Installation requires a professional mechanic. Prior to beginning, inspect the vehicle’s steering, driveline, and brake systems, paying close attention to the control arms and bushings, anti-sway bars and bushings, steering linkage, 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.

• Front end realignment is necessary.

• A foot-pound torque reading is given in parenthesis ( ) after each appropriate fastener.

• Do not install any additional components or modify this system to gain additional
suspension height.

• Prior to attaching components, be sure all mating surfaces are free of grit, grease,
undercoating, etc.

• Speedometer recalibration is recommended if a taller tire is used.

• 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.

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.

NOTE: Save all factory components and hardware for reuse.

1)  PREPARE VEHICLE... Place 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 the rear tires. Remove the front tires.

2)  ANTI-SWAY BAR… On each side, loosen and remove the bushings and hardware attaching the anti-sway bar links to the anti-sway bar body. .

3)  ABS WIRE… Unplug the ABS wire connector located on the driver side inner fender then detach the wire from the upper control arm; the ABS wire clips to the control arm at two points. NOTE: Perform steps 4 through 9 one side at a time, starting with driver side.

4) UPPER CONTOL ARM’S BALL JOINT…

 Loosen the nut to the bottom of the stud, leaving treads engaged from top to bottom of the nut. Do not remove.

 Break loose the ball joint stud from the knuckle so the ball joint stud can be moved up and down within the knuckle. This can be done by tapping on the ball joint boss of the knuckle with a mallet; careful as not to damage the knuckle. Do not remove the ball joint from the knuckle.

5)  TIE ROD END… Remove the nut from the outer tie rod end; then remove the tie rod from the knuckle using the correct puller. Do no damage the threads during removal.

6) LOWER CONTROL ARMS… [SEE PHOTO - STRUT REMOVAL]

 Position a floor jack under the lower control arm so that it supports, but does not raise, the control arm.

 An eccentric cam bolt assembly attaches each leg of the lower control to the frame; the cam bolts are also used for front end alignment. Loosen (do not remove) the cam bolts. Prior to loosening, mark the cam washers’ orientation, in relation to the control arm, for later reference.

 Loosen (do not remove) the bolts attaching the upper control arm-to-frame.

7) STRUT ASSEMBLY REMOVAL… [SEE PHOTO - STRUT REMOVAL]

 Remove the bolt securing the strut-to-lower control arm.

 Remove the three nuts securing the strut-to-frame.

 Lower the floor jack supporting the lower control arm then remove the strut assembly.

8) REASSEMBLY… [SEE PHOTO - STRUT ASSEMBLY]

 Using the appropriate cutting tool cut 1/2” off of the factory stud length. Clean the threads after cutting.

 Position one of the supplied strut spacers (#66-02-40019) over the strut’s studs. Secure the spacer-to-strut using the supplied 10mm Stover nuts. (45)

 Slide the strut assembly through the upper control arm, and locate the upper end of the assembly in the frame. Loosely attach the upper end of strut using the supplied 7/16” Flange nuts.

 Raise the jack supporting the lower control arm. Loosely attach the lower end of the strut-to-lower control arm using the factory hardware. Do not tighten at this time.

 Tighten the upper end of the strut. (37)

 Reattach the sway bar end link to the sway bar body. Tighten until bushings swell slightly.

 Reattach the tie rod end to the knuckle. Tighten (85).

 Tighen the upper ball joint nut. (50).

9)  TIRES / WHEELS…[SEE DIAGRAM] Tighten the lug nuts (95) 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 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.

10) TIGHTEN HARDWARE… Lower vehicle to floor. The suspension is now supporting vehicle weight.

 Prior to tightening the lower control arms eccentric cam bolts, realign the cams using the scribe marks made in step 4 during disassembly (150).

 Tighten upper control arm bolts (130).

 Tighten the strut-to-lower control arm bolt (155).

11)  ABS ROUTING… [SEE TOP PHOTO]

Route the ABS wire as shown. Plug-in the connector at the fender. The outboard attachment clip will not be used. Snap the inboard attachment clip into the hole located on the rear leg of the Superlift® extension travel dampener bracket.

12)  INITIAL CLEARANCE CHECK... Again lift the vehicle and secure a jack stand
beneath each frame rail. With 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.

13)  FINAL CLEARANCE and TORQUE CHECK... Lower vehicle to the floor. With the suspension supporting vehicle weight, cycle steering lock-to-lock and inspect the tires / wheels, and the steering, suspension, and brake systems for proper operation, tightness, and adequate clearance.

14)  HEADLIGHTS… Readjust headlights to proper setting.

15)  SUPERLIFT® WARNING DECAL… Install the WARNING TO DRIVER decal on the inside of the windshield, or on the dash, within driver’s view. Review to the “Important Product Use and Safety Information / Warnings” text found at the end of instructions.

16)  ALIGNMENT… Realign vehicle to factory specifications.