PullRite Super 5th SuperRail Mounting Instructions

SuperRail Installation Inst. Rev. 2/23/2003 Page

1

SuperRail Mounting Kit

Mounting Instructions

Specifications:

The following Kits fit both the 6’ and the 8’ truck beds.

See Specifications for . . . . . . . . . . . . . . . . 15,500 lb. Super 5th Wheel Hitch, P/N 1200

or . . . . . . . . . . . . . . . . . . . .20,500 lb. Super 5th Wheel Hitch, P/N 0800

See page 7, Truck Bed Layout Table, for hitch location ahead of axle.

Important Notes:

1. Trucks with bed liners may need a tall Mounting Post. See “NOTE” under item 4 of
“Drilling the Bed” on pg. 3 for details.

Introduction

This guide provides several pages of instructions for the installation of the SuperRail towing system
Read these instructions completely and follow them accurately. Should you have any questions, please
call the factory at [phone] for installation assistance.

Pullrite/Pulliam Enterprises, Inc.

13790 E. Jefferson Blvd.

Mishawaka, IN 46545

[phone]

Fax [phone]

www.pullrite.com • [e-mail]

SuperRail Installation Inst. Rev. 2/23/2003 Page

2

Table of Contents

Introduction 1

20,500 & 15500 Parts List 3

20,500 & 15500 Assembly Instructions 4

General Installation Instructions 5

Layout Dimensions and Drawings 7

FORD SD Specific Instructions 8 – 9

FORD SD Supplemental Drawings 10 – 11

Parts List 0851 FORD SD 12

DODGE Specific Instructions 13

DODGE Supplemental Drawings 14 – 15

Parts List 0852 DODGE 16

CHEVY Specific Instructions 17

CHEVY Supplemental Drawings

Parts List 0853 CHEVY 19

2003 DODGE Specific Instructions 20 – 23

2003 DODGE Parts List 24

18

SuperRail Installation Inst. Rev. 2/23/2003 Page

3

20,500 PARTS LIST

Ref. Part # Part Name

Figure 1

1
2
3

4
5

6
7
8

9
10
11
12
13
14

3601 Plate
98410111 Clevis Pin
98410127 Clevis Pin Clip

0802 Rocker Arm

0803 Crossmember
98200142 1/2” Lock Washer
98150153 1/2”-13 Hex Nut
98010147 Rocker Arm Pivot Bolt
98010167 1/2”-13 x 1 1/2” HHCS

0804 Base
98410127 Clevis Pin Clip
08060001 Base Rail Hinge Pin
98200124 3/4” Split Lock Washer
98150131 3/4”-10 Hex Nut

Table 1

15,500 PARTS LIST

Ref. Part # Part Name

1
2
3
4
5
6
7
8

9
10
11
12
13
14

3601 Plate
98410111 Clevis Pin
98410127 Clevis Pin Clip

0802 Rocker Arm

1202 Crossmember
98200142 1/2” Lock Washer
98150153 1/2”-13 Hex Nut
98010147 Rocker Arm Pivot Bolt
98010167 1/2”-13 x 1 1/2” HHCS

1203 Base Sides (set)
98410560 Plastic Barbed Fastener

120302 Cover Assembly
98410127 Clevis Pin Clip
08060001 Base Rail Hinge Pin

Figure 2

15
16

98200124 3/4” Split Lock Washer
98150131 3/4”-10 Hex Nut

Table 2

SuperRail Installation Inst. Rev. 2/23/2003 Page

4

Hitch Assembly

Hitch Assembly for 20,500#:
If the hitch type to be installed is a 20,500# (Part #0800), there is no assembly required

except to attach the Base Rails to the base feet of the hitch Base using the four 1/2” Base
Rail Pins and four #3 Pin Clips (See exploded drawing on page 3).

This hitch has four height settings and should be adjusted according to the directions
found in the Operators Instructions found in the same box as the hitch. Be sure to torque
all four 1/2” x 1 1/2” Bolts to 75 foot pounds after adjusting height.

Hitch Assembly for 15,500#:
If the hitch type to be installed is a 15,500# (Part #1200), it will be necessary to assem-

ble the hitch first. Refer to page 3, the exploded view of this hitch and the parts list below
the drawing then follow these steps:

1. Attach the Base Sides to the Base Rail Assembly using the four 1/2” Base Rail Pins and
four #3 Pin Clips.

2. Remove the 3/4” x 7” Pivot Bolt from the Rocker Arm and Crossmember.

3. The Rocker Arm is shipped upside down in the Crossmember for better packaging and
will need to be removed and reinstalled right side up in the Crossmember as shown in
the exploded view drawing on page 3. Tighten the 3/4” x 7” Pivot Bolt only enough to
flatten the 3/4” Lock Washer or enough so that the Rocker Arm will rotate stiffly. Lu­bricate the 3/4” Pivot Bolt with heavy grease before installing.

