WJ 6.5 Premium Long Arm Kit Installation Instructions

Transcription

1 WJ 6.5 Premium Lng Arm Kit Installatin Instructins Parts Checklist: *BOX 1* 24x12x Frnt spring (2) 6.5 Rear spring (2) *BOX 2* 24x14x6 Literature (instructins, steering shimmy checklist) Invice Irn Rck Off Rad lg decal (2) Irnrckffrad.cm decal (1) JKS Sway bar quicker discnnect set 3104 (1) Rear sway bar links center t center (2) WJ 4 hle transfer case drp spacer (2) Frnt cntrl arm munting bracket (92016, 92017) (1 left, 1 right) Upper cil spring retainer (4) #1 - Frnt Track Bar Hardware (1) Track bar bushing half M20919 (4) 12mm track bar bushing sleeve (2) 7/8-14 Jam Nut (1) #2 - Rear Sway Bar Link Hardware (1) 3/4 hurglass bushing M00393 (4) 12mm sway bar blt sleeve (2) 10mm sway bar blt sleeve (2) M10 x 60 sway bar link blt (2) M10 X 1.5 hex nut (2) 7/16 USS washer (2) #3 Shcks Hardware (1) 12mm shck blt sleeve (2) 7/16 washer (6) 5/16 x 1 hex blt (4) 5/16-18 hex nut (4) 5/16 washer (8) #5 - T-Case Drp Hardware (1) M10 x 150mm class 10.9 blt (4) 3/8 USS washer (4) #6 - Frnt Brake Line Spacers, Cil Spring Retainer Hardware (1) Frnt brake line spacer (10mm SBL sleeve) (2) M6 x 45 Frnt brake line blt (2) 1/4 USS washer (2) 1/2 x 5 scket head cap screw (2) #7 - Frnt Cntrl Arm Brackets Hardware (1) 2.75 nut plate (4) 7/16 x 1 1/4" gr8 hex blt (8) 7/16 USS washer (8) #23 Rear Cil Spring Retainers Hardware (1) 7/16 x 5 scket head cap screw (2) #65 Adjustable LCA Clamping Blts Hardware (2) 1/4-28 x 1 1/8 scket head cap screw (4) 1/4-28 hex nut (4) #76 - Caster Adjuster Hardware (1) 5/16 x 1 Carriage Blt (4) M10 x 90 Hex Head Blt (1) #78 - Lwer Cntrl Arm Spacers Hardware (2) Lwer cntrl arm bushing spacer (4) # /8 6 Blt IRO Flex End Hardware (6) Inner race (2) Thrust washer (2) Ball (1) x 1-3/4 Scket Head Cap Screw (6) Nylck Nut (6) 90 Degree ¼ -28 Grease Zerk Fitting (1) ¼ USS Flat Washer (4) 3/8 USS Flat Washer (2) 5/16 Hex Nut (4) M10 nylck hex nut (1) #160 - WJ 4-Link Crssmember Hardware (1) 7/16-14 x 1-1/4 gr8 hex blt (10) 7/16 USS washer (10) 7/16-14 Serrated flange nut (2) M14 x 100 cl10.9 hex blt (4) 9/16 USS washer (8) M14 cl10.9 hex nut (4) 2 hle nut plate (4) #161 - WJ 4-Link Axle Bracket Hardware (1) M14 x 35 cl10.9 hex blt (3) M14 x 100 cl10.9 hex blt (2) M14 x 120 cl10.9 hex blt (2) 9/16 USS washer (8) M14 cl10.9 hex nut (4) 1/4 cntrl arm spacer (4) Shcks Optinal: Detsch Tech Shcks Frnt shcks DT 8421 (2) Rear shcks DT 8403 (2) #9 DT Shcks (1) Frnt barpin (2) Optinal: Bilstein Shcks Frnt shcks (2) Rear shcks (2) #17 - Bilstein Shck Hardware (1) Frnt barpin (2) 12mm Shck sleeve (4) SBL U-bracket (2) 1/2 x 1 1/2 Hex blt, gr8 (2) 1/2 Hex nut, gr8 (2) 1/2 Flat washer (2) 1/2 Lck washer, gr8 (2) 7/16 USS Flat Washer (6) M12x60 Hex blt, cl10.9 (2) M12 Hex nut, cl10.9 (2) *BOX 4* 42x15x7 Frnt Irn Y and Passenger Side Lwer Cntrl Arm with bushings installed (1) Optinal: Fixed (Standard 92150, r High Clearance 92151, 92155) Optinal: Adjustable (Standard 92152, r High Clearance 92153, 92157) Lng Arm Male End (2) ¼ 28 x Scket head cap screw (4) ¼ 28 Gr8. Nuts (4) Caster Adjust Bracket (1) WJ Adjustable Track bar (1) Track bar male end (1) WJ right rear lng UCA (1) WJ left rear lng UCA (1) WJ right rear lng LCA (1) WJ left rear lng LCA (1) WJ lng arm male end (4) WJ rear 4-link crssmember (1) WJ rear 4-link axle bracket (1)

