
(156). Reinstall the factory dust cap.
 Position a CV axle spacer (#66-223322) between the differential flange
and the flange on the CV axle. Line
up the mounting holes and install the
supplied 10mm x 70mm bolts with flat
washers through the CV axle, spacer,
and into the differential flange. Take
precautions to avoid overtightening
and stripping these bolts. Tighten (58).
23) BRAKE CALIPERS…
 Reinstall the brake rotors and
attach the caliper brackets to the
knuckle using the factory hardware
along with the supplied threadlocking compound. Tighten (133).
 [DIAGRAMS 4A and 4B] Verify
that the hub assembly is oriented
so that the ABS sensor is pointed
toward the front of the vehicle.
Route the ABS wire under the tie
rod mounting boss as shown.
Position the supplied clamps on
the wire and secure the clamps to
the pre-drilled holes in the
backside of the knuckle using the
supplied 1/4” x 1/2” self-tapping
bolts. Tighten (76 in-lb).
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 Re-attach the factory brake hose bracket to the upper control arm if it was unbolted during
disassembly. Also attach the other bracket to the backside of the knuckle as shown. Be
sure to follow the brake routing exactly as shown.
 Reconnect the ABS wire to the wiring at the frame and attach the wire to the brake hose as
shown in the Diagrams.
24) SHOCK ABSORBERS…
 Remove the factory lower shock brackets from the lower control arms. Attach the supplied
lower shock brackets (#55-18-3290) using the factory hardware and tighten (23).
 Install the supplied bushings and sleeves in the shock absorbers. Attach the lower end of
the shocks to the “18” brackets using the factory hardware. Attach the stem end of the front
shocks to the factory mount using the supplied bushings, washers, and fine-thread nut.
 Tighten the lower end (59) and upper end of the shock until the bushing swells slightly.
25) FRONT ANTI-SWAY BAR…
 Attach the front anti-sway bar drop brackets (#55-09-3320 driver side and #55-08-3320
passenger side) to the bar’s factory location on the frame using the factory hardware. Note
that the brackets have offset mounting faces; the lower end of the brackets should be offset
toward the front of the vehicle. Do not tighten the hardware at this time.
 Attach the anti-sway bar to the “08” and “09” brackets using the supplied 3/8” x 1-1/4” bolts,
washers, and nuts.
 Tighten the factory hardware (23) and the 3/8” hardware (23).
 Attach the factory anti-sway bar end links to the lower control arms and anti-sway bar using
the factory bushings and hardware. Tighten (24).
26) TORSION BAR DROP BRACKETS…
 Four rivets attach the factory torsion bar crossmember mount to the frame; two on the
bottom of the frame and two on the side. If applicable (not present on all models) use an air
chisel or torch to remove the two rivets from the bottom of the frame so that the torsion bar
crossmember drop brackets will fit flush with the frame.

If applicable, remove and
discard the emergency
brake cable keeper on the
side of the frame that
interferes with the “15”
bracket to be installed.
 Locate and install the
appropriate bushings and
sleeves (lubricate the
outside of the sleeves
with grease) for the “15”
and “16” brackets.
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PAGE 12 OF 18
 [DIAGRAM 5] Line up the recesses in the Superlift torsion bar drop bracket (55-15-3292
driver side and 55-16-3292 passenger side) with the remaining two rivets on the side of the
frame as shown and firmly clamp the bracket into place.
 Scribe marks on the frame for all the holes (six for each bracket) needed to mount the “15”
and “16” brackets. Remove the brackets and use a 15/32” bit to drill the holes. Clean up any
burrs using a file.
 Slide the torsion bars into the lower control arms. Make sure the bars are properly indexed
according to the marks made during disassembly.

