DODGE TRUCK INSTALLATION INSTRUCTIONS /2500/3500 PICKUP KIT SUM /2500/3500 PICKUP KIT SUM

Transcription

1 DODGE TRUCK INSTALLATION INSTRUCTIONS /2500/3500 PICKUP KIT SUM /2500/3500 PICKUP KIT SUM Installation of a body lift will change the center of gravity and the handling characteristics of the vehicle. Because of the higher center of gravity and larger tires, the vehicle will handle and react differently both on and off-road. You must drive it safely! Extreme care must be taken to prevent vehicle rollover or loss of control, which could result in serious injury or death. Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fastened. Read and understand all instructions, warnings, cautions, and notes in this sheet and in your owners manual before you begin the installation of this body lift kit. CAUTION Proper installation of a body lift kit requires knowledge of the factory recommended procedures for disassembly and assembly of original equipment components. We recommend that the factory shop manual and any special tools necessary to your vehicle be on hand during the installation. Installation of this body lift kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of your vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components install this body lift kit. This body lift kit should only be installed on vehicles in good working condition. Before installation, the vehicle should be thoroughly inspected for evidence of corrosion or deformation of the sheet metal around the factory body mounts. This body lift kit should not be installed on any vehicle that is suspected to have been in a collision or misused. Off-road use of your vehicle with this body lift installed may increase the stress applied to the factory body mounts. We do not recommend that any vehicle with a body lift installed be involved in any extreme off-road maneuvers such as jumping. Failure to observe this warning may result in serious personal injury and/or severe damage to your vehicle. Many states now have laws restricting bumper heights and vehicle lifts. Local laws should be consulted to determine if the changes you intend to make to your vehicle comply with state laws. Before combining a body lift with a suspension lift, consult an installation professional to see how this will affect your specific application. The installation of larger wheel and tire combinations may reduce the effectiveness of the anti-lock braking system. We will not warranty any damage to the A/C system. Always wear eye protection when operating power tools. Ensure that your vehicle tires are properly blocked and secured before you begin installation of this lift kit. NOTE We recommend using the Loctite supplied in the kit on all hardware unless noted in the instructions. The Supplemental Restraint System (SRS, or air bag) must be deactivated during lift kit installation to avoid accidental air bag deployment while working near SRS sensors and wiring. Do not allow anyone near the air bag during lift kit installation. Accidental deployment can result in serious personal injury or death. Refer to your factory service manual/owner s manual for the recommended procedure to disable the SRS. The SRS must be reactivated before driving the vehicle.

2 A. Before you start. NOTE This kit is designed to fit appropriate application 2WD and 4WD, standard and extended cab full size Dodge pickups with gasoline engines only. This kit is not designed to fit vehicles equipped with diesel engines. 1. Read all warnings and instructions completely and carefully before you begin. Check the kit for proper contents (refer to the parts list). 2. Park the vehicle on a clean, dry, flat, level surface. Block the tires so the vehicle cannot roll in either direction. 3. Disconnect both battery cables. Be sure to disconnect the negative cable first, then the positive cable. Remove the airbag fuse from the airbox. 4. Remove the bolt that attaches the parking brake cable to the frame under the driver s side door. Remove the clamp from the cable. Turn the clamp upside down and reattach it to the cable. Remove the two front bolts that mount the vapor cannister to the frame (if equipped). Reroute the brake cable between the legs of the cannister. Mount the clamp on the cable to the whole in the frame that is above and to the rear of the original hole. Remount the legs of the vapor cannister to the frame. 