2 Installatin Instructins: Safety Warning: Installing a suspensin lift kit raises the center f gravity f the vehicle. This increases the pssibility f a rllver accident. Avid sudden maneuvers at high speed and avid all situatins where a side rllver may ccur. In additin larger tires decrease braking perfrmance, please drive accrdingly. We recmmend a tire and wheel cmbinatin that make the vehicle's track width wider (wheels with less backspacing). This will lwer the center f gravity and add stability. We als recmmend that this system be installed by a qualified prfessinal. Knwledge f suspensin cmpnent functin is necessary fr safe installatin and pst installatin inspectins. Be sure t re-trque all suspensin cmpnents and lug nuts after the first 100 miles f use, and frequently inspect all safety critical suspensin cmpnents. Befre yu begin: **Ensure that all parts are present and in gd cnditin using the included shipping checklist.** Read all safety warnings. Read and understand installatin instructins. Check all steering and suspensin cmpnents fr wear and replace as needed. Cntact Irn Rck Off Rad with any questins befre, during, r after installatin. This kit will require a custm exhaust. Be sure yu have the fllwing tls and supplies: Flr jack and jack stands Basic hand tls Trque wrench Multi-purpse grease (all plyurethane bushings shuld be greased befre installatin) Hand drill with ne r mre gd quality 7/16 drill bit (s) Letter T drill bit. 1/2-20 fine thread hand tap with tap handle and cutting il. 7/16-14 curse thread hand tap with tap handle Tuch up paint t match the clr f yur unibdy frame. Rubberized undercating. High strength threadlcker adhesive such as Lctite red. Anti-seize cmpund fr blts. Prepare the parts fr installatin: 1. Lcate hardware kit 3 and the rear shcks. 2. Grease and install the 5/8 I.D. shck bushings included with the shcks (if needed). Barpin Installatin 3. Grease and install the 12mm fur shck blt sleeves, tw frm hardware kit 3, tw frm shck bx. The rear shcks use 12mm sleeves at the tp and bttm. 4. Leave the rest f the hardware in the bag fr future use. 5. Lcate the frnt track bar, track bar male threaded end, and hardware kit Install the jam nut nt the male end, apply ant-seize cmpund t the threads and install male end. 7. Grease and install the track bar bushings. 8. Grease and install the track bar blt sleeves. 9. Adjust track bar t 33 9/16 center t center. Tighten jam nut finger tight. 10. Lcate the rear sway bar links ( center t center) and hardware kit Grease and install the hurglass bushings. 12. Grease and install the sway bar link blt sleeves. Each link gets ne 12mm I.D. sleeve and ne 10mm I.D. sleeve. 13. Leave the rest f the hardware in the bag fr future use. 14. Lcate the frnt JKS sway bar quick discnnects. Prepare them per JKS instructins. 15. Lcate the rear lwer cntrl arms, male threaded ends and hardware kit 65. (Qty: 2) 16. Apply anti-seize cmpund t male threads and thread int lwer cntrl arms. 17. Install clamping blts and nuts frm hardware kit 65. D nt tighten at this time. 18. Adjust t 39 center t center 19. Lcate rear upper cntrl arms, male ends and hardware kit 65. (Qty: 2) 20. Apply anti seize t male threads, install and adjust t 30 center t center. 21. Install clamping blts; d nt tighten at this time. 22. Lcate frnt Irn Y lng arm, passenger side arm, male ends, caster adjuster and hardware kits 65 & Apply anti seize t male threads, install and adjust t 32-3/8 center t center. 24. Assemble Caster Adjuster. See Fig 1. a. Slide Caster adjuster n tp f welded n u-shaped bracket as shwn. b. Insert the (4) 5/16 carriage blts frm the inside f the bracket utwards, engaging the square end f the carriage blt int the welded-n bracket. c. Install washers and nuts n the carriage blts finger tight. d. Once Irn Y is installed in vehicle, install washer nt the 10mm blt and slide thrugh the caster bracket assembly and upper cntrl arm bushing. Add the last washer and nylck nut, trque t spec 25. Assemble all flex ends per attached flex end instructins (secnd t last page). Transfer Case Drp Kit and Frnt Lwer Cntrl Arm Munting Brackets: 26. Lcate the frnt lwer cntrl arm munting brackets (apprx. 