Car Care


High-Rise Construction
Installing a lift kit on a Dodge Ram
Created by Steve TempleSetting up a vehicle for going off-road is like playing with dominoes. Tip over one, and suddenly you've got a whole lineup of things to handle. Going to bigger tires is a good example. When you throw on a set of 33- or 35-inch knobbies, you should plan on lifting the suspension. And that's just the beginning. You also may need to trim the fenders, along with changing the gear ratio in the axles and adding air lockersand those projects turn into another game of dominoes altogether.
Moving Up
In addition to creating a better looking 4x4, the obvious reason for installing a lift kit with larger tires is to add more ground clearance and achieve better traction. That's where a 4-inch lift really comes in handy. In this case, we followed the installation of a suspension package for an '02 Dodge Ram 1500. This particular kit from Rancho allows for the use of 35-inch tires and alignment to OE specs. It was developed using a 35-inch tire on a 17x8-inch wheel with five inches of backspacing.
Keep in mind that while a lift kit can enhance the off-road performance of your vehicle, it will handle differently, both on and off-road. Use care during abrupt maneuvers to prevent loss of control or a rollover. Also, before installing this system, make sure the alignment is to factory specs and that the frame is sound, with no cracks, damage or corrosion.
Basic Bolt
This project is just about an all-day deal (if you haven't done this sort of job before, it may take a bit longer). Overall, the install is basically a bolt-on process, with no welding or cutting required (we did do a bit of grinding, though). Be sure to use thread-locking compound to all bolts during installation. The exhaust system did not need to be modified (except for a bit of bending to clear the driveshaft, or you can have an exhaust shop splice in a new piece if tubing).
As for tools and equipment, you will need a lift or jackstands, along with a well-stocked toolbox and a fair amount of mechanical experience. It also helps to have an extra pair of hands to help lift some of the bulkier pieces into place, such as the one-piece, MIG-welded subframe. But doing a project with your buddies is all part of the fun, right? Just promise to take them with you when you're ready to head for those off-road trails.

Step 1
Rancho's 4-inch lift kit includes a skid plate, bump stops, brake hoses, a reinforced MIG-welded subframe, rear riser blocks and U-bolts, and drop brackets for the front differential and torsion bars.
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Step 2
With the vehicle on a lift or jackstands, the first step is to remove the stock suspension pieces such as the torsion bars and its crossmember.
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Step 3
Next unbolt and remove the steering knuckle, shock absorber and lower control arm on each side.
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Step 4
The reinforced subframe for the transfer case is pretty heavy, so get some help to lift it in place.
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Step 5
Here you can see the amount of drop in the transfer case provided by the subframe to produce four inches of lift.
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Step 6
All of these drop-down brackets need to be fitted loosely before tightening the bolts.
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Step 7
The new, longer end link for the front swaybar has urethane (red) bushings for less suspension deflection.
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Step 8
A side-by-side comparison of the stock (left) and Rancho (right) steering knuckles clearly shows the 4-inch lift. After relocating the stock hubs on the new steering knuckles, install them back on the chassis.
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Step 9
Cut off 1/2-inch from the tie rod so the steering can be correctly aligned.
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Step 12
Rancho's bump-stop has a spacer to compensate for the lift in the suspension.
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Step 13
The aft braces included with the lift kit have urethane bushings to minimize suspension deflection and binding.
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Step 14
A bit of bending on the exhaust system may be needed to provide enough driveshaft clearance, or you can splice in a curved tube.
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Step 15
To install the drop-down brackets for the torsion bars, you'll need to tap a bolthole in the frame members. Once the drop-down brackets are installed, you can replace the torsion bar crossmember.
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Step 16
You'll need a C-clamp to put tension on the "pork chop" for the torsion bar.
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Step 17
To lift the rear end, start by removing the stock shocks, and then install the lift brackets for the rear bump stops.
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Step 19
Unbolt the brackets for the leaf springs to install the riser blocks. The riser blocks fit between the leaf springs and the axle.
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