5. Remove the automatic shift linkage from the pivot assembly on the driver s side frame rail. Remove the linkage from the lever at the steering column. REmove the linkage rod from the vehicle : Remove the cap on top of the 4-wheel drive shift lever. Loosen the nut that mounts the knob to the shift lever. Remove the screws that mount the shift boot to the floorboard. Remove the shift boot from the vehicle. Remove the nut that mounts the transfer case linkage rod to the tranfer case. Remove the two bolts that mount the transfer case shift assembly to the side of the transmission. Remove the transfer case shift assembly from the vehicle : Loosen the linkage bolt to allow it to extend while the vehicle is lifted.. Failure to install the steering extension properly could result in loss of steering, causing damage to the vehicle and possible personal injury. Be sure that the steering shaft does not turn independently of the steering gearbox. This could cause the air bag system to malfunction. 7. Mark the steering shaft where it connects to the steering gearbox. This is to ensure proper alignment after the steering extension has been installed. Remove the bolt that mounts the steering column to the gearbox. Remove the steering shaft from the gearbox. Install the steering extension into the steering shaft. It should only go in one way. Install the stock bolt. Do not tighten at this time. Extend the mark on the steering shaft down the steering extension so it can be realigned with the mark on the gearbox. Install the steering extension onto the gearbox. Be sure that the marks are properly aligned. If the steering extension is not installed properly, it could cause the steering wheel alignment to be off. Insert a 3/8 x 1 3/4 allen in the steering extension. Double-check the steering alignment. Tighten all steering hardware securely. 8. Remove the front bumper. If the vehicle is equipped with driving lights, disconnect the single wire connector under the core support that is connected to both driving lights. Disconnect the horn wires and the two ground wires on the driver s side outside bumper support bracket. Check for any other wires that may be attached to the bumper or any of the mounting brackets. Disconnect as necessary. Remove the two bolts (one on each side) attaching the outside bumper support brackets to the frame. Loosen the nuts that mount the outside support brackets to the bumper (when equipped). Remove the bolts that mount the inside bumper brackets to the frame. Remove the bumper from the vehicle. 9. Remove the heater hose from the bracket on the passenger side valve cover. 10. Remove the windshield washer bottle from the side of the fan shroud. There are bumps on the washer bottle that lock into holes on the fan shroud. Lay the bottle out of the way so the wiring does not need to be disconnected. Remove the coolant recovery bottle from the fan shroud. Remove the four bolts that mount the shroud to the radiator. Lay the fan shroud against the engine. 11. Check the engine compartment and under the cab for any wires, hoses, cables, etc. that may need to be disconnected before lifting the cab. Disconnect as necessary. Measure the distance between the cab and the bed. Record these measurements for later reference. 12. Loosen, but do not remove all cab mounting bolts. There are eight on extra cab models and six on standard cab models. All cab mounting bolts screw up from the bottom and thread into the body. They are located in the following positions on both sides of the

3 vehicle: In front of the core support; under the front floorboard; under the rear floorboard; and at the rear of the cab (extra cab models only). 13. Remove the cab mounting bolts from the passenger side of the cab only. Be sure the doors are closed. This will help prevent the cab from flexing while lifting. Using a hydraulic jack and wooden block (place the wooden block under the side of the cab in a location that will not be damaged by the weight of the cab on the wooden block), slowly lift the cab just high enough to place the spacers on top of the stock bushings. Be sure to check for any wires, hoses, cables, etc. that may be binding. After the spacers have been placed on the stock bushings, insert the new cab mounting bolts with 7/16" washers installed through the stock hardware, the spacer block, and into the nut inside the body (the stock bushings should all be in their original positions including the donut bushing under the frame mount). The cab uses 12mm x 180mm bolts in all locations (12mm x 160mm for a two inch kit). Do not tighten. Lower the cab onto the spacer blocks. 