4. Fasten the Crossmember and Base Sides together using six each of the 1/2”-13 x 1
1/2” Bolts, 1/2” Lock Washers and 1/2”-13 Hex Nuts, tighten bolts to 75 foot pounds.
This hitch has four height settings and should be adjusted according to the directions
found in the Operators Instructions found in the same box as the hitch.

5. Fasten the Fifth Wheel Plate in the Rocker Arm using two each of the 1/2” Clevis Pins
and #3 Pin Clips after installing the Release Handle and Main Spring as shown below.
Be sure to install the Main Spring so that the end with the swivel hook is inserted into
the open end of the Release Handle as shown below.

Fig. 3.

SuperRail Installation Inst. Rev. 2/23/2003 Page

5

General Installation Instructions

General Installation Instructions

General Installation Instructions

NOTE: Refer to the Specific Vehicle’s Figures

and Reference information for all references
made herein. The location of the Specific

Vehicle can be found by referring to the Table
of Contents.

Truck Preparation

1. Check part quantities using the Parts List for the

specific vehicle type.

2. Block vehicle wheels. Some vehicles may require
you to raise the rear of the truck in order to make
it easier to drill for installing the Mounting
Brackets on the truck frame.

3. You may wish to remove the wheels, to give
yourself greater working room.

4. At this point, the bed should be laid out and
marked for drilling using either the LAYOUT
METHOD or the TEMPLATE METHOD.

Marking Bed for Drilling (layout
method)

1. For layout using the Template method, see Layout
(Template Method) on next page.

2. See Truck Bed Layout Dimensions table pg. 7
for the dimension values for items A - D located
in the ‘LAYOUT METHOD’ illustration.
Measure and mark from the back of the bed
forward the values for A and B. Do this at any
point on both sides of the bed.

3. Draw a line across the bed from mark to mark.

4. Find the centerline of the bed. Draw a line down
the middle of the bed from front to rear. See
Figure 5 on pg. 7. Center the measurement of C
across the centerline at the front most line you
made in step 2, and mark the measurement on
each side (parallel to the centerline). Center the
measurement of D for the rear most line made in
step 2, and again mark the measurement on each
side (parallel to the centerline). This will locate
the 4 drill holes.

5. Go to your truck’s SPECIFIC LISTING (listed
in the Index on pg.2) and perform the steps listed
in PART I. The truck Specific Listings begin
after page 7 of these instructions.

Drilling the Bed

1. After you have removed the Mounting Brackets,

use a 1 3/4” hole saw, centered over the 1/16”
pilot hole, cut the bed for the mounting posts.

2. De-bur inside the holes, then use a paint stick to
touch up the edges.

3. Re-install the Mounting Brackets and secure those
that have no existing mounting holes in a
temporary fashion, using ‘C’ clamps. Those that
have holes, secure by lightly attaching with bolts
( tighten sufficiently to where the Mounting
Brackets lay flat against the truck frame).

4. Install the Mounting Posts through the bed into
the Mounting Bracket Post Holders. Rotate the
Posts a quarter turn. (See the illustrations in the

truck Specific Listings).
NOTE: The Mounting Post should be tall enough

to clear most bed mats. Vehicles using bed liners
may require taller Mounting Posts to seat into the
Post Holders properly. A Tall Mounting Post (1”

taller) is available under part # 330705. Four posts
are required for installation.

5. Remove the Base Rails from the shipping carton,
leaving the Base Rail Extensions loose to allow
lateral movement as you place the Rail assembly
over the Mounting Posts. See drawing on next
page.

6. Install the Base Rails in the bed of the truck, and
center the Base Rails between the Base Rail
Mounting Posts. Finger tighten the Base Rail
mounting Bolts.

7. Set the 5th Wheel Hitch on the Base Rails, and
align the Hitch Assembly with the Base Rail
mounting holes, using a drift pin punch to aid
your alignment. Install the Mounting Pins from
the inside. Then install the Pin Clips, to secure the
Hitch assembly to the Base Rails. See drawing on
next page.

8. Center the Hitch assembly within the truck bed,
from side to side. You might need to use a rubber
mallet to get the unit to move while centering.
Once the unit is centered, tighten the Base Rail
Extension Bolts to 31 ft. lbs..

9. The 5th Wheel Hitch, and the Base Rails, must be
removed to verify that the Mounting Post can be
inserted and removed freely, without binding. A
slight adjustment might be required to obtain un-

3

3

SuperRail Installation Inst. Rev. 2/23/2003 Page

6

restricted access.

10. Reinstall the Mounting Posts, the Base Rails, and
the 5th Wheel Hitch assembly.

11. Complete the final steps needed to install the
Mounting Brackets to the truck frame. Go to the
truck Specific Listings, Part II at this time.

12. Due to slight inconsistency in manufacturing
processes, it is recommended that you mark the
Base Rails in such a manner that you will be able
to re-install them into the same relative position as
you have them presently installed.

Torque Table

3/8” Bolt — 31 ft. lbs.
1/2” Bolt — 75 ft, lbs.
5/8” Bolt — 151 ft. lbs.
3/4” Bolt — 266 ft. lbs.

Layout (Template Method)

A Template set containing all available
Templates can be ordered, P/N 08400000,
from your distributor. Templates do not
come with the installation kit.

1. Lay the Template in the truck bed, centering it
from side to side, and parallel to the end of the
truck bed, using the dimension X listed in Truck
bed layout dimension table on pg. 7.

2. Mark the 4 holes, while making sure the template
does not move.

3. Go to the truck SPECIFIC LISTING and begin
with the steps listed in PART I.

Fig. 4

Base Rail parts identification

SuperRail Installation Inst. Rev. 2/23/2003 Page

7

CAB

Figure 5

NOTES: The TEMPLATE should be orientated as shown in Figure 3 above after checking dimensions “C” and “D”

in the table below.
INSTALLATION TIP: The template has a tendency to move when placed on the slick paint of new truck

beds, and it may be helpful to place a small piece of NON-SKID matting, such as “SCOOT-GARD” ™, to help keep the
template from moving.

Vehicle Type Bed

Chevy

0843

Dodge

0842

Ford SD

0841

03 Dodge, 3/4

& 1 Ton 4x4,

0844

Lght.

6 ft.
8 ft.

6 ft.
8 ft.

6 ft.
8 ft.

6 ft.
8 ft.

Truck Bed Layout Dimensions

"A" "B" "C" “C” / 2 "D" “D” / 2 Template

26 5/8”

31 15/32”

28 5/16”

32 1/8”

31 5/32”
31 5/32”

29 11/16”
31 9/16”

24”
24”

24”
24”

24”
24”

24”
24”

43 13/32”
43 13/32”

40 7/8”
40 7/8”

41"
41”

43 7/16"
43 7/16”

21 23/32”
21 23/32”

20 7/16”
20 7/16”

20 1/2”
20 1/2”

21 23/32”
21 23/32”

40”
40”

40 7/8”
40 7/8”

41”
41”

41 13/32“
41 13/32”

20”
20”

20 7/16”
20 7/16”

20 1/2”
20 1/2”

20 23/32”
20 23/32”

Mode

25 5/8”

30 15/32”

27 15/16”

31 1/8”

30 5/32”
30 5/32”

28 11/16”

30 9/16”

“X”

Template

Part #

085300 1/4”

085200 1/2”

085100 1/2”

085400 1 3/8”

Distance
Ahead of

Axle

SuperRail Installation Inst. Rev. 2/23/2003 Page

8

FORD SD 1999 to Current Year

FIGURE 1

PART I Truck Preparation

1. Unfasten the emergency brake cable bolt (A) on the driver’s
side of the frame. (See drawing Ford 1). (B) is the overload
spring bracket, if equipped, and must be removed at this time.

Mounting Bracket Installation,

1. Place the driver side Mounting Bracket against the truck frame,
aligning the hole C , and the hole directly above hole C. (See
Ford 1, as your guide for placement of the Mounting
Bracket). Be sure to place the Mounting Bracket behind the
emergency cable.

2. Temporarily attach the Mounting Bracket to the frame,
using the 3/4” x 2 1/2” bolt in hole C, and the 3/8” x 2” bolt
into the hole directly above C (Figure 1 above). If the truck
is equipped with overload springs, use one of the bolts that
you removed when taking the overload bracket off, and
place the bolt into a hole B. If the truck is NOT equipped
with overload springs, use a 1/2” x 1 1/2” bolt provided (Figure 1 above).
(Some Mounting Brackets may have a slight warp to them due to the metal characteristics during
the welding process. If the bracket has a warp, you will need to draw the bracket tight against the
frame using either the bolts or by adding a clamp to assist in drawing the bracket against the
frame.) Tighten sufficiently to hold the Mounting bracket tight against the frame.

3. Install the Mounting Bracket on the passenger side repeating steps 1-3, except there will not be
the emergency brake cable to have to contend with.

4. Figure Ford 2 illustrates the drilling of the truck bed, using a 1/16” drill.

5. Drill the first 1/16” hole in the truck bed over the rear Post Hole on the driver side Mounting
bracket, where you made the mark during Truck Bed Layout. The bit should come down through
the Post Holder of the Mounting Bracket, centered front to rear and side to side.

6. If the first pilot hole is off center (front to rear) to the post holder, adjust the drill placement and
re-drill.

NOTE: If you have to re-drill in order to be centered, remember to adjust the other three holes
accordingly.

7. Drill the remaining three pilot holes, again checking to be sure the hole in the center of the Post

Hardware

A. 3/8” x 2”

Qty.= 1

C. 3/4” x 2 1/2”

Qty.=2

D, B. 1/2” x 1 1/2”

Qty.=9

Bolt Plate = 1

Ford 1

NOTE: Hole “D” does not exist

on the 6’ truck frame.

Ford 2

SuperRail Installation Inst. Rev. 2/23/2003 Page

9

FORD SD continued

Holder.

8. Remove the Mounting Bracket, and return to Drilling the Bed on pages 5 & 6 .

PART II Mounting Bracket installation continued.

1. Attach the brake cable to the Mounting bracket using the 3/8” x 2” bolt through hole A (directly
above hole C on the driver side). (See Figure 1).

2. Install bolts B (Figure 1), or use the bolts that were removed with the overload spring bracket
into the B indicated holes, and tighten. ( It may me necessary to drill these holes out to 1/2” to
accept the 1/2” bolts ).

3. Install the 3/4” bolt C shown in figure 1.

4. Drill hole D to 1/2”, and fasten on the driver side with the Bolt Plate shown in Figure 1, and on
the passenger side with 1/2” x 1 1/2” bolt D.

5. Torque all bolts per the table on pg. 6.

SuperRail Installation Inst. Rev. 2/23/2003 Page

10

FORD SD

Ford Mounting Posts illustration

Ford Base Rail illustration

SuperRail Installation Inst. Rev. 2/23/2003 Page

11

FORD-SD

Note: The 3/8” x 2” bolt shown, is only present on the driver side of the vehicle. This bolt holds the brake
cable.

The insert on the right side shows the use of a BOLT PLATE for the driver side mounting bracket. This plate
is necessary because of the limited clearance between the truck frame and the gas tank.

Cutaway view, of Mounting Plate installation

Detail view of Mounting Plate installation

SuperRail Installation Inst. Rev. 2/23/2003 Page

12

REVISION: 4-14-01

BASE RAIL MOUNTING POSTS

SUPER RAIL MOUNTING KIT

PASSENGER SIDE

1

1

P/N 0841

330701 4

BOLT PLATE 081004 1 DRIVER SIDE BOLT PLATE

MOUNTING POST

WEIGHT 34.03 LBS

1/2", FRAME BOLTS 98010167 9 1/2"-13 x 1 1/2" HHCS GRD 5

1/2" FLAT WASHER 98250145 17 1/2" FLAT WASHER

MOUNTING POST BRACKET 085101

MOUNTING POST BRACKET 085102 1 DRIVERS SIDE

1/2" - 13 HEX NUT 98150153 10 1/2" - 13 HEX NUT

1/2" SPLIT LOCK WASHER 98200142 10 1/2" SPLIT LOCK WASHER

3/8" FLAT WASHER 98250175 2 3/8" FLAT WASHER

3/8” BRAKE CABLE BOLT 98010223 1 3/8"-16 x 2" HHCS, GRD 5

MOUNTING BRACKET KIT 0851 1 KIT MOUNTING BRACKET KIT

99 FORD SUPER DUTY

** LAYOUT TEMPLATE 08510000

BASE RAIL 084001 2 BASE RAIL

3/8" - 16 HEX NUT 98150211 1 3/8" - 16 HEX NUT

3/4" FRAME BOLTS 98010128 1 3/4"-10x2 1/2" HHCS GRD 5

3/8" LOCK WASHER 98200151 1 3/8" LOCK WASHER

3/4" FLAT WASHER 98250190 1 3/4" FLAT WASHER

3/4"-10 HEX NUT 98150131 1 3/4"-10 HEX NUT

3/4" LOCK WASHER 98200124 1 3/4" LOCK WASHER

BASE RAIL EXTENSION 084002 4 BASE RAIL EXTENSION

BASE RAIL ASSEMBLY KIT 0840 1 KIT BASE RAIL ASSEMBLY KIT

COTTER PIN 98410127 4 #3 COTTER PIN

BASE RAIL PIN 08060001 4 BASE RAIL PIN

BASE RAIL BOLT 98050140 8 3/8”-16 X 3 1/2” CARRIAGE GRD. 5

BASE RAIL FLAT WASHER 98250175 8 3/8” FLAT WASHER

BASE RAIL HEX NUT 98150211 8 3/8” - 16 HEX NUT

BASE RAIL LOCK WASHER 98200151 8 3/8” LOCK WASHER

BASE RAIL HARDWARE KIT 084003 1 KIT BASE RAIL HARDWARE KIT

NOTE: ** = NOT INCLUDED IN KIT.

SuperRail Installation Inst. Rev. 2/23/2003 Page

13

DODGE, 1995 to 2002 Except 2002 1/2 Ton

PART I Truck Preparation

Dodge 1

1. For the 6’ bed truck, cut off the lower sheet metal support as shown illustrated in figure Dodge-1 on both
the driver side and passenger side of the truck bed, if this sheet metal exists.

Mounting Bracket Installation,

1. Locate the two existing holes that are to be used to mount the front Mounting Bracket, as shown

in the drawing of Dodge 1. Install the Mounting Bracket over the holes, using 5/8” x 1 1/2:
bolts. Tighten sufficiently to hold the Mounting bracket tight against the frame.

2. Install the Mounting Brackets on the passenger side repeating steps 1.

3. Drill the four pilot holes in the truck bed where you marked the bed during Truck Bed Layout.
Check each of the holes to be sure that the pilot hole is centered in the Mounting Post Hole.
Adjust the drill holes if needed. Keep in mind that realigning any one hole will affect the relative
spacing of the other pilot holes. The pilot hold should come down in the center of the Mounting
Post hole of the bracket.

4. Remove the four Mounting Brackets, and return to the General Instructions on pages 5 & 6
continue with ‘Drilling the Bed’.

PART II Mounting Bracket installation continued.

1. Install the Mounting brackets using the 5/8” x 1 1/2” bolts provided. The hardware is illustrated in the
Detail View of Mounting Plate Installation on page 12 .

2. Tighten all the previous installed mounting bolts on the Mounting Brackets. Torque all bolts per the table
on pg. 6.

3. You may wish to remove and install the 5th Wheel Hitch to be sure the hitch will go on and off freely.

SuperRail Installation Inst. Rev. 2/23/2003 Page

14

Dodge

Cutaway view of Base Rail Installation

Enlarged Cutaway view of truck bed

SuperRail Installation Inst. Rev. 2/23/2003 Page

15

DODGE

Dodge Base Rail Illustration

Dodge Detail Base Rail Illustration

SuperRail Installation Inst. Rev. 2/23/2003 Page

16

REVISION: 4-14-01

BASE RAIL MOUNTING POST

SUPER RAIL MOUNTING KIT

PASSENGER SIDE

1

1

P/N 0842

330701 4

DODGE

MOUNTING POST

WEIGHT 34.03 LBS

5/8", FRAME BOLTS 98010231 4 5/8"-11 x 1 1/2" HHCS GRD 5

MOUNTING POST BRACKET 085201

MOUNTING POST BRACKET 085202 1 DRIVERS SIDE

MOUNTING BRACKET KIT 0852 1 KIT MOUNTING BRACKET KIT

** LAYOUT TEMPLATE 08520000

5/8" - 11 HEX NUT 98150175 4 5/8" - 11 HEX NUT

5/8" FLAT WASHER 98250115 4 5/8" FLAT WASHER

5/8" SPLIT LOCK WASHER 98200133 4 5/8" SPLIT LOCK WASHER

BASE RAIL 084001 2 BASE RAIL

BASE RAIL EXTENSION 084002 4 BASE RAIL EXTENSION

BASE RAIL ASSEMBLY KIT 0840 1 KIT BASE RAIL ASSEMBLY KIT

COTTER PIN 98410127 4 #3 COTTER PIN

BASE RAIL PIN 08060001 4 BASE RAIL PIN

BASE RAIL BOLT 98050140 8 3/8”-16 X 3 1/2” CARRIAGE GRD. 5

BASE RAIL FLAT WASHER 98250175 8 3/8” FLAT WASHER

BASE RAIL HEX NUT 98150211 8 3/8” - 16 HEX NUT

BASE RAIL LOCK WASHER 98200151 8 3/8” LOCK WASHER

BASE RAIL HARDWARE KIT 084003 1 KIT BASE RAIL HARDWARE KIT

NOTE: ** = NOT INCLUDED IN KIT.