7 x 11 ), 4 hle transfer case drp spacers, hardware kit 5, and hardware kit Lift frnt f vehicle and supprt with jack stands under the frnt axle. **Tip: break lug nuts lse befre lifting vehicle. 28. Ensure that vehicle is safely supprted. 29. Place a flr jack under the center f the transmissin/transfer case crssmember fr supprt. 30. On ne side remve the 4 blts that hld the crssmember t the unibdy. 31. Lwer the crssmember away frm the unibdy enugh t install the spacer and the crrect left r right side lwer cntrl arm munting bracket. It may be necessary t lsen the blts n the ther side f the crssmember. 32. Install the spacer and bracket using the 2 lng existing blts and the 2 new blts and washers. 33. Align the lwer cntrl arm munting bracket t the vehicle.

3 34. Tighten blts 35. Using the bracket as a guide, drill the fur 7/16 munting hles at the frnt f the bracket. 36. Take the bracket ut and remve any burrs frm the drilled hles and paint any expsed metal. 37. Insert the nut plates thrugh the hle in the unibdy frame and mve them int psitin abve the drilled hles. 38. Spray the area where the cntrl arm munting bracket meets the unibdy frame with rubberized undercating t seal ut any misture between the bracket and the unibdy. 39. While the undercating is still wet, re-install the munting bracket and transfer case spacer. Use washers under all blts. 40. Trque all 8 blts t 65 ft. lbs. 41. Repeat fr the ther side. 42. Re-trque all 16 blts. Rear crssmember: 43. Lift rear f vehicle and supprt with tall jack stands under the unibdy frame. **Tip: break lug nuts lse befre lifting vehicle. 44. Ensure that the vehicle is safely supprted. 45. Remve rear tires. 46. Cut exhaust between catalytic cnverter and muffler. Remve tailpipe and muffler. 47. Remval f catalytic cnverter may be necessary depending n intended ruting f new custm exhaust. 48. Lcate crssmember and hardware kit Psitin crssmember with cntrl arm brackets facing rear f vehicle. 50. Line up crssmember with large hles in frame. 51. Using the crssmember as a template, drill all ten 7/16 hles. 52. Remve crssmember, deburr hles, and paint expsed metal. 53. Insert nut plates int frame and psitin ver 4 uter hles per side. 54. Install crssmember with 7/16 blts and washers. 55. Install 7/16 blt, washer, and serrated nut int center hle n each side. 56. Trque all blts t 65 ft-lbs. Frnt Suspensin: 57. Lift frnt f vehicle supprt with tall jack stands under the unibdy frame r transfer case crssmember. 58. Ensure the vehicle is safely supprted. 59. Place a flr jack under the frnt axle fr supprt, d nt lift vehicle. 60. Remve frnt tires. 61. Remve the frnt shcks. 62. Remve the track bar. 63. Remve frnt sway bar links. 64. Lcate hardware kit Install frnt brake line spacers between frnt brake line and axle where the brake line meets the shck munt. Use new M6 blts and washers. 66. Remve all frnt upper and lwer cntrl arms. 67. With the axle hanging as lw as pssible, remve cil springs and lwer cil spring islatrs. 68. Lcate Irn Y cntrl arm and 2 cntrl arm bushing spacers (large 1/4 thick washers). 69. Install Irn Y cntrl arm n the driver s side. First install the axle end lwer bushing int the axle with 2 spacers n the utbard side, then rtate up t install the arm nt the upper cntrl arm bushing n the axle. Use existing lwer cntrl arm blts, and new m10 x 90 blt washers, and lcknut fr the upper cntrl arm. Finally install the back side int the new lwer cntrl arm munting bracket. D nt tighten blts at this time. 70. Install passenger side lwer cntrl arm using 2 cntrl arm bushing spacers n the utbard side f the axle end. D nt tighten blts at this time. 71. Lcate the cil spring retainers (apprx. 2 diameter x 5 lng aluminum cylinders) and the remainder f hardware kit 6. The cil spring retainers blt nt the frnt upper cil spring perch t keep the cil springs frm falling ut under extreme drp. 72. Using yur 1/2-20 fine thread hand tap, tap the existing hle in the center f each frnt upper cil spring perch (n need t drill). 