Mount and tighten the “15” bracket using the provided 7/16” x 1-1/4” bolts and related
hardware (37 lb-ft).
 [DIAGRAM 6] Loosely install
the outside bolts for the “16”
bracket and slide the torsion
bar crossmember into position
as shown using the factory
bolts. Install the remaining
7/16” bolts and tighten (37 lbft). Tighten the factory torsion
bar bolts (70).
27) LOADING THE TORSION
BARS…
 Hold the adjuster arms inside
the crossmember and slide
each torsion bar back into
place. Make sure the bars are
properly indexed with the
adjusters by following the marks made during disassembly.
 Load the torsion bar using the special tool and reinstall
the factory adjusting bolt and nut block. Leave about
half of the bolts threads visible below the nut block and
unload the tool. Final ride height adjustments will be
made once the vehicle is on the ground.
28) TIRES / WHEELS...

[DIAGRAM 7] Tighten the lug nuts (145 lb-ft) in the
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 metalto-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 #3320.06-031711
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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.
29) 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.
REAR PROCEDURE
30) PREPARE VEHICLE...
 Raise rear of vehicle with a floor jack positioned under the rear axle. Place jack stands
under the frame rails, a few inches in front of the rear springs’ front hangers. Ease the jack
down until the frame is resting on the stands. Keep a slight load on the jack. Chock front
tires to prevent accidental movement.
2009 Models
 …Unclip the ABS wires at the bottom and inside of frame rail on both sides of the vehicle.
 Remove the tires, U-bolts, and shocks.
31) LIFT BLOCKS AND U-BOLTS…
 Lower the axle by carefully easing down the jack. Do not overextend the brake lines and
axle vent hoses.
NOTE: Spring perches are prone to collapse or warp where the leaf springs or blocks seat
on the axle, especially towards the ends. Without a perfectly flat mounting surface, the block
may fail and “roll” out off of the perches. If the perches are not flat, fix them by welding on a
piece of ¼” plate (or something similar) or replace the perches completely.
 Make sure the top of the spring perches and the bottom of the springs are clean and free of
any debris. Position the Superlift blocks in between the leaf springs and the factory blocks.
WARNING: If vehicle is equipped with short cast spacer blocks located between the leaf
springs and the axlehousing. These factory blocks must be retained because they seat
properly against the axle mounts; the Superlift spacer blocks do not. When using Superlift
blocks, install them on top of the factory blocks.
 Install the supplied U-bolts, then toque the bolts in an “X” pattern to the following
specifications:
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SUPERLIFT U-BOLT TORQUE GUIDE
NOTE: Torque specifications apply to Superlift U-bolts only
DESCRIPTION
PLATED (lb-ft)
PLAIN FINISH (lb-ft)
½” dia., up to 13” long
57
92
9/16” dia., up to 13 ½” long
82
131
9/16 dia., 13 ½” and longer
106
185
5/8” dia., up to 14 ½” long
112
181
5/8” dia., 14 ½” and longer
145
256
32) CARRIER BEARING SPACER…
The carrier bearing is part of the rear driveshaft assembly. It supports the rear driveshaft
and is attached to a frame crossmember between the transmission and the rear axle. The
carrier bearing spacer (55-30-3290) installs between the bearing and the crossmember.

Determine the amount of drop needed. The carrier bearing spacer (55-30-3290) is
essentially a rectangular piece of box steel. One side of the “box” will space the bearing
down 1”, while the other will space the bearing down 1-1/2”. It can be installed either way.
The correct way to install the spacer depends on the wheelbase:
 For long-bed crew cab trucks, position the spacer so that is lowers the bearing 1-1/2”.
 For most other applications, position the spacer so that it lowers the bearing 1”.

Unbolt the carrier bearing from the frame crossmember.

Position the “30” spacer between the bearing and the crossmember with the correct amount
of drop for the wheelbase.

Attach the bearing and spacer assembly to the crossmember using the supplied 7/16” x 23/4” bolts, washers, and nyloc nuts. Tighten (50).
33) COMPRESSION TRAVEL STOPS...
 Remove the factory rear compression travel stops and install the extension brackets (55-193290) in the same location with the supplied 7/16” x 1-1/4” bolts and related hardware.
Attach the factory compression travel stops to the “19” brackets and tighten (11).
34) BRAKE HOSE RELOCATION…

Locate the factory rear brake hose bracket mounted to the top of the driver side frame rail.
Unbolt the bracket from the frame.
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PAGE 15 OF 18
Carefully bend the steel brake line to reach
the new bracket location without touching or
interfering with other components. The
bracket should be directly below the
bracket’s original mounting location.
2008 and Older Models

[DIAGRAM 8] Using the bracket as a
template, scribe two marks for new mounting
holes at the bottom of the frame. Remove
the bracket and drill two 17/64” holes. Clean
up any burrs with a file.

