JEEP WRANGLER INSTALLATION INSTRUCTIONS KIT SUM

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1 JEEP WRANGLER INSTALLATION INSTRUCTIONS 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 owner s 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.

2 1. Read the instructions completely and carefully before you begin. Check kit for proper contents (refer to parts list and picture diagrams). 2. Park the vehicle on a clean, dry, flat (level) surface. Block tires so that the vehicle cannot roll in either direction. Automatic transmissions should be placed in park. Manual transmissions should be placed in neutral. 3. Remove both battery cables. Be sure to remove the negative cable first, then the positive cable. 4. Remove the plastic Jeep cover that mounts to the frame in front of the grill. 5. Manual transmission: Remove the transmission shift knob. There is a lock nut that needs to be loosened before the shift knob can be removed. Remove the 4 wheel drive shift knob. There is a lock nut that needs to be loosened before the shift knob can be removed. Remove all of the shift boot mounting screws. Carefully remove the shift boot from both of the shift levers. Automatic Transmission: Follow the same procedure to remove the 4 wheel drive shift boot as listed for the manual transmission. If the vehicle has an inner boot, remove that boot also. 6. Remove the air intake duct from the core support. Remove the top screw and gently pull up and out away from the core support. 7. Remove all six radiator mounting bolts. NOTE: On models equipped with power steering It may be necessary to remove the power steering reservoir from the core support. The vent hose will be remounted to the middle radiator mount. After the radiator mounts have been removed, lift the radiator up to pull the locating tab out of the core support. The locating tabs will be straightened before radiator drop down brackets can be installed. Gently bend the locating tabs flat. 8. Automatic Transmission models only. Remove the upper linkage rod from the steering column lever. Remove the lower linkage rod from the pivot assembly. Remove the 2 bolts that mount the pivot assembly to the pivot bracket. Remove the linkage and pivot assembly from the vehicle. 9. Remove the steering shaft. Mark the shaft where it attaches to the steering gearbox splined shaft and where it attaches to the column at the firewall, this is to ensure proper alignment after the lifting operation is complete. Remove the bolt attaching the steering shaft to the gearbox. Remove the bolt attaching the steering shaft to the column at the firewall. Remove the steering shaft from the vehicle. 10. Disconnect the vacuum hoses that go from the engine to the vacuum canister on the drivers side fender well. One hose will need to be lengthened. 11. The heat shield above the muffler will need to be trimmed to allow the exhaust hanger to be lowered. Mark the heat shield along the line of the exhaust hangers. Remove the heat shield mounting screws. Remove the bolts mounting the exhaust hangers to the body. Remove exhaust from the rear frame hanger. Remove the heat shield from the vehicle. 12. Remove the plastic tabs that hold the fuel filter hose cover over the fuel filler hose. Loosen the hose clamps that attach the fuel filler and the vent to the filler neck. The filler hose may need to be adjusted after the lifter operation is complete. CAUTION: Gasoline is a highly flammable and explosive substance. Extreme care should always be used when working with or around gasoline. 13. Loosen, but do not remove all 11 body mounting bolts. They are located as follows: one in the front center of the grill, 3 on each side along the frame rail under the doors, one on each side of the frame just behind the rear wheels, and 2 on the rear frame rail at the very rear of the vehicle. 14. Remove the body mounting bolts from the passenger side of the vehicle, and the frontcenter mount only. Using a hydraulic jack and a wooden block, slowly lift the passenger side of the vehicle just high enough to place the spacer

3 blocks on the frame mounts. Be sure to constantly check for any wires, hoses cables, etc. that may be binding. The large (3 x3 ) spacers go on the frame rail mounts under the doors (three on each side of the vehicle). The small spacers go on the rear two mounts on each side and on the front-center mount. NOTE: It will not be possible to place a spacer block under the front-center mount until the driver s side of the vehicle has been lifted. After the spacers have been placed on the mounting pads on the passenger s side of the vehicle, install the new body mounting bolts using the stock mounting hardware. They are installed in the following order: front-center 7/16 x 5 1/2 (7/16 x 4 1/2 for 2" kit); along the frame rail under the doors (three mounts on each side) 1/2 x 6 1/2 (1/2 x 5 1/2 for 2" kit), and at the two rear mounts 7/16 x 5 1/2 (7/16 x 4 1/2 for 2" kit). All bolts screw up and into the stock nuts that are inside the body. DO NOT TIGHTEN AT THIS TIME. 15. Repeat step 14 for the driver's side of the vehicle. Be sure to install the front-center spacer and mounting bolt. Place the two steel body support brackets on the frame rail under the rubber pads on both sides of the grill. These support brackets will need to be tack welded in place. We recommend that a certified welder do all welding. After the body support brackets have been tack welded in place, it may be desirable to paint steel parts to help prevent rusting. Tighten all body mounting bolts securely to vehicle torque specifications. We recommend the use of Loctite or similar adhesive on all mounting hardware. 16. Extend the steering shaft. Slide the rubber grommet down from the position at the slip joint. Extend the steering shaft until the small spring is exposed. Remove the small spring clip. NOTE: There are two spring clips in the steering shaft, a small one and a large one. Be sure that the large spring clip remains in the original position, and that the steering does not extend enough to expose the large spring clip. Slide the rubber grommet back to its original position. 17. Reinstall the steering shaft in the vehicle. Align the marks made earlier at the gearbox and at the column. Reinstall both steering shaft mounting bolts. Tighten both mounting bolts securely to the vehicle torque specifications. We recommend the use of Loctite or similar adhesive on all mounting hardware. 18. Remove the 4-wheel drive shift lever. Remove the spring clips that attach the shift lever to the transfer case. Remove the shift lever from the vehicle. It needs to be lengthened. Scribe a line along the shift lever just below the stock bend. Cut the lever through the scribed line. Insert the 1/2" transfer case extension pin between the two pieces. Realign the scribed lines. Weld the extension in place. BE SURE THE SCRIBED LINES ARE LINED UP BEFORE WELDING THE EXTENSION IN PLACE. We recommend that a certified welder do all welding. The shift lever will also need to be heated and bent slightly toward the passenger s side of the vehicle. It may be desirable to paint steel parts to help prevent rusting. This will help allow proper engagement in all 4-wheel drive ranges. Reinstall shift lever in the vehicle. Check engagement in all 4-wheel drive ranges. If the shift lever still does not engage in all ranges, it may be necessary to bend the shift lever slightly further, or it may be necessary to notch the floorboard where the shift lever is making contact. Manual Transmission only: Check engagement in all gears, if the shift lever does not fully engage in all gears; it may be necessary to heat and bend the shift lever or notch the floorboard to allow for complete engagement. 19. Reinstall the shift boot. If an inner boot was removed, do not reinstall it. Reinstall all shift boot mounting screws. Check both shift levers' operation again; it may be necessary to also trim the shift boot housing if the shift levers do not fully engage in all gears with the shift boot installed. Reinstall both gearshift knobs and locknuts. Tighten locknuts securely. 20. Automatic Transmission only: Lengthen the upper shift rod. Scribe a line along a straight part of the linkage rod. Cut the upper linkage rod in half through the scribed line. Insert the extension pin between the two halves of the linkage rod. Realign the scribed lines. Weld the extension in place. BE SURE THE SCRIBED LINES ARE LINED UP BEFORE WELDING THE