73. Apply a liberal cating f high strength threadlcker adhesive (such as Lctite red) t the threads f bth 1/2" x 5 scket head cap screws. Apply antiseize cmpund t the unthreaded shaft f the blt (nt the threads). 74. Psitin the cil spring retainer nt the upper cil spring pad and install the blt. Trque t 60 inch punds. Repeat fr ppsite side. 75. Snap the cil spring islatr nt the new spring. 76. Install new spring in vehicle being careful t align islatr pin with the hle in the spring bucket. 77. Repeat fr ther frnt cil spring. 78. Install new frnt shcks using prvided blts, washers, and nuts. Tighten upper stud munt nuts just enugh t slightly cmpress the bushings. Overcmpressing these bushings will result in damage t the bushings and premature bushing failure. 79. Install new JKS sway bar quick discnnect links per JKS instructins. 80. Install track bar. Trque t 80 ft. lbs. *Nte: The bends in the track bar are fr clearance f the differential and the bracket n the axle. The threaded adjusting end attaches t the uni-frame. 81. Install frnt tires. 82. Lwer vehicle frm jack stands. 83. With the vehicle n the grund, trque any lse blts t spec. including upper and lwer cntrl arm blts, caster adjuster blts, lug nuts, etc 84. Tighten track bar jam nut VERY tight. Rear Suspensin: 85. Lift rear f vehicle and supprt with tall jack stands under the unibdy frame. **Tip: break lug nuts lse befre lifting vehicle. 86. Ensure that the vehicle is safely supprted. 87. Remve rear tires. 88. Place a flr jack under the center f rear axle fr supprt (d nt lift vehicle). 89. Remve rear shcks. 90. Remve sway bar links. 91. Lsen lwer cntrl arm blts. Remve nuts but d nt remve blts. 92. Allw suspensin t drp as much as pssible. 93. Remve cil springs. 94. Discnnect all brake lines and ABS wires frm upper a-arm. 95. Place a jack stand under the pinin t keep the axle frm rtating. 96. Remve the a-arm and a-arm ball jint frm the vehicle (n need t separate them)

4 97. Lcate 4-link axle bracket and hardware kit Raise rear axle up t a cmfrtable psitin t access the 3 a-arm retaining blts n tp f the differential. 99. Place a jack stand under the pinin t keep the axle frm rtating Remve the 3 a-arm blts n tp f the differential Remve rear a-arm Install the 4-link axle bracket n the tp f the differential using supplied M14x35 blts Trque t 100 ft. lbs Install new upper cntrl arms with the threaded male end lcated at the axle side. D nt tighten blts at this time. Bend hangs dwn t clear the flr Lcate lwer cntrl arms and 4 cntrl arm bushing spacers (large 1/4 thick washers) Install new lwer cntrl arms with spacers n the utbard side f the bushings (pushing cntrl arm twards center f vehicle), 2 at each axle bushing. Use the M14 x 120 blts at axle. D nt tighten blts at this time. Threaded male ends at the unibdy. Bends face up fr increased grund clearance, and inward t clear the uniframe Install cil spring retainers (2 diameter x 5 lng black aluminum cylinders). They install in the center f the unibdy side cil spring pad. Using plenty f il, drill the center hle with letter T drill bit, again with plenty f il, tap with 7/16-14 hand tap. Clean the new threads with brake cleaner. Apply high strength threadlcker t the blts frm hardware kit 23. Install cil spring retainers and trque t 60 inch punds Install new cil springs being careful t align the spring t the islatr Raise the vehicle and supprt with jack stands under the rear axle With full vehicle weight n the suspensin, check if the rear axle is centered as desired in the wheel pening. Adjust lwer cntrl arms t desired axle psitin. Adjust upper cntrl arms t desired pinin angle (see