14. Repeat step 13 for driver s side of the cab. Align the cab to the bed using the measurements recorded earlier. Remove cab-mounting bolts, one at a time, apply Loctite(, reinstall bolt and tighten to vehicle manufacturer torque specifications. Use extreme caution when working near fuel lines and fuel tank. Clean up spilled fuel immediately. Any spark could cause an explosion or fire resulting in serious personal injury and property damage. 15. Remove the three screws that mount the fuel filler neck to the plastic housing. Remove the fuel cap to allow the filler neck to slide through the plastic housing. Loosen the large hose clamp that mounts the filler hose to the fuel tank. Loosen the small hose clamp that mounts the vent hose to the fuel tank. Remove the filler hose and the vent hose from the fuel tank. Remove the fuel-filler assembly from the vehicle. 16. Disconnect the license plate lights from the rear bumper. Remove the six bolts that mount the rear bumper to the frame (three on each side). Remove the rear bumper from the vehicle. 17. Lower the spare tire to the ground. Remove the clip that connects the spare tire crank rod to the cranking mechanism. Remove the crank rod from the vehicle. Leave the spare tire in its lowered position. 18. Loosen but do not remove all bed mounting bolts. Short bed models have six, long bed models have eight. Check for any wires, hoses, cables, etc. that may bind while lifting. 19. Remove the bed mounting bolts from the passenger side of the bed only. Using a hydraulic jack and a wooden block, slowly lift the passenger side of the bed just high enough to place the spacer blocks on the mounting pads. The bed should lift off of the frame very easily. After the spacer blocks have been placed on the mounts, Install the new bed mounting bolts with a 10mm fender washer and the stock hardware. All stock hardware should be in its original position. Use the 10mm x 100mm bolts (10mm x 80mm bolts for a two inch kit) to mount the bed. Do not tighten. Lower the bed onto the spacer blocks. 20. Repeat step 19 for driver s side of the bed. Realign the bed to the cab. Refer to the measurements recorded earlier. Remove bed-mounting bolts, one at a time, apply Loctite, reinstall bolt and tighten to vehicle manufacturer torque specifications. 21. Lengthen the fuel filler hose. Cut the rubber section of the fuel filler hose into two pieces approximately in the middle of the hose. Install the fuel filler extension pipe between the two sections of the hose. Install a #28 hose clamp at each end of the extension. Be sure that there is ample engagement between the hose and the extension. Tighten the hose clamps securely. Remove the hose clamp that mounts the vent hose to the fuel filler assembly. Remove the vent hose from the filler assembly. Install the new longer vent hose on the filler assembly. Install a #10 hose clamp on the hose. Be sure that there is ample engagement between the hose and the filler assembly. Tighten the hose clamp securely. Install the other #10 hose clamp at the other end of the vent hose. Be sure that the stock hose clamp is still on the bottom of the fuel filler hose. Reinstall the filler assembly on the fuel tank. Before tightening any hose clamps, reinstall the filler neck through the hole in the plastic housing at the top. It is not necessary to install the three mounting screws at this time, just be sure that it is aligned properly. Be sure that the filler hose and the vent hose both have ample engagement on the pipes at the tank. Tighten both hose clamps securely. Reinstall the three fuel filler mounting screws. Tighten securely. Reinstall the fuel filler cap. 22. Lower the fan shroud. In order to lower the fan shroud, the lower mounting tab on the passenger s side of the radiator must be cut off. This is to allow for clearance at the lower radiator hose. Cut the mounting tab off flush with the side of the fan

4 shroud. Using the stock bolts, mount the three fanshroud lowering-brackets to the other stock fan shroud mounting locations. Do not tighten. Mount the fan shroud to the stud on the fan shroud brackets. Using the remaining stock fan shroud bolt, mount the "L" shaped fan shroud bracket to the stock lower passenger side fan shroud mounting hole. Position the "L" shaped bracket so the hole in the bracket is aligned with the side of the fan shroud. Mark the fan shroud through the hole in the bracket. Remove the fan shroud from the other brackets. Drill a 5/16" hole through the mark on the fan shroud. Remount the fan shroud to the brackets. Install a 1/ 4" x 1" bolt with a 1/4" washer through the fan shroud and the lower mounting bracket from the inside of the fan shroud. Install a 