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

Transcription

1 ZJ Frnt 3-Link Lng Arm Upgrade Installatin Instructins Jeep Grand Cherkee ZJ Parts Checklist: *BOX 1* Instructins Invice Lg decal (Qty: 1) Rck-Link decal (2) Irnrckffrad.cm decal (1) Subframe center (1) Subframe left uter (1) Subframe right uter (1) ZJ T-case drp spacer (2) 4 hle t 2 hle adapter bracket (1) # /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) ¼ grease zerk fitting (1) ¼-28 straight grease zerk fitting (1) #180 3-Link Lng Arm Subframe Hardware (1) M14 x 2.0 x 90 hex blt class 10.9 (1) M14 x 2.0 x 110 hex blt class 10.9 (2) 7/16-14 x 1 ¼ hex blt grade 8 (8) M10 x 1.5 x 80 hex blt class 10.9 (1) M10 x 1.5 X 25 carriage blt (4) M10 x 1.5 x 50 carriage blt (4) M10 x 1.5 x 30 flange blt class 10.9 (8) M14 x 2.0 nylck flange nut class 10 (2) 7/16-14 flange nut, zinc (8) M10 x 1.5 hex nut class 10 (4) M10 x 1.5 nylck flange nut class 10 (1) 9/16 F436 hardened washer (5) 3/8 USS washer (9) 7/16 F436 hardened washer (8) #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. washer 95229A480 (1) *BOX 2* ZJ Lng LCA Left (1) ZJ Lng LCA Right (1) ZJ 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. 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 7/16 drill bit 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 ends. 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 ), install straight grease zerk. 5. Apply a light cat f anti-sieze cmpund t the threads and thread the male ends int cntrl arms. 6. Adjust cntrl arm lengths per the chart. 7. Install clamping blts frm hardware kit #181. 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. Raise transfer case very slightly and supprt with a jack stand. 10. Remve the fur transmissin munt nuts frm the transmissin crssmember r the single blt fr the 2 hle subframe. 11. Remve the factry transmissin munting crssmember. 12. Lcate the three subframe parts and hardware kit Install left and right uters using the prvided M10 flange blts in the same hles that held the factry crssmember. Be sure that the cntrl arm munting pckets are facing frward. 14. Install center sectin using M10 x 25 carriage blts and M10 nuts. 15. Tighten blts firmly (blts will be remved after drilling.) 16. Drill the 8 additinal 7/16 munting hles using the subframe as a guide. 17. Remve subframe center sectin then left and right uters. Remve any burrs and sharp edges arund the hles. Clean, prime and paint any expsed metal. 18. Install upper cntrl arm int left subframe uter; use M14 x 90 blt and trque t 135 ft punds. The threaded male end is installed at the subframe with the bend hanging dwn t clear the flr. 19. Install left and right uters using M10 flange and 7/16 blts, flange nuts, and washers frm hardware kit If yu have nly ne blt munting the transmissin t the crssmember (2 hle) install prvided 2 hle adapter bracket (large u-shaped bracket) inside the subframe center sectin. Use prvided M10 flange blts, washers, and nuts. Trque blts t 50 ft punds. 21. Using M10 x 25 carriage blts, 3/8 washers, and M10 nuts, assemble subframe center sectin t the uters (center sectin underneath the uters). ***The lng side f the center sectin attaches t the left uter subframe.*** 22. If yur transfer case will be drpped, then install prvided transfer case drp spacers between the subframe uters and center sectin using the lnger 50mm carriage blts. 23. Trque 7/16 blts t 65 ft punds. Trque M10 blts t 31 ft punds. Cntrl Arm Length (Starting Lengths - Center t Center) Lwer Cntrl Arms 36 ½ (Shrt Side) Upper Cntrl Arm 37 1/4

3 24. Trque subframe center sectin blts t 45 ft punds. 25. Lwer the transfer case n t subframe. 26. Fr 4 blt transmissin munts, install the fur existing transmissin munt nuts and trque t ft punds. 27. Fr 1 blt transmissin munts, install the factry blt and nut and trque t 78 ft punds. Frnt Suspensin: 28. Remve upper and lwer factry cntrl arms. 29. 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. 30. Tie the upper cntrl arm ut f the way. 31. 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.*** 32. 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. 33. Clean up any burrs r sharp edges and grind smth fr an attractive appearance. 34. Clean, prime, and paint any expsed metal. 35. 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. 36. Install Lwer cntrl arms with threaded adjusting end at the uniframe, and bends facing inward t clear the tires, thread clamping blts facing dwn. At the subframe, use prvided M14 x 110 blts, 9/16 washers, and nylck nuts. At the axle, re-use factry cam blts and nuts. D nt tighten at this time. 37. Raise vehicle and repsitin jack stands under the frnt and rear axles. 38. Temprarily install tire n ne side. 39. Verify that the axle is centered as desired frnt t rear. Check caster befre adjusting. 40. 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. 41. 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.*** 42. Check axle psitin left t right. Adjust track bar length as needed. 43. Trque Lwer cntrl arm blts t 135 ft punds. 44. Trque Upper cntrl arm nut at axle t 60 ft punds. 45. Install tires and wheels. Trque lug nuts t spec. (Typical specificatin is ft-lbs., depending n yur wheels) 46. Recheck all fasteners and trque any remaining lse nuts r blts t spec. Caster Angle (Starting pint) Lift Height Caster degrees degrees degrees degrees Adjustments and Final Inspectin: 47. 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 Te-in: +1/16 t +1/8

4 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) ¼ grease zerk fitting (1) ¼-28 straight 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 evenlystarting 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