Parts Checklist: XJ Front 3-Link Long Arm Upgrade Installation Instructions *BOX 1* *BOX 2* Jeep Cherokee XJ

Transcription

1 XJ Frnt 3-Link Lng Arm Upgrade Installatin Instructins Jeep Cherkee XJ Parts Checklist: *BOX 1* Instructins Invice Lg decal (1) Rck-Link decal (2) Irnrckffrad.cm decal (1) Subframe center (1) Subframe left uter (1) Subframe right uter (1) T-Case drp spacer (2) # /8 6 Blt IRO Flex End Hardware (2) Inner race (2) Thrust washer (2) 2-5/8" Flex End Ball (1) x 1-3/4 Scket Head Cap Screw (6) Nylck Nut (6) 90 Degree ¼ -28 Grease zerk Fitting (1) # /8 Flex End Hardware (1) End cap (2) Inner race (2) Flex end ball (1) 8-32 x 1-1/2 scket head cap screw (8) 90 ¼ -28 grease zerk fitting (1) Straight 1/4-28 grease zerk fitting (1) #181-3-Link Cntrl Arm Clamping Hardware (1) 1/4"-28 x 1-1/8 scket head cap screw (4) 3/8-16 x 1 1/4 hex blt grade 8 (1) 1/4"-28 hex nut, grade 8 (4) 3/8-16 nylck flange nut (1) 3/8 Mil Spec Hardened washer (1) #182 - XJ 3-Link Lng Arm Subframe Hardware (1) M14 x 2.0 x 90 hex blt cl10.9 (1) M14 x 2.0 x 100 hex blt cl10.9 (2) M14 x 2.0 x 110 hex blt cl10.9 (2) M10 X 30 cl10.9 hex blt (4) M10 x 80 cl10.9 hex blt (1) M10 x 25 carriage blt (4) M10 X 50 carriage blt (4) M cl10.9 hex nut (4) M cl10.9 nylck flange nut (1) 7/16-14 X 1-1/4 gr8 hex blt (2) M14 Nylck flange nut cl10.9 (5) 3/8 USS flat washer (12) 9/16 F436 hardened washer (5) *BOX 2* XJ Lng LCA Left (1) XJ Lng LCA Right (1) XJ 3-Link Frnt UCA (1) Angled Lng Arm Male End (2) 2 3/8 UCA Male End (1)

2 Installatin Instructins: Safety Warning: ***Imprtant! Read befre installatin.*** We recmmend 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 after the first 100 miles f use, and frequently inspect all safety critical suspensin cmpnents. Befre yu begin: Read all safety warnings. Read and understand installatin instructins. *2000 and 2001 mdels with autmatic transmissins will require ld style transmissin munt such as Anchr 2625* 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. Ensure that all parts are present and in gd cnditin using the included shipping checklist. Be sure yu have the fllwing tls and supplies: Flr jack and jack stands. Basic hand tls (wrenches, sckets, etc ). Multi-purpse grease Metal cutting tls such as a 4 ½ angle grinder with thin metal cutting wheel, and a sandpaper flap wheel fr an attractive finish. Pssibly a sawzall with metal cutting blades. Paint and primer (fr uniframe - black r yur chice f clr). Anti-seize cmpund Hand Drill 23/64 drill bit 7/16-14 hand tap, tap hlder and cutting il Angle finder String level r laser level Prepare the parts fr Installatin: 1. Lcate the lwer cntrl arms (larger), male ends (larger, angled), hardware kit 127 and Assemble flex ends int male end. Use hardware kit 127 and attached instructins (2-5/8 ). 3. Lcate the upper cntrl arm (smaller), male end (smaller, straight), and hardware kit Assemble flex end int upper cntrl arm. Use hardware kit 168 and attached instructins (2 3/8 ). 5. Apply a light cat f anti-seize cmpund t the threads and thread the male ends int cntrl arms. 6. Adjust cntrl arm lengths per the chart. 7. Install clamping blts. D nt tighten at this time. Cntrl arm munting subframe: 8. Lift frnt and rear f vehicle and supprt with jack stands under the uniframe. Leave rm t cut ff the stck lwer cntrl arm munts. 9. Remve the fur transmissin munt nuts frm the transmissin. 10. Raise transfer case slightly and supprt with a jack stand. 11. Remve the factry transmissin munting crssmember. 12. Using a stud puller, remve the tw crssmember munting studs. If yu d nt have a stud puller, yu can install 2 nuts and tighten ne against the ther then remve using a bx end wrench n the inner nut. 13. Drill and tap the third munting hle n each side (the next hle directly frward frm the tw crssmember munting hles) using the 23/64 (.359 diameter) drill bit and 7/16-14 hand tap. Use plenty f il during drilling and tapping and keep the drill bit and tap as straight as pssible. 14. Install upper cntrl arm int left subframe uter. Make sure the threaded male end is installed in the subframe using the M14 x 90 blt and the arm is riented with the bend hanging dwn t clear the flr. Blt faces frm center ut s it can be remved later if needed. 15. Install subframe uter in vehicle using M10 flange and 7/16 blts, and washers frm hardware kit Install right subframe uter using the same hardware. 17. *2000 and 2001 w/aut trans nly* Remve trans islatr munt. Grind ff lcating pin frm munting plate. Install lder style trans munt. Trque t 78 ft-punds. 18. Using M10 x 25 carriage blts, 3/8 washers, and M10 nuts, lsely assemble the subframe center sectin t the uters (center sectin underneath the uters). ***The text side f the center sectin face frward when installed in the vehicle.*** Cntrl Arm Length (Starting Lengths - Center t Center) Lift Height LCA UCA / /8 37 1/ /2 37 1/ /8 37 3/ /4 RIGHT OUTER LEFT OUTER CENTER SECTION

