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1 #J2400 Installation Instructions Jeep Grand Cherokee/Commander 4 Suspension System Read and understand all instructions and warnings prior to installation of product and operation of vehicle. Zone Offroad Products recommends this system be installed by a professional technician. In addition to these instructions, professional knowledge of disassembly/ reassembly procedures and post installation checks must be known. Minimum tool requirements include the following: Assorted metric and standard wrenches, hammer, hydraulic floor jack and a set of jack stands. See the "Special Tools Required" section for additional tools needed to complete this installation properly and safely.»product» Safety Warning Certain Zone Suspension Products are intended to improve off-road performance. Modifying your vehicle for off-road use may result in the vehicle handling differently than a factory equipped vehicle. Extreme care must be used to prevent loss of control or vehicle rollover. Failure to drive your modified vehicle safely may result in serious injury or death. Zone Offroad Products does not recommend the combined use of suspension lifts, body lifts, or other lifting devices. You should never operate your modified vehicle under the influence of alcohol or drugs. Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions. Always wear your seat belt.»technical» Support Live Chat provides instant communication with Zone tech support. Anyone can access live chat through a link on may have additional information about this product including the latest instructions, videos, photos, etc. Send an to tech@zoneoffroad.com detailing your issue for a quick response ZONE Call to speak directly with Zone tech support.»pre-installation» Notes 1. Special literature required: OE Service Manual for model/year of vehicle. Refer to manual for proper disassembly/reassembly procedures of OE and related components. Difficulty Level 2. Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the OE manual. 3. Larger rim and tire combinations may increase leverage on suspension, steering, and related components. When selecting combinations larger than OE, consider the additional stress you could be inducing on the OE and related components. 4. Post suspension system vehicles may experience drive line vibrations. Angles may require tuning, slider on shaft may require replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced. 5. Secure and properly block vehicle prior to installation of Zone Offroad Products. Always wear safety glasses when using power tools. 6. If installation is to be performed without a hoist, Zone Offroad Products recommends rear alterations first. easy difficult Estimated installation: 6-8 hours Special Tools Required High Quality Strut Compressor Reciprocating Saw/Cut-off Tool Welder Tire/Wheel Fitment Tire: 32 x Wheel: x 8, 5.5" BS 7. Due to payload options and initial ride height variances, the amount of lift is a base figure. Final ride height dimensions may vary in accordance to original vehicle attitude. Always measure the attitude prior to beginning installation.»» Zone Offroad Products 491 W. Garfield Ave., Coldwater, MI ZONE rev061013

2 Kit Contents Qty Part 1 Steering Knuckle (drv) 1 Steering Knuckle (pass) 2 Rear Coil Spring 1 Front Crossmember 1 Rear Crossmember 4 Cam Washer 2 Cam Bolt 1 Differential Bracket (drv front) 2 Differential Bracket Spacer (drv front) 2 Differential Drop Bracket (drv front) 1 Differential Drop Bracket (pass) 1 Differential Drop Bracket (drv rear) 1 Differential Drop Bracket (drv rear) 2 Front Sway Bar Link 8 Sway Bar Link Bushing x x Sleeve 2 Strut Spacer 2 Strut Preload Spacer 1 Differential Skid Plate 1 Weld-in Plate 4 Brakeline Relocation 2 Bolt Pack 1 Bolt Pack 1 Bolt Pack 1 Bolt Pack 2 Rear Sway Bar Link 2 Rear Upper Control Arm Assembly 4 90 deg grease zerk 8 Control Arm Bushing x x Sleeve 2 Bump Stop Spacer 1 Rear Track Bar Bracket 1 Nut tab - Rear Track Bar Bracket x x Sleeve FRONT CROSSMEMBER FRONT SWAY BAR LINK (2 PCS) REAR SWAY BAR LINK (2 PCS) REAR CROSSMEMBER BRAKE LINE BRACKET (4 PCS) STRUT SPACER (2 PCS) BUMP STOP SPACER (2 PCS) DIFF. SKID PLATE WELD-IN PLATE PRELOAD SPACER (2 PCS) FRT UPPER DIFF BRACKET FRT DIFF BRACKET PLATE (2 PCS) PASS DIFF. BRACKET DRV REAR DIFF. BRACKETS FRT DIFF BRACKET SPACER (2 PCS) REAR TRACK BAR BRACKET J2400 Installation - pg. 2