step 2) Trque all cntrl arm nuts t 120 ft punds Tighten all cntrl arm adjusting thread clamping blts Install new shcks. Use prvided 7/16 washers n the upper shck munts, place ne washer behind the shck bushing, and 2 washers in frnt f it (tward the utside f the vehicle) Install sway bar links using the existing upper blt and the new lwer blt, washer, and nut. Trque t 78 ft. lbs. (upper blt) and 50 ft.lbs. (lwer blt) Install rear tires Lwer vehicle frm jack stands With the vehicle n the grund (r jack stands under the axles), trque any lse blts t spec. including lug nuts. Grease all flex ends frnt and rear. Adjustments and Final Inspectin: 118. Check all cmpnents fr clearance fr suspensin t fully cycle up and dwn and wheels t turn lck t lck. Pay special attentin t brake lines, axle vent hses, and ABS wires. Repsitin as needed by bending the brackets, relcating, r extending hses and wiring Re-center steering wheel by adjusting the drag link (lnger) until the steering wheel is centered. * A prfessinal frnt end alignment is required after installatin. We recmmend the fllwing alignment settings: Caster: t +6.0 (+4.5 is preferred) Te-in: +.20 degrees (+1/16 t +1/8 measured at the tire) Final Safety Warning: * Re-trque all fasteners including lug nuts after 100 miles, and frequently inspect all safety critical suspensin cmpnents. It is the respnsibility f the installer t be sure all fasteners are prperly tightened after installatin and t ensure the wner knws his/her nging respnsibility. It is the respnsibility f the wner f the vehicle t be sure all safety critical cmpnents are inspected frequently, especially after ff rad r ther demanding use. WJ 6.5 inch premium lng arm kit install.dc Rev. 2.0

5 Fits All Irn Rck Off Rad Lng Arm Systems, WJ A-Arms, and Build Yur Own Flex End Assemblies. 2 5/8 IRO Flex End (6 blt) Assembly Instructins Parts Checklist: Outer husing, weld n (may already be attached t yur existing cntrl arm) # /8 6 Blt IRO Flex End Hardware Inner race (2) Thrust washer (2) Ball (1) x 1-1/4 Scket Head Cap Screw (6) Nylck Nut (6) 90 Degree ¼ -28 Grease Zerk Fitting (1) Befre yu begin: Read and understand installatin instructins. Cntact Irn Rck Off Rad with any questins befre, during, r after installatin. Ensure that all parts are present and in gd cnditin per attached shipping checklist! Have these tls handy: 5/32 allen head scket 3/8 pen end wrench Inch-lb. trque wrench Assembly: 1. Insert tw scket head cap screws int ne thrust washer and ne plastic race. Spherical bre f race facing away frm thrust washer. 2. Install this small assembly int the flex end husing. The races are a light press fit, use a wide punch and hammer t assist yu if needed. 3. Apply a thin cating f multi-purpse grease t the mating surfaces f the ball and bth races. 4. Place the ball in the race (inside the flex end). The ball shuld perfectly fit the cntur f the race. 5. Insert the ther race nt the ball s that the spherical bre is cntacting the ball. Once again, the races are a light press fit, use a hammer and wide punch if needed. (The tw screws shuld be thrugh ne washer and bth races at this pint) 6. Insert the secnd thrust washer n tp f the flex end husing, sliding the blts thrugh the hles. 7. Start Nylck nuts n the tw blts that are in the flex end assembly. Hld the nut and turn the blt. 8. Insert the remaining fur cap screws thrugh the remaining hles and install nuts. 9. Snug up all f the blts fairly tight. 10. Trque blts evenly starting at ne blt using a crisscrss pattern, like trqueing lug nuts. Trque all six blts t 70 in/lbs., then t 85 in/lbs. 11. Install 90 Degree grease zerk fitting s that it is easily accessed in the vehicle. 12. Grease flex end until grease cmes ut f the races arund the ball. 13. Re-trque blts t 85 in-lbs. after 5 minutes.

6 Steering Shimmy Eliminatin Checklist Nte: Steering Shimmy is als knwn as death wbble r speed wbble. It is a vilent shaking f the vehicle caused by the frnt tires turning side t side repeatedly until yu slw dwn. It usually ccurs after hitting a bump r pthle a varius speeds abve 30MPH. If yu experience this steering shimmy just remain calm, yu still have steering and braking cntrl. Just gently apply the brakes and slw dwn until the shimmy disappears. Safety Warning: Sme f these adjustments will reduce steering shimmy, but als reduce steering stability and steering respnsiveness. Test drive carefully after every mdificatin, if yu feel any mdificatin is unsafe d nt prceed. Keeping yur vehicle safe t drive is the respnsibility f the persn making the adjustments and the driver. The driver must ntice any unsafe actins f the vehicle and crrect the prblem immediately (e.g. wandering r unrespnsive steering). Irn Rck Off Rad prmtes these mdificatins fr lw speed ff rad use nly, sme f these mdificatins may nt be safe fr use n public r private rads, especially at highway speeds. We recmmend wrking with an experienced alignment shp that has the ability, knwledge, and experience t keep yur vehicle safe t drive at highway speeds. Check all tie rd ends fr wear and replace as needed. Adjust te-in t exactly zer. Nte: a slight te-in is preferred fr stability, te ut will reduce steering shimmy. See safety warning at the tp f this sheet. Adjust caster t 3.0 t 5.5 degrees (mre caster will imprve stability, less caster will reduce steering shimmy). See safety warning at the tp f this sheet. Check steering stabilizer including bushings, replace if cnditin is less than perfect. We have researched extensively and fund the best steering stabilizers available with the least amunt f free play. Balance tires and put the best balanced tires in frnt. The frnt tires MUST be dynamically balanced, meaning they must have wheel weights n bth the inner and uter rim flanges as directed by the balancing machine. If yu dn t like hammer-n weights n the uter flange either fr appearance reasns r because f frequent rck damage, then use stick-n weights fr the uter weights in this case functin must precede frm dn t balance statically with weights just n the inner rim edge. If a tire/wheel requires mre than 6 unces f ttal balance weights (inner and uter cmbined), d nt use it n the frnt axle. Check all suspensin bushings fr wear and lse fasteners including cntrl arms and track bar. Any rubber bushing with cracks, r where the rubber is separating frm the steel shuld be replaced. Check steering gearbx fr wear and adjust r replace as needed. Check wheel bearings fr wear. Check ball jints fr wear. Install dual steering stabilizer kit. Reduce tire air pressure (try 29psi fr OEM size tires, less fr larger tires). Nte: Reducing air pressure t far can cause tires t verheat and blwut at highway speeds. See safety warning at the tp f this page. Check vehicle stance. Hub t fender measurements shuld be minimum ¼ higher in the rear (like OEM stance) fr maximum stability (this transfers weight t the frnt tires). Measure n a level surface with nrmal carg and ½ tank f gas fr maximum accuracy.