4 EXTENSION IN PLACE. We recommend that a certified welder do all welding. It may be desirable to paint steel parts to help prevent rusting. Install the transmission linkage pivotrelocating bracket to the stock pivot bracket using the stock hardware. Reinstall the transmission pivot assembly and linkage in the vehicle. Install the pivot assembly into the stock enginemounted pivot bracket and the new pivot relocating bracket, attach the pivot assembly to the new relocating bracket with two 1/4 x 1 bolts, four 1/4" washers, and two 1/4" Nylock nuts. Do not tighten completely at this time. Reinstall the lower linkage rod to the pivot assembly. Reinstall the upper linkage rod to the steering column lever. Tighten the pivot assembly mounting bolts securely. We recommend the use of Loctite or similar adhesive on all mounting hardware. 23. Trim the exhaust heat shield according to the outlines made earlier. Drill the exhaust hanger mounting holes (in the body) to 5/16". Mount the exhaust hanger relocating brackets to the original holes (the ones that were just drilled) using two 5/ 16 x 2 3/4" bolts, four 5/16" washers, and two 5/ 16" Nylock nuts. Do not tighten. Reinstall the heat shield to the body. Tighten all mounting screws securely. Install the exhaust hanger to the hanger relocating brackets using four 1/4 x 1" bolts, eight 1/4" washers, and four 1/4" Nylock nuts. Remount the exhaust to the rear frame hanger. Tighten all exhaust hardware securely. We recommend the use of Loctite or similar adhesive on all mounting hardware. 24. Bend the parking brake cable bracket that is over the rear differential straight up and down. 25. Adjust the fuel filler hose as necessary. Tighten both hose clamps securely. Replace the cover over fuel filler hose. NOTE: It may not be possible to remount all of the plastic tabs without putting the tiller hose in a bind. Reconnect as many tabs as possible. 26. Replace the plastic "Jeep" cover in the front of the vehicle. 21. Using the stock hardware, mount the six radiator drop-down brackets to the core support. Do not tighten. Mount the radiator to the 1/4" studs protruding from the radiator brackets. Install one 1/4" washer and Nylock nut on each stud. Do not tighten. NOTE: On some models the radiator brackets will be mounted to the radiator, and the studs will be mounted to the core support. Adjust fan-to-fan shroud clearance. Mount the vent hose to the middle radiator mount. Tighten all radiator mounting hardware securely. We recommend the use of Loctite or similar adhesive on all mounting hardware. If the power steering reservoir was removed, remount the reservoir to the core support at this time. Remount the air intake duct to core support at this time. 22. Reconnect the vacuum hoses to the vacuum canister. If a hose is too short, replace a section of the hose with the hose provided. 29. Reconnect both battery cables. Be sure to connect the positive cable, then the negative cable. 27. Place the warning sticker on the dash in plain sight of all vehicle occupants. 28. Double-check vehicle. Before starting the vehicle, check gearshift and transfer case shift lever operation. Be sure that there is complete engagement in all gears and 4-wheel drive ranges. Check fan-to-fan shroud clearance. Be sure that the fan cannot contact the tan shroud. Check again for any wires, cables, hoses, etc. that may be binding. Check steering operation. Turn the steering wheel from side to side. Be sure that there is no binding. Test drive in all gears and 4-wheel drive ranges. Check operation of all vehicle systems: brakes, steering, clutch, etc. Double-check all hardware and all vehicle systems again in 500 miles, and as part of your regular maintenance schedule.

5 Kit# Parts List Quantity Description 6 3 Large blocks 5 3 Mini blocks 6 1/2 x 6 1/2 Bolts 5 7/16 x 5 1/2 Bolts 1 1/2 4WD Shift extension pin 1 3/8 Transmission shift extension pin (Auto only) 1 Auto transmission pivot bracket (Auto only) 6 Radiator drop-down brackets 2 Front body support brackets 4 Exhaust hanger relocator brackets 1 6 Vacuum hose 2 5/16 x 2 3/4 Bolts 4 5/16 washers 2 5/16 Nylock nuts 6 1/4 x 1 Bolts 18 1/4 washer 10 1/4 Nylock nuts Kit# Parts List Quantity Description 6 2 Large blocks 5 2 Mini blocks 6 1/2 x 5 1/2 Bolts 5 7/16 x 4 1/2 Bolts 1 1/2 4WD Shift extension pin 1 3/8 Transmission shift extension pin (Auto only) 1 Auto transmission pivot bracket (Auto only) 6 Radiator drop-down brackets 2 Front body support brackets 4 Exhaust hanger relocator brackets 1 6 Vacuum hose 2 5/16 x 2 3/4 Bolts 4 5/16 washers 2 5/16 Nylock nuts 6 1/4 x 1 Bolts 18 1/4 washer 10 1/4 Nylock nuts

6 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