SuperRail Installation Inst. Rev. 2/23/2003 Page

17

PART I Truck
Preparation

CHEVY HD & LD, 1999 To Current Year

HARDWARE

1/2 x 1 1/2 Bolt Qty. 8

1/2 Lock Washer Qty. 8

1/2 Flat Washer Qty. 4

1/2 Nut Qty. 4

D.S Nut Plate Qty. 1

P.S. Nut Plate Qty. 1

Driver Side Rear

1. Take note of drawing

Chevy-1. It should help
you position the
Mounting Brackets.

Mounting Bracket Installation,

1. From the truck bed, drill a 1/16” pilot hole over the forward most driver side hole that you
marked during layout. Then slide the Front Driver Side Mounting Bracket up in place, holding it
firmly against the truck frame. Check to see if the 1/16” hole aligns with the center of the
Mounting Bracket Post Hole.

2. If the drill bit missed the center of the hole in the Mounting Bracket, check your measurements
again. Re-drill the hole if necessary to get correct alignment. Adjust the other hole markings for
the remaining three holes if needed. Drill the pilot holes for the remaining three hole and check
each hole using it’s appropriate Mounting Bracket. Once the alignment looks good, remove the
brackets.

3. Go to “Drilling the Bed” on pages 5 & 6.

Part II. Mounting Bracket installation continued.

1. Drill the frame holes for the Mounting Brackets, using a 1/2” drill bit.

2. Install the 1/2 x 1 1/2” bolts to secure the Mounting Brackets to the frame.

The front Mounting Brackets require Nut Plates, so start both bolts into the Nut Plate before you
begin tightening the bolts. (Refer to the drawing above, and on page 18).

3. Tighten all bolts, torque all bolts per the table on page 6.

Chevy - 1

SuperRail Installation Inst. Rev. 2/23/2003 Page

18

CHEVY HD & LD

Base Rail Cutaway View Illustration

Base Rail Detail View Illustration

SuperRail Installation Inst. Rev. 2/23/2003 Page

19

REVISION: 4-14-01

BASE RAIL MOUNTING POST

SUPER RAIL MOUNTING KIT

PASSENGER SIDE

1

1

P/N 0843

330701 4

CHEVY

MOUNTING POST

WEIGHT 34.03 LBS

1/2", FRAME BOLTS 98010167 8 1/2"-13 x 1 1/2" HHCS GRD 5

MOUNTING POST BRACKET 085301

MOUNTING POST BRACKET 085302 1 DRIVERS SIDE

MOUNTING BRACKET KIT 0853 1 KIT MOUNTING BRACKET KIT

** LAYOUT TEMPLATE 08530000

1/2" - 11 HEX NUT 98150153 4 1/2" - 13 HEX NUT

1/2" FLAT WASHER 98250145 4 1/2" FLAT WASHER

1/2" SPLIT LOCK WASHER 98200142 8 1/2" SPLIT LOCK WASHER

DRIVER SIDE NUT PLATE 085306 1 DRIVER SIDE NUT PLATE

PASSENGER SIDE NUT PLATE 085307 1 PASSENGER SIDE NUT PLATE

BASE RAIL 084001 2 BASE RAIL

BASE RAIL EXTENSION 084002 4 BASE RAIL EXTENSION

BASE RAIL ASSEMBLY KIT 0840 1 KIT BASE RAIL ASSEMBLY KIT

COTTER PIN 98410127 4 #3 COTTER PIN

BASE RAIL PIN 08060001 4 BASE RAIL PIN

BASE RAIL BOLT 98050140 8 3/8”-16 X 3 1/2” CARRIAGE GRD. 5

BASE RAIL FLAT WASHER 98250175 8 3/8” FLAT WASHER

BASE RAIL HEX NUT 98150211 8 3/8” - 16 HEX NUT

BASE RAIL LOCK WASHER 98200151 8 3/8” LOCK WASHER

BASE RAIL HARDWARE KIT 084003 1 KIT BASE RAIL HARDWARE KIT

NOTE: ** = NOT INCLUDED IN KIT.

SuperRail Installation Inst. Rev. 2/23/2003 Page

20

Dodge 2003, 3/4 & 1 Ton 4 x 4

HARDWARE

1/2 x 7 1/2” Bolt Qty. 2

1/2 Lock Washer Qty. 6

1/2 Flat Washer Qty. 4

1/2 Nut Qty. 4

5/8” x 4 1/2” Bolt Qty. 2

5/8” Lock Washer Qty. 2

5/8” Nut Qty. 2

PART I Truck Preparation

After blocking the front wheels, place jack stands under the frame so that the rear of
the truck is high enough to allow the rear wheels to drop. This will give easy access to
the frame area in the rear wheel well. Remove the emergency brake cable bracket
located in the driver side wheel well, refer to figure 1 on this page. Replace this bracket
after installing the hitch mounting brackets. If the truck is a two wheel drive, remove
the axle jounce bumper located just above the axle on the bottom of the frame, replace
after the hitch is installed. If the truck is a two wheel drive one ton, this mounting
system will not work.
Refer to figure 1 this page, if the installation is for a six foot bed truck. Trim the cross
sill extensions located under the front bed cross sill even with the bottom of the main
cross sill as they will interfere with the installation of the Front Mounting Bracket.

Mounting Bracket Installation,

1. From the truck bed, drill a 1/16” pilot hole over the forward most Driver side hole that you
marked during layout on page 7. Slide the Rear Driver Side Mounting Bracket up in place,
holding it firmly against the truck frame. Check to see if the 1/16” hole aligns with the center of
the Mounting Bracket Post Hole.

2. If the drill bit missed the center of the hole in the Mounting Bracket, check your measurements
again. Re-drill the hole if necessary to get correct alignment. Adjust the other hole markings for
the remaining three holes if needed. Drill the pilot holes for the remaining three hole and check
each hole using it’s appropriate Mounting Bracket. Once the alignment looks good, remove the
brackets.

3. Go to “Drilling the Bed” on pages 5
& 6.

Fig. 1

SuperRail Installation Inst. Rev. 2/23/2003 Page

21

Dodge 2003, 3/4 & 1 Ton 4 x 4

Part II. Mounting Bracket installation continued.

1. Find the Bolt Plate with welded 1/2” bolts P/N: 081605 in the Hardware Kit.
Make sure that the 1/2” Hex Nuts will thread on to the bolts and that the bolts
will fit into the existing frame holes, see figure 2 this page.

2. Find the existing frame holes as shown in figure 3 this page. The 5/8” Front
Bracket holes and the large round holes located on the
bottom of the frame towards the rear of the truck.

3. Insert a “fish” wire into the front 5/8” existing frame hole
and thread it towards the large hole located on the bottom of
the frame at the rear, see the figure below. Use a short
piece of wire, fashioned like a fish hook, to insert into the large hole
to snare the “fish” wire down through the large hole.

4. Attach the “fish” wire to the eyelet welded to the bolt portion of the Bolt Plate P/
N: 081605, also attach another wire to the small hole located in one end of the
Bolt Plate to be used as a retrieval wire if the “fish” wire should break. Be sure
the first wire is attached to the bolt welded to the opposite end of the retrieval
wire hole.

5. Repeat steps 3 and 4 for the rear 5/8” existing frame hole and second bolt of
the Bolt Plate. This wire should be attached to the bolt nearest the retrieval
wire hole.

6. When running the “fish” wire through the passenger side frame be careful to
avoid running the wire over the top of the muffler brackets. The muffler
brackets are rods that run through the frame rail and welded in place. If the
“fish” wire is run over the top of these rods the Bolt Plate will not pass over
them. Remove axle jounce bumpers for two wheel drive trucks only.

7. Gently pull the Bolt Plate through the large rear hole and out through the front
existing frame holes. Make sure the bolt nearest the retrieval wire goes through
last.

8. Position the Mounting Bracket on the frame so that the 1/2” bolt of the Bolt
Plate passes through the pre drilled holes in the Mounting Bracket. Secure the
Mounting Bracket in place by threading the ½”-13 Hex Nuts, ½” Lock Washers
and ½” Flat Washers on to the ½” bolt of the Bolt Plate, see figure 3 this page
and figure 4 on page 22. Finger tighten only.

Fig. 3

Fig. 2.