1/4" washer and Nylock nut on the bolt. Check the fan-to-fan shroud clearance. Be sure that it is the same all the way around. Install a 1/4" washer and Nylock nut on the other three fan shroud mounting brackets. Tighten all fan shroud mounting hardware securely. Tighten the "L" shaped bracket first, then the other three brackets. Check the fan shroud clearance once more. Check the clearance between the fan shroud and the automatic transmission cooling lines. It may be necessary to carefully bend the cooling lines down to prevent the cooling lines from rubbing on the shroud. Remount the windshield washer bottle on the shroud. Trim approximately 1/2" off of the locating tab on the coolant recovery bottle. This is for clearance for the transmission cooling lines. Remount the coolant recovery bottle to the fan shroud. Remove the stock hose from the coolant recovery bottle. Install the new coolant recovery hose on the coolant bottle and the radiator. 23. Remove the stock inner bumper brackets from the front bumper. It will be necessary to gently pull the plastic cover back to allow the bolt to move enough for the bracket to come off of the bolts. Install the new front bumper brackets to the bumper. Do not tighten the nuts at this time. Trim approximately 1/4" to 1/2" off of the front frame horns to allow for clearance of the bumper valance in the new raised position. Using the stock hardware, mount the bumper to the frame. Do not tighten. Using the stock hardware, mount the outside support relocating brackets to the frame (the sport model only uses the center bumper brackets). Do not tighten. Using a 7/16" x 1 1/2" bolt, two 7/16" washers, and a 7/16" Nylock nut, mount the outside bumper support brackets to the relocating brackets. Do not tighten. Adjust the bumper-to-body clearance. Tighten all bumper mounting hardware securely. Reconnect the horn wires to the horns. Reconnect the two ground wires to the outside support bracket on the driver s side of the vehicle. If the vehicle is equipped with driving lights, reconnect the wiring. CAUTION A certified welder should perform all welding : Lengthen the four-wheel drive shift lever. Scribe a line along the shift lever just above the square section of the lever (above the shifter-positioning bracket). Cut the shift lever through the line approximately 1 3/4" above the positioning bracket. Insert the 1/2" shift extension pin between the two pieces of the shift lever. Align the two parts of the scribed line. Weld the extension in place. Reinstall the shift lever in the vehicle. Mount the shift lever assembly to the side of the transmission using the stock bolts. Reconnect the linkage rod to the transfer case. Install the stock nut. Tighten the nut securely. Tighten the two mounting bolts at the transmission. Check shift lever operation. Be sure that it will engage in all four-wheel drive ranges (it may not be possible to shift into four-wheel drive low until after the vehicle has been started). Reinstall the shift boot. Tighten all mounting screws securely. Reinstall the shift knob and shift knob nut. Tighten securely. Reinstall the shift knob cap : Adjust the linkage following the manufacturer s procedure. 25. Automatic transmission models only: Lengthen the transmission shift rod. Scribe a line along the shift rod in the middle of the rod. Cut the shift rod into two pieces through the scribed line. Insert the 3/ 8" shift extension pin between the two pieces of the shift rod. Realign the scribed lines. Weld the extension in place. Reinstall the shift rod to the pivot assembly at the frame. Loosen the adjustment bolt; the lever will require adjusting after the rod has been installed at the steering column lever. Install the shift rod in the column shift lever. Adjust the shift rod so the shift indicator registers properly. Tighten the adjustment bolt. Manual transmission models only: Check transmission shift lever operation. Be sure that the shift lever engages fully in all gears. If the shift lever does not engage completely in all gears, it may be necessary to heat and bend the shift lever. 26. Remove the rear license plate from the plastic license plate holder. Remove the screws that mount the plastic license plate holder to the body. Remove the holder from the vehicle. On the right side of the holder, measure in from the edge of the license plate light 1". Measure down from the top of the holder 2". Using a 1" hole saw, cut a hole in the holder at this location. This is to relocate the spare tire crank rod. Reinstall the plastic license plate holder to the body.