Remount the factory brake bracket to the
bottom of the frame using the supplied 1/4” x
1” bolts and nyloc nuts.
2009 Models

[DIAGRAM 8A] Position the factory brake
line bracket onto the Superlift 55-19-3290
bracket and secure using the factory
hardware (250 in. lbs.).

Lubricate the rubber grommet on the ABS
and slide it up the line and reconnect to the
clip located on the bottom of the frame. Do
not reconnect the clip on the side of the
frame.

Check for adequate length of the rear brake
hose in the new location. On certain
applications, a little more length is needed.
If so, bend the factory bracket down slightly
to gain the necessary slack in the hose.
35) EMERGENCY BRAKE CABLES…

There are two brackets constructed of heavy-gauge wire attached to the driver side frame
rail near the rear tire that hold the emergency brake cables. Remove and discard the
rearward-most bracket (closest to the back bumper).

Remove the other bracket from the frame and attach the supplied emergency brake cable
drop bracket (55-26-3280) to the frame in its place using the factory hardware. Now, attach
the factory bracket to the “26” bracket using the supplied 5/16” x 1” bolt, washers, and nyloc
nut (11).
2008 and Older Models

On the driver side lower shock mount there is a clamp that secures the driver side
emergency brake cable to the axle. Unbolt the clamp, remove it from the cable, and discard.
Reinstall the bolt securing the brake line and tighten to factory specifications.
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PRINTED IN U.S.A.
PAGE 16 OF 18
2009 Models

On the driver side lower shock mount there is a
clamp that secures the driver side emergency brake
cable to the axle. Unbolt the clamp, move to the
axle pad and attach using the 5/16” x 1” bolt,
washer, and flange nut. Reinstall the bolt securing
the brake line and tighten to factory specifications.

Disconnect the driver side emergency brake cable
from the caliper. Route the cable over the axle tube
and then re-attach it to the caliper. Re-attach to the
caliper and check for proper operation.
36) SHOCK ABSORBERS...
 Install the shock absorbers and position one 3/4” USS washer over each side of the lower
shock sleeve and install the Superlift® shock absorbers using the factory hardware
 Install the tires and wheels per step 28 and lower the vehicle to the floor.
FINAL PROCEDURES
37) ADJUSTING FRONT RIDE HEIGHT...

Manually bounce the front and rear of the vehicle to normalize the torsion bars and leaf
springs.
 On each side, fully tighten the LCA-to-crossmember bolts (107).
 [DIAGRAM 9] 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 5”;
maximum is 5.5”. Ideal ride height is 5.25”. 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.
38) FINAL CLEARANCE and TORQUE CHECK...
NOTE: If the optional stainless steel front brush guard has been purchased, install now per
separate instructions.

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.
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PRINTED IN U.S.A.
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Reconnect the battery.
39) Activate four wheel drive system and check front hubs for engagement
40) HEADLIGHTS...

Readjust headlights to proper setting.
41) SUPERLIFT WARNING DECAL...

Install the 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.
42) 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:
• Alteration, modification or failure to maintain.
• Normal wear and tear (bushings, tie-rod ends, etc.). Scratches or defects in product finishes (powder coating,
plating, etc.),
• Damage to or resulting from vehicle’s electronic stability system, related components or other vehicle
systems.
• 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
• 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.
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PAGE 18 OF 18
• 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 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 mechanical 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.
SUPERLIFT SUSPENSION SYSTEMS
300 Huey Lenard Loop Rd.
West Monroe, Louisiana 71292
Phone: (318) 397-3000
Sales / Tech: 1-800-551-4955
FAX: (318) 397-3040
www.superlift.com
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