3 Pre-Installation Notes Vehicles equipped with Electronic Stability Program: Premature stability control engagement may be encountered after the installation of this or any other type/manufacturer s lift system. The Electronic Stability Program (ESP) is affected by a multitude of factors such as wheel and tire size, wheel offset and poor alignment. If the system regularly activates during normal driving (nearly always while turning), the system can be deactivated by pushing the off button on the center console. This button must be turned off each time the vehicle is started. American Expedition Vehicles (AEV) offers an Electronic Geometry Recalibration Module that can be installed as well. A high quality strut compressor is required for the installation of this system. Some large wheel and tire combinations will require trimming of the back section of the front inner fender. Refer to the end of the instruction sheet for details on proper trimming for optimal clearance. All vehicles are equipped with wheel mount air pressure sensors. If the factory wheels are replaced, these sensors must be removed and reinstalled in the aftermarket wheels. If the sensors are not reinstalled a low pressure warning light will appear on the dash at all times. Welding is required for installation of this system. Zone Offroad recommends having a certified welder perform this operation. Take care to have a proper fire extinguisher available whenever cutting or welding is done on the vehicle. The factory service manual specifically states that striking the knuckle to loosen the ball joints or tie rod ends is prohibited. Striking the aluminum knuckle can damage it. A special puller tool #8677 (or equivalent ball joint tool) is recommended to be used to separate these components from the knuckle. Important measure before starting! Measure from the center of the wheel up to the bottom edge of the wheel opening LF RF LR RR J2400 Installation - pg. 3

4 Installation Instructions Front Installation 1. Park the vehicle on a clean, flat surface and block the rear wheels for safety. 2. Open the hood. Disconnect the negative and positive battery cables. 3. On the driver s side of the vehicle, pull the long narrow electrical box from the plastic retaining clips to expose one of the three mounting nuts for the power distribution center. Remove the three nuts and pull the power distribution center up to access the top strut nuts (Figure 1). Figure 1 Step 5 Caution DO NOT remove the center stem nut, it is under extreme pressure. 4. Remove the four driver s side strut retaining nuts. Save nuts for installation. DO NOT remove the center stem nut, it is under extreme pressure. 5. On the passenger s side, remove the coolant reservoir mounting hardware and move the reservoir to expose the passenger s side strut nuts. Remove the four strut nuts and retain. 6. Raise the front of the vehicle and support with jack stands behind the rear portion of the lower control arms. 7. Remove the wheels. 8. Remove the four bolts mounting the factory belly pan skid plate to the vehicle (Figure 2). This will not be reused. Figure 2 J2400 Installation - pg. 4

5 9. Disconnect the sway bar links from the lower control arms (Figure 3). Save mounting bolts. 10. Remove the nut mounting the steering to the knuckle (Figure 3). Using the appropriate puller, separate the steering from the knuckle. Save nut. Figure Disconnect the ABS line connector at the body. Remove the line from the retaining clips on the body, strut and knuckle (Figure 4). The plastic clips will all be reused. Figure Disconnect the brake caliper from the knuckle by removing the two main mounting bolts (Figure 5). Properly support the caliper and hang it out of the way. DO NOT allow the caliper to hang by the brake hose. Save mounting bolts. J2400 Installation - pg. 5

6 Figure Carefully remove the o-ring retaining the brake rotor to the hub assembly (Figure 6). Remove the rotor from the hub and set off to the side with the o-ring. Figure Remove the axle shaft nut from the axle shaft and save. 15. Remove the upper and lower ball joint nuts and thread back on a couple of turns by hand. Separate the upper and lower joints with the appropriate puller. 16. Remove the upper and lower ball joint nuts and remove the knuckle/hub assembly from the vehicle. 17. Remove the three hub mounting bolts and remove the hub and dust shield from the factory knuckle (Figure 7). Remove any corrosion that may have built up on the hub mounting surface to ensure it will fit properly in the new knuckle. J2400 Installation - pg. 6

7 Figure Install the hub and dust shield in the corresponding new steering knuckle. Fasten the hub to the knuckle with the factory bolts. Apply Loctite to the bolt threads and torque to 100 ft-lbs. 19. Mark the struts to indicate driver's versus passenger's side. Remove the strutto-lower control arm bolt and remove the strut from the vehicle (Figure 8). Save bolt. Figure Carefully pry the CV axle shafts out of the differential. Take care not to damage any seals. Mark the shafts to indicate driver s and passenger s side. 21. Remove the 3 bolts mounting the lower control arm to the frame and remove the lower control arm from the vehicle (Figure 9). Save hardware. J2400 Installation - pg. 7