SuperRail Installation Inst. Rev. 2/23/2003 Page

22

Dodge 2003, 3/4 & 1 Ton 4 x 4

Fig. 4

Fig. 5

SuperRail Installation Inst. Rev. 2/23/2003 Page

23

Dodge 2003, 3/4 & 1 Ton 4 x 4

1 Referring to figure 5 on this page figure 5 on page 22, install the Rear Mounting

Brackets P/N: 085403 and 085404. When fastening the Rear Mounting Bracket rear
hole location, make sure that the Frame Shim P/N: 33180701 is installed so that it
does not extend past the side wall of the frame. This will insure that the 5/8”-11 x 4
½” Bolt will fasten the Rear Mounting Bracket tightly to the frame. If the Frame
Shim does extend past the side wall of the frame, it is either made too long or it is
not seated properly against the Mounting Bracket through the opposite obround
hole. Finger tighten the 5/8”-11 Hex Nut and 5/8” Split Lock Washer.

2 To fasten the Rear Mounting Bracket front hole location, find the obround hole lo-

cated in the bottom of the frame rail just below and slightly behind the cross sill lo­cated just ahead of the Rear Mounting Bracket position. Referring to figures 5 and
6, fasten the Rear Mounting Bracket at this location using the ½”-13 x 7 ½” Bolt,
Center Hole Back Up Plate P/N: 05070302 and 1/2” Lock Washer (nut is welded to

the bracket). Finger tighten only.
3 Return to pages 5 & 6 steps 4 through 12 to complete installation of hitch.
4 Torque all bolts per Torque Table specifications located on page 6

Fig. 6

SuperRail Installation Inst. Rev. 2/23/2003 Page

24

PASSENGER SIDE

BASE RAIL MOUNTING POST

SUPER RAIL MOUNTING KIT

1

1

1 DRIVERS SIDE

P/N 0844

330701 4

MOUNTING POST

WEIGHT 34.03 LBS

2003 DODGE

MOUNTING BRACKET KIT 0854 1 KIT MOUNTING BRACKET KIT

** LAYOUT TEMPLATE 08540000

085403 1 PASSENGER SIDE

BASE RAIL 084001 2 BASE RAIL

1/2" FLAT WASHER 98250145 4 1/2" FLAT WASHER

5/8” REAR FRAME BOLTS 98010231 2 5/8”-11 x 1 1/2” GRD. 5 HHCS

REAR MOUNTING BRACKET

FRONT MOUNTING BRACKET 085401

REAR MOUNTING BRACKET 085404

FRONT MOUNTING BRACKET 085402 1 DRIVERS SIDE

FRONT BRACKET BOLT PLATE 081605 2

REAR BRKT., 5/8” HLOE, BACK UP PLATE 08160307 2 1/4” x 3” x 1 7/8”, WITH 5/8” HOLE

BACK UP PLATE, CENTER HOLE 08070302 2 1/4” x 2” x 4”, WITH 1/2” HOLE

REAR BRACKET, FRAME SPACER 33180701 2 1” RD. TUBING x 2 3/4”

1/2" SPLIT LOCK WASHER 98200142 6 1/2" SPLIT LOCK WASHER

1/2", REAR FRAME BOLTS 98010214 2 1/2"-13 x 7 1/2" HHCS GRD 5

FRONT BRACKET FRAME NUTS 98150153 4 1/2" - 13 HEX NUT

5/8” REAR FRAME BOLT, LOCK WASHER 98200133 2 5/8” SPLIT LOCK WASHER

BASE RAIL ASSEMBLY KIT 0840 1 KIT BASE RAIL ASSEMBLY KIT

5/8” REAR FRAME BOLT, HEX NUT 98150175 2 5/8”-11 HEX NUT

BASE RAIL EXTENSION 084002 4 BASE RAIL EXTENSION

COTTER PIN 98410127 4 #3 COTTER PIN

BASE RAIL PIN 08060001 4 BASE RAIL PIN

BASE RAIL BOLT 98050140 8 3/8”-16 X 3 1/2” CARRIAGE GRD. 5

BASE RAIL FLAT WASHER 98250175 8 3/8” FLAT WASHER

BASE RAIL HEX NUT 98150211 8 3/8” - 16 HEX NUT

BASE RAIL LOCK WASHER 98200151 8 3/8” LOCK WASHER

BASE RAIL HARDWARE KIT 084003 1 KIT BASE RAIL HARDWARE KIT

NOTE: ** = NOT INCLUDED IN KIT.