3 19. If yur transfer case will be drpped, install prvided transfer case drp spacers between the subframe uters and center sectin using the lnger 50mm carriage blts. 20. Trque 7/16 blts t 65 ft punds. Trque M10 blts t 50 ft punds. 21. Trque subframe center sectin blts t 45 ft punds. 22. Trque upper cntrl arm blt t 135 ft punds. 23. Lwer the transfer case n t the subframe. 24. Install the fur transmissin munt nuts and trque t 15 ft punds. Frnt Suspensin: 25. Remve upper and lwer factry cntrl arms. 26. Discnnect the driveshaft n the axle side and tape the u-jint s the caps d nt fall ff. Tie the driveshaft ut f the way (use tape, zip tie, mechanic s wire, etc ) fr easier access t the lwer cntrl arm munt. 27. Tie the upper cntrl arm ut f the way. 28. Cut ff factry lwer cntrl arm munts frm the uniframe n the driver s and passenger's side. ***Tip: Our favrite tl fr this is a 4 ½ angle grinder with a thin cutting wheel. Remve in pieces fr ease f access.*** 29. Remve anything n the driver s side that extends inward (tward the transmissin) beynd the uniframe. D nt remve any f the uniframe; just make it ne cntinuus edge frm frnt t rear. 30. Clean up any burrs r sharp edges and grind smth fr an attractive appearance. 31. Clean, prime, and paint any expsed metal. 32. Cnnect the upper cntrl arm t the axle using M10 x 80 blt with washer and nylck flange nut. D nt tighten at this time. 33. Install lwer cntrl arms with threaded adjusting end at the uniframe, and bends facing inward t clear the tires, thread clamping blts facing dwn. Use prvided M14 x 100 blts (at axle), M14 x 110 blts (at subframe), 9/16 washers, and nylck nuts. D nt tighten at this time. 34. Raise vehicle and repsitin jack stands under the frnt and rear axles. 35. Temprarily install a tire n ne side. 36. Verify that the axle is centered as desired frnt t rear. Check caster befre adjusting. 37. Check caster angle. Using a laser level r string level, set the frnt axle level t the rear axle (left side and right) Bunce the Jeep up and dwn t ensure the suspensin is in resting psitin (at exact ride height). Place the angle finder under the axle "C" (r n tp f the upper ball jint). Ensure the angle finder is parallel t the Jeep frnt t rear. This is yur caster angle. See chart fr desired setting. 38. Adjust cntrl arms t the desired psitin. T adjust axle frnt t rear, adjust upper and lwer cntrl arms by the same amunt. 12 turns equal ne inch. T adjust nly caster, adjust nly the upper cntrl arm (3 turns equals rughly 2 degrees). T adjust bth, adjust bth at the same time. ***Caster angle may need t be adjusted after a test drive t eliminate driveline vibratins.*** 39. Check axle psitin left t right. Adjust track bar length as needed. 40. Trque Lwer cntrl arm blts t 135 ft punds. 41. Trque Upper cntrl arm nut at axle t 60 ft punds. 42. Install tires and wheels. Trque lug nuts t spec. (Typical specificatin is ft-lbs., depending n yur wheels) 43. Recheck all fasteners and trque any remaining lse nuts r blts t spec. Caster Angle (Starting pint) Lift Height Caster degrees degrees degrees degrees

4 Adjustments and Final Inspectin: 44. 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. * A prfessinal frnt end alignment is required after installatin.* Recmmended alignment settings: Caster: t +7.5 See chart abve. Te-in: +1/16 t +1/8 Final Safety Warning: * Re-trque all fasteners 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.

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 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 Multipurpse grease/grease gun Parts Checklist: Outer husing, weld n (may already be attached t yur existing cntrl arm) # /8 IRO Flex End (6 blt) 2-5/8" flex end race (2) Thrust washer (2) 2-5/8" flex end ball (1) #10-32 nylck nut (7) #10-32 x 1-3/4" scket head cap screw (6) 90 ¼ -28 grease zerk fitting (1) Assembly: Figure 1 1. Insert tw #10-32 scket head cap screws int ne thrust washer and ne plastic race. Spherical bre f race facing away frm thrust washer. (Figure 1) 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. (Figure 2) 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. (Figure 3) 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. (Figure 4) 9. Snug up all f the blts fairly tight. Figure Trque blts evenly, starting at ne blt and cntinuing using a crisscrss pattern. Trque all six blts t 70 in-lbs., then t 85 in-lbs. 11. Install 90 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. *Reference Only* Cmplete jint shwn fully assembled withut husing Figure 3 Figure 4

6 2-3/8 IRO Flex End (8 blt) Assembly Instructins 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: 9/64" allen head scket 3/8" pen end wrench Inch-lb. trque wrench Multipurpse grease/grease gun Parts Checklist: Outer husing, weld n (may already be attached t yur existing cntrl arm) # /8 IRO Flex End (8 blt) Inner race (2) Thrust washer (2) Ball (1) #8-32 x 1-1/2 scket head cap screw (8) 90 ¼ -28 grease zerk fitting (1) Figure 1 Assembly: 1. Insert tw #8-32 scket head cap screws int ne thrust washer and ne plastic race. Spherical bre f race facing away frm thrust washer. (Figure 1) 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 eight blts t 50 in-lbs., then t 65 in-lbs. 11. Install 90 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 65 in-lbs. after 5 minutes. *Reference Only* Cmplete jint shwn fully assembled withut husing