5 Tighten the mounting screws securely. Install the spare tire crank rod through the hole in the license plate holder and onto the crank mechanism. Reinstall the mounting clip in the crank rod and crank mechanism. If the crank rod is tight going through the license plate holder, it may be necessary to file the opening slightly. The crank rod should be snug, but not tight. Raise the spare tire to the stowed position. Reinstall the license plate. Reinstall the license plate lights.. Raising the rear bumper is intended to enhance the appearance of the vehicle only. The rear bumper will no longer be rated for towing of any kind. Attempting to tow with the rear bumper after it has been raised can result in damage to the vehicle and possible personal injury. A class III receiver hitch must be installed in order to tow with the vehicle after the rear bumper has been raised. 27. Reinstall the rear bumper (Optional rear bumper bracket kit is available part #60023). The measurements for repositioning the rear bumper are very important. The hole must be drilled in the correct positions for the bumper to fit properly. It may be desirable to trial-fit the bumper several times during this procedure to be sure that the holes are in the proper positions. To raise the rear bumper 3": Measure 3" straight up from the stock bumpermounting hole that is closest to the edge on the frame (according to the diagram). Drill a 1/2" hole at this location. Go to the next stock hole forward on the frame and measure straight up 2". Drill a 1/2" hole at this location. Go to the next stock hole forward and measure straight up 1 3/4". Drill a 1/2" hole at this location. The stock bumper brackets have two parts on each side: An inside bracket and an outside bracket. These two parts are joined at two locations when the bumper is mounted to the frame. One location is where the brackets mount to the very rear hole in the frame. This location will remain the same. At the next location forward, measure straight down (in respect to how the brackets would be positioned on the vehicle) 1". Drill a 1/2" hole through the outside bracket and the inside bracket. The next hole forward is only on the inside bumper bracket. Measure straight down 1 1/4" (close to the corner of the bracket). Drill a 1/2" hole in this location. To raise the rear bumper 2": Measure straight up on the frame 2" from the rear two stock bumper mounting holes. Drill a 1/2" hole in these locations. Measure straight up 3/4" from the last stock bumper-mounting hole. Drill a 1/2" hole at this location. Measure 1 1/4" straight down from the hole in the bumper bracket that only mounts the inside bracket to the frame. The other two locations will use the stock holes and mount to the new holes in the frame. Align the hole in the bumper brackets with the new holes in the frame. Mount the rear bumper to the frame using six 7/16" x 1 1/2" bolts, six large 7/16" washers, six small 7/16" washers, and six 7/16" Nylock nuts (three of each for each side of the vehicle). Align the bumper to the body. Tighten all rear bumper mounting hardware securely. 28. Install the bed overload spacers. There are four locations that the bed rested on the frame, but there were no mounting bolts (in the wheel wells). Place the overload spacers on the frame in these locations. Tack weld the spacers to the frame. 29. Reconnect the battery cables to the battery. Be sure to connect the positive cable first, then the negative cable. Reinstall the air bag fuse in the fuse box. 30. Place the warning sticker on dash in plain sight of all vehicle occupants. 31. Install Gap Guards. a. You did remember to buy your gap guards, didn t you? 32. Double-check the vehicle. CAUTION All fasteners should be retorqued after 500 miles and after off-road use. All body lift components should be visually inspected and fasteners retorqued during routine vehicle servicing. a. Check for any wires, cables, hoses, etc. that may be binding. b. Check transmission and transfer case operation. Be sure that there is complete engagement in all gears and 4-wheel drive ranges. c. Start the vehicle. d. Check steering operation. Be sure that there is no binding. e. Check fan-to-fan shroud clearance again. f. Check clutch operation. g. Test drive in all gears and 4-wheel drive ranges. h. Double-check all hardware again in 500 miles, and as part of your regular maintenance schedule.

6 NOTE The vehicle owner must retain all warranty information, instruction sheets, and other documents regarding the installation of this product. Information contained in the instructions and on the warranty card will be required for any warranty claims. The vehicle owner needs to understand the modifications that have been made to his vehicle and how they affect the handling and performance of the vehicle. Failure to provide the customer with this information can result in damage to the vehicle and possible personal injury. CAUTION We do not recommend any particular wheel and tire combinations for use with our body lifts and can not assume responsibility for the customer s choice of wheels and tires. Your owner's manual can be referenced for recommended tire sizes and warnings related to the use of oversized tires. Larger wheel and tire combinations increase stress and wear on steering and suspension components, which leads to increased maintenance and higher risk for component failure. Larger wheel and tire combinations also alter speedometer calibration, braking effectiveness, center of gravity, and handling characteristics. Consult with an experienced local off-road shop to find what wheel and tire combinations work best with your vehicle.

