Owners manual

ManualsBrandsSKYJACKER ManualsAutomotiveSkyjacker D75 Softride Coil Spring Fits 94-02 Ram 2500 Ram 3500

Before beginning the installation, read these instructions and the enclosed driver’s WARNING

NOTICE thoroughly and completely. Also affix the WARNING decal in passenger compartment in

clear view of all occupants. If any of these items are missing from this instruction packet, do not pro-

ceed with installation, but call SKYJACKER

to obtain needed items. If you have any questions or

reservations about installing this lift kit, call SKYJACKER

at 318-388-0816 for Technical Assistance

or Customer Service departments.

Make sure you park the vehicle on a level concrete or asphalt surface. Many times a vehicle is

uneven (side-to-side) from the factory, but usually not noticed until a lift kit has been installed which

makes the difference more visible. Using a measuring tape, measure the front and rear (both sides)

from the ground up to the center of the fender opening above the axle. Record below for future ref-

erence.

Driver Side Front: Passenger Side Front:

Driver Side Rear: Passenger Side Rear:

IMPORTANT NOTES:

• Seal Adapter Part # DTSA10, and new seal Part # TCS2675 are both included with this lift.

• 6 Speed Manual Transmission models will require modifications to Transmission Bracket.

• 3/4 & 1 Ton models equipped with 360 engine, the front will sit slightly higher than the rear.

• Please refer to Parts List to insure that all parts and hardware are received prior to disassembly of

vehicle. If any parts are found to be missing, contact your dealer as soon as possible.

• If larger tires (10% more than stock diameter) are installed, speedometer recalibration is necessary

(see Ford dealer or Tire Store).

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

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

1994-2001 Dodge 1/2-1 Ton 4x4

7” Suspension lift

Installation Instructions

REQUIRED TOOL LIST:

* Metric and Standard wrenches and sockets

* Allen Wrenches

* Assorted Drill Bits

* Bristle Disc

* Floor Jack

* Jack Stands

* Measuring Tape

* Ratchet Strap

* Torsion Bar Tool

* Torque Wrench

* Transmission Jack

www.skyjacker.com

I-D7075 4-04 Pg 1

Summary of content (15 pages)

PAGE 1
994-2001 Dodge 1/2-1 Ton 4x4 7” Suspension lift Installation Instructions www.skyjacker.com REQUIRED TOOL LIST: * Metric and Standard wrenches and sockets * Allen Wrenches * Assorted Drill Bits * Bristle Disc * Floor Jack * Jack Stands * Measuring Tape * Ratchet Strap * Torsion Bar Tool * Torque Wrench * Transmission Jack Before beginning the installation, read these instructions and the enclosed driver’s WARNING NOTICE thoroughly and completely.
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Kit Box Breakdown: D7075-DX: ITEM# DUL75-DX DLL75-DX D70CM-5 D70FDI-1 D70FPI-2 D70FPO-3 D70FDO-4 D70SP-7 DTB70-B D70TB IXR10 RBL60 VT53229 HB-D7075-1 HB-D7075-BL HB-D7SHK DTSA10 TCS2675 DESCRIPTION DODGE UPPER LINKS 7" PAIR DODGE LOWER LINKS 7" PAIR DODGE 94-01 7" CROSS MEMBER DODGE 94-01 7" FRAME DRIVER INNER BRKT DODGE 94-01 7" FRAME PASSENGER INNER BRKT DODGE 94-01 7" FRAME PASSENGER OUTER BRKT DODGE 94-01 7" FRAME DRIVER OUTER BRACKET DODGE 94-01 7" SKID PLATE DODGE 94-01 7" TRACK BAR-BRACKET DODGE 7"
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TS250 S-FR7D SPACER .250" LONG SLEEVE,FRAME,3.125" HB-D7075-BL Brakeline Hardware ITEM# DBLE70 DVL10 14X1FTB 516X114FTB 14FTN 516FTN 14SAEW 516SAEW DESCRIPTION BRAKE LINE EXTENSION DODGE VACUUM LINE BRACKET-FLAT 1/4 X 1 FINE THREAD BOLT GRD 8 5/16 X 1 1/4 FINE THREAD BOLT 1/4-28 FINE N/I LOCK NUT 51/6-24 FINE N/I LOCK NUT 1/4 SAE WASHER 5/16 SAE WASHER HB-D7SHK Shock Hardware ITEM# 142118 HOURGLASS 3/4 DESCRIPTION ES34 SLEEVE/404094 1.
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Hardware Bag Breakdown: DS397 Dual Shock Kit ITEM# DS397-UL DS397-UR DS390-BL DS390-BR 12X3CTB 12X40MMB 12CTN 12MMN 12SAEW DESCRIPTION 7"UPPER LEFT SHOCK BRACKET 7"UPPER RIGHT SHOCK BRACKET BOTTOM LEFT DUAL SHOCK BRACKET BOTTOM RIGHT DUAL SHOCK BRACKET 1/2 X 3 COARSE THREAD BOLT 12 X 40 METRIC BOLT/10.
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IMPORTANT NOTES: Safety Recall #835 1994-95 models 2500 and 3500 with 5.9 diesel or 8.0 ltr. V-10, The vehicle manufacturer has a safety recall #835, which reinforces the coil towers. The part # for this upgrade is #CBBR8352.Check with your local dealer in regards to this upgrade prior to installing this suspension system. Front: 1. If equipped, remove factory skid plate that attaches to underside of Transfer Case. Remove rear skid plate cross member. “Located behind transfer case”. (See Photo #1 and #2) 2.
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8. Remove transfer case shift linkage from transfer case bracket. “This should easily pop off with use of a long screwdriver.” (See Photo #8) 9. Transfer case can now be removed with a transmission jack. 10. With transfer case out of vehicle, remove the 6 retaining studs on the front of transfer case using stud remover. 11. Clean outside edge of transfer case with bristle disc being sure to remove all silicone. This surface should be clean and free of residue.(See Photo #9) Photo #8 12.
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17. Loosen transmission mount from cross member using 5/8” socket. (See Photo #15) 18. Support transmission with jack; remove bolts from cross member using 15mm socket, 13 mm wrench, and a 6” extension. Bolts can be reached through outside holes in frame rail. (See Photo #16) 19. Remove vacuum line retaining bolt from cross member using 10 mm socket. Then, remove factory cross-member. 20. Using 15mm socket, remove rubber transmission mount. Then remove transmission mount bracket using 16mm socket.
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26. Install new cross-member with tabs down and pointing forward. Install using 1/2” x 3 1/2” fine thread bolts, SAE washers and self-locking nuts. Bolts should be installed so that they point toward the front of vehicle. 27. Install factory rubber transmission mount to new upper transmission bracket using factory hardware. Then, attach rubber mount to new crossmember using 7/16” x 1 1/2” fine thread bolts, washers, and self-locking nuts. (See Photo #22) 28.
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33. Remove sway bar links from axle, and clamps from the frame using 15mm socket. Remove sway bar and lay to the side. (See Photo #29) 34. Remove draglink from pitman arm using 21mm socket. Remove nut from steering box shaft using 1 5/16” socket. Using pitman arm puller, remove pitman arm. Install new Skyjacker EXTREME drop pitman arm. (See Photo #30) 35. Remove cotter pin from passenger side tie rod. Using 21mm socket, remove nut from tie rod end.
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43. Remove front tires and lower down front axle. Remove factory coil spring and inside tower ring. The factory rubber isolator pad will be reused. (See Photo #36) 44. Remove factory “rubber” bump stops from frame rails. These are easily removed using a pair of pliers. (See Photo #37) 45. Remove both upper and lower control arms. Be sure to leave at least one lower control arm in at all times. This will make sure that axle does not roll.
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50. Using a grinder, grind off the bottom lip of the bump stop cup on the frame. This will allow for clearance of the new bump stop bracket. Slide new bump stop bracket over factory bump stop cup. Make sure the bracket is flush against frame rail and mark both holes that will need to be drilled. Remove bracket and drill both holes to 1/2”. Install poly. bump stop to bracket using 3/8” coarse thread nut. Install bump stop bracket using 1/2”x 3” fine thread bolts, washers, and nuts.
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54. Once again, remove tie rod from passenger side. This will allow access to track bar mount on passenger side. Using the template from page #15 as a guide cut out sway bar bracket on passenger side of axle. Install new grease fitting, sleeve, and bushings into track bar. Be sure to grease bushings prior to installation. Place step down spacers into rod end. Install track bar with rod end at the axle end. The track bar will attach to the axle using new Allen head bolt supplied.
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Rear: 59. Remove both rear shocks. Spare tire may need to be removed to allow access to upper shock mount on driver side. 60. Disconnect rear brake line and vent hose. Remove rear u-bolts. Jack up frame away from axle to allow installation of new springs. (See Photo #57) 61. Loosen retaining straps on gas tank. Do not remove the straps. Only loosen to allow access to front spring eye bolt on drivers side. Place 2x4 between gas tank and frame; this will allow you to remove the spring eye bolt. 62.
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FINAL NOTES: -On 3/4 and 1 Ton models equipped with rear brake proportioning valve, it may be necessary to lengthen extension linkage for proper use. NOTICE: Retorque ALL nuts, bolts and especially the u-bolts after the first 100 miles, again after another 100 miles, and then check periodically thereafter. -Before driving the vehicle, check to make sure the brakes are operating properly and need no further bleeding.