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2003 Dodge 3/4, and 1 Ton 5″ Suspension Lift Installation Instructions

December 1st, 2009 · No Comments

Installation:
1. Secure and properly block the tires of vehicle on a level concrete or asphalt surface.
2. Open hood, remove the upper shock nuts and retainers, remove the 3 nuts on the upper shock tower brackets.
3. Jack up front of vehicle and install jack stands under frame behind the lower link rear brackets. Remove tires and brake- line anchor bracket between the upper and lower links behind coil spring.
4. Loosen trackbar at the axle housing, then remove other end from the frame, and lower down.
5. Remove drag link from pitman arm and lower it down, then remove pitman arm from steering sector (a puller will be required, See photo #1). Install new Skyjackerо drop pitman arm using the original lock washer and nut, and torque to OEM specs (do not reinstall drag link to pitman arm at this time).
6. Loosen the front sway bar bolts at frame, but do not remove. At the differential end of the sway bar (at front of coil springs), disconnect sway bar link from the sway bar. (See Photo #2).
7. Remove upper shock tower, remove lower shock bolts and pull shocks up through the coil spring under the hood. Now lower front axle down until coil springs become loose. Remove coils, rubber insulator and 3-bolt tower ring. (See Photo #3)
8. Locate the front rubber bumpstops, mounted on the frame rail behind the coils. Remove bumpstop from its pocket by using a large flat screwdriver to pry them out or using a pair of channel lock pliers working back and forth. (See Photo #4).
9. At the front lower link adjustment cams, mark (with an ink marker, or scribe a mark) the vertical line on the cam and the reinforcement bracket for reference so you can realign the marks after installation. (See Photo #5.)
10. Install drive-in zirk fittings in each end of all 4 links by using a 1/4″ socket over the fitting, tap with a hammer until fitting is completely tapped in.
11. Install poly bushings in each end: #2617 in the lower/larger links, #2618 in the upper/smaller links. Be sure to slightly grease them prior to installation. Insert the steel sleeve tube in the links: 2.645″ long sleeve in the lower/larger links, 2.375″ long sleeve in the upper/smaller links.

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