7 Parts List 3 Kit Quantity Description 14 3x3 blocks 2 3x2 blocks 4 3x2 steel spacers with one hole 2 Front bumper brackets 1 Front bumper outer support brackets 1 Lower fan shroud bracket 1 1 1/2 Fuel filler extension 1 13/4 x 16 Fuel vent hose 1 Warning to driver sticker 1 Logo label 1 10ml bottle Loctite Bolt pack 8 12mm x 180mm bolts 8 10mm x 100mm bolts 7/16" USS washers 8 10mm fender washers 1 se 8000 steering extension 3/8" x 1 1/4" allen head bolt 1 Hardware Pack Bolts 8 7/16 x 1 1/2 bolts 1 1/4 x 1 bolts Washers 10 7/16" USS washers 6 7/16 SAE washers 5 1/4" SAE washers Nuts 8 7/16" nylock nuts 4 1/4" nylock nuts Miscellaneous 1 1/2 Dia. transfer case extension 1 3/8 Dia. transmission shift extension 3 Straight fan shroud brackets 1 "L" shaped ground extension 2 #10 Hose clamps 2 #28 Hose clamps Parts List 2 Kit Quantity Description 14 2x3 blocks 2 2x2 blocks 4 2x2 steel spacers with one hole 2 Front bumper brackets 1 Front bumper outer support brackets 1 Lower fan shroud bracket 1 1 1/2 Fuel filler extension 1 13/4 x 16 Fuel vent hose 1 Warning to driver sticker 1 Logo label 1 10ml bottle Loctite Bolt pack 8 12mm x 160mm bolts 8 10mm x 80mm bolts 8 7/16 USS washers 8 10mm fender washers 1 se 8000 steering extension 1 3/8 x 1 1/4 allen head bolt 1 Hardware Pack Bolts 8 7/16 x 1 1/2 bolts 1 1/4 x 1 bolts Washers 10 7/16" USS washers 6 7/16 SAE washers 5 1/4" SAE washers Nuts 8 7/16" nylock nuts 4 1/4" nylock nuts Miscellaneous 1 1/2 Dia. transfer case extension 1 3/8 Dia. transmission shift extension 3 Straight fan shroud brackets 1 "L" shaped ground extension 2 #10 Hose clamps 2 #28 Hose clamps

8 Limited One-Year Warranty This Limited One-Year Warranty is given to the original purchaser (the Buyer ) of this new Summit or Summit Performance Branded Product. Summit Racing Equipment warrants that the product will be free from defects in workmanship and materials under normal use and service for one year from the date of purchase. Your responsibilities: Keep a sales receipt, canceled check, or payment record to verify your purchase date. Operate and maintain the product in accordance with the specifications provided to you with the product. Arrange for or pay items and costs that are not covered by this Limited Warranty. Claims Procedure: The duration of this warranty is limited to claims made in writing to Summit Racing Equipment within one year after the Purchase Date. The Buyer should call the telephone number below to report a possible warranty claim. The Buyer must also allow Summit Racing Equipment to inspect the product, and the Buyer must reasonably cooperate with Summit Racing Equipment with respect to verifying the warranty claim of the Buyer. In the event that a warranted defect is discovered, Summit Racing Equipment will repair or replace the product, or return the purchase price to the Buyer, at the option of Summit Racing Equipment. All shipping costs are paid by the Buyer. Merchandise returned to Summit Racing Equipment without prior authorization will not be accepted. What is not covered: 1. Damages caused by shipping, product misuse, misapplication, improper installation or maintenance, or damages resulting from accidents, contact with onroad or off-road hazards, or racing engine use. 2. Labor costs to remove and install the products or component parts. 3. The costs of shipping the product to and from Summit Racing Equipment. This warranty extends only to the Buyer and is not transferable. Implied warranties applicable to this transaction extend only to one year. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. Summit Racing Equipment shall not be responsible for any incidental or consequential damages of the Buyer. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. This warranty gives you very specific legal rights, and you may also have other rights which vary from state to state SummitRacing.com Copyright 2003 Summit Equipment 1200 Southeast Avenue Talmedge, OH 44279