8 Figure Mark the relationship between the differential input flange and the driveshaft. Disconnect the driveshaft from the differential. Save bolts. 23. Disconnect the axle breather tube from the differential. 24. Support the differential with an appropriate jack. Remove the rear upper driver s side differential mounting bolt as well as the passenger s side bolt. Also remove the 2 driver s side front bolts mounting the differential bracket to the frame (Figure 10). Carefully lower the differential from the vehicle. Save all hardware. Figure Mark the relationship between the front driveshaft and the transfer case output flange. Disconnect the driveshaft from the transfer case and remove the driveshaft from the vehicle by pulling it out toward the front. Some vehicles may be equipped with a transfer case skid plate that can be removed to gain better access to the driveshaft. 26. The factory rear crossmember must be modified to provide clearance for the front drive shaft. In order to have better access to the area to be modified it is sometimes beneficial to lower the exhaust by disconnecting it at the engine and at the inlet to the muffler. This step is not necessary but helpful. J2400 Installation - pg. 8

9 27. Starting along the front of the crossmember measure up from the bottom edge 5/8 and mark. Make a cut line along the crossmember at the 5/8 marked height. This line should be parallel to the bottom edge of the crossmember if done properly. 28. Along the rear of the crossmember measure up from the bottom edge 1 and mark (Figure 11). Make a cut line along the crossmember at the 1 marked height. This line should be parallel to the bottom edge of the crossmember if done properly. Step 27 Note It is important to make precise measurements and cuts to ensure that the weld-in reinforcement plate will fit well. Follow the provided measurements closely and double check them before making any cuts. The area to be modified is located directly below where the driveshaft normally runs. When the reinforcement plate is installed correct the rear crossmember will be as strong as it is in the unmodified state. The addition of the new rear crossmember (to be installed later) will further strengthen this area. Use a cut-off wheel, reciprocating saw, plasma cutter or a combination of these tools to make the cuts. Regardless of cutting method used, be sure to have a fire extinguisher readily available. Figure Measure in from the outside (drv) edge of the subframe 13 and mark (Figure 12). Measure back from the 13 mark (toward drv) 4-1/2 on the front edge and mark. Make a vertical cut line that runs up from the 13 mark to the top of the crossmember and then down the back side to the 1 cut line made there. This new cut line should be perpendicular to the horizontal cut lines made earlier. Figure Make a cut (to the bottom edge) at the 13" mark down to the front and back horizontal marks. J2400 Installation - pg. 9

10 31. Make perpendicular cut just off the weld at the tubular upright (approx. 5-1/2 toward drv side from the 13 mark). Cut down to the flat control arm mounting surface in the front and to the 1" cut line in the back. Make cut from that point diagonal to the 4-1/2 mark on the front. 32. Remove the cut portion of the crossmember and test fit the new weld in plate. Remove any debris in the crossmember left from the cut process. The large hole in the plate will set on the threaded boss in the bottom of the crossmember. Make the necessary adjustments to the crossmember cut to obtain a good fit (Figures 13, 14). Figure 13 Figure 14 Step 34 Note If equipped, reinstall the transfer case skid plate. 33. Clean the edges of the cut area to promote quality welds and weld the plate into place. After the area has cooled, paint any bare metal to prevent corrosion. 34. Reinstall the driveshaft to the transfer case with the factory hardware. Make sure to line up the index marks made during removal. Torque bolts to 24 ft-lbs. 35. If the exhaust was loosened for the rear crossmember modification, reattach now. 36. Remove the factory differential mounting bracket from the front of the differential. Retain the bracket and discard the hardware. J2400 Installation - pg. 10

11 37. Remove the top two differential front cover bolts. Install the new upper differential mounting bracket using the two holes with 10mm x 35mm bolts and 10mm flat washers. Torque bolts to 35 ft-lbs (Figure 15). Step Note Differential bracket hardware is located in bolt pack #742. Figure Locate the two lower differential mounting plates. Install the factory differential mount over the new upper mounting bracket followed by the lower mounting plates on each side to sandwich the entire assembly (Figure 16). Fasten all the brackets together at this point with 12mm x 60mm bolts, nuts and ½ SAE washers. Leave hardware loose. Step 38 Note The lower plates should be lined up with the original lower mounting location on the differential when installed correctly. Figure Place the provided 3-hole spacer plates between each of the lower mounting plates and the original differential mount (Figure 17). Fasten the assembly with 12mm x 60mm bolts, nuts and ½ SAE washers. Torque all six 12mm differential bolts to 65 ft-lbs. J2400 Installation - pg. 11

12 Figure Install the provided passenger s side differential bracket in the factory differential mount in the vehicle (Figure 18). Install the bracket with the original hardware so that the bracket offsets toward the front and then angles back toward the rear. Leave hardware loose. Figure 18 Step 41,43 Note Differential bracket hardware is located in bolt pack # Locate the two new rear driver s side differential brackets. Attach the brackets to the original driver s side rear differential mounting location (Figure 19). The bracket with the longer sleeve mounts inside the factory mount so that the plate is toward the rear. The outer plate mounts to the outside-front portion of the factory mount with the sleeve toward the rear. Fasten the brackets to the factory mount with a 12mm x 100mm bolt, nut and 1/2 SAE washers. Leave hardware loose. J2400 Installation - pg. 12

13 Figure Using an appropriate jack, reinstall the differential in the vehicle. Attach the front mount to the original thread holes in the factory front crossmember with the factory bolts. Leave loose. 43. Fasten the differential to the rear driver s side and passenger s side drop brackets with 12mm x 90mm bolts, nuts and ½ SAE washers. Leave loose. 44. With all of the differential mounting bolts in place, go back and torque all hardware to 65 ft-lbs. There will be six bolts in all, two at each mount. 45. Attach the front driveshaft to the differential by aligning the marks made during disassembly. Apply Loctite to the original bolts and fasten the driveshaft to the differential. Torque bolts to 75 ft-lbs. 46. Support the sub-frame with a hydraulic jack where the main tube ends at the rear crossmember. With the sub-frame supported, remove the two rear sub-frame mounting bolts (Figure 20). Figure Loosely attach the new rear crossmember to the bottom of the sub-frame with the two factory mounting bolts (Figure 21). J2400 Installation - pg. 13

14 Figure 21 Step 48 Note Rear crossmember hardware is located in bolt pack # Loosely install 8mm x 35mm bolts and 5/16 USS washers through the bottom of the rear crossmember into the two factory skid plate mounting holes (Fig 21). Carefully align the four outer (two per side) slotted control arm mounting holes in the crossmember to the slots in the sub-frame. With the slots properly aligned torque the 8mm bolts to 20 ft-lbs. Go back and torque the two sub-frame bolts to 65 ft-lbs. 49. The front control arm mounting pockets must be trimmed slightly to install the front crossmember. Make a cut mark along the front lower bottom edge of the pocket to be flush to the control arm mounting surface. Also, make a mark in line with the inside lower edge to remove the rounded corner from the lower plate (Figure 22). Cut the marked area of the control arm pocket and paint any bare metal to prevent corrosion. Figure Install the new front crossmember in the factory front lower control arm pockets so that the flat face is to the front. Fasten the crossmember with the original control arm bolts and nut tabs installed from back to front (Figure 23). Leave hardware loose. J2400 Installation - pg. 14

15 Figure The factory rear lower control arm mounts are pressed on to the control arms from the factory. These mounts need to be rotated 180 degrees so they can mount to the bottom of the new rear crossmember. Secure the control arm in a vise. Mark the relationship between the end of the control arm and the rubber mount (Figure 24). Hold on to the mounting tabs of the control arm mount with an adjustable wrench and rotate it until the marks are 180 degrees from each other. Step 51 Note Spraying silicone based lubricant on the center of the bushing will help it to rotate easier. Figure Mount the lower control arms in the front crossmember with a provided cam bolt and cam washer from the front to back (Figure 25). Loosely fasten the cam bolt with a second cam washer and 5/8 nut. Attach the control arm to the bottom of the rear crossmember with 12mm x 80mm bolts and 7/16 USS (yellow zinc) washers from the top down (Figure 26). Fasten the bolts with the factory nut tabs. Torque the rear 12mm hardware to 65 ft-lbs. Snug front hardware. Final cam bolt torque will be done with the vehicle on the ground. Step 52 Note Lower control arm hardware is located in bolt pack #743. J2400 Installation - pg. 15

16 Figure 25 Figure 26 Step 54 Note Differential skid plate hardware is located in bolt pack # Ensure that the front crossmember is centered in the vehicle and torque the crossmember to sub-frame bolts to 125 ft-lbs. 54. Attach the new differential skid plate to the welded nuts in the front and rear crossmember (Figure 27) with 7/16 x 1 bolts and 7/16 SAE washers. Apply Loctite to the bolt threads and torque bolts to 45 ft-lbs. J2400 Installation - pg. 16

17 Figure Install the CV axle shafts in the proper side of the differential. Be sure the retaining ring snaps in place so the axle can not come back out. 56. Mark the relationship between the top strut plate, top rubber isolator and coil spring (Figure 28). Position the strut in a high-quality strut compress and compress the coil to relieve pressure on the top plate. Remove the top strut rod nut and remove the top plate and rubber isolator. Figure Remove the rubber isolator from the strut plate and install the provided preload spacer on the strut plate by lining up the small hole in the plate to the hole in the preload spacer (Figure 29). Be sure the preload spacer sets flush to the plate, it may need to be tapped on with a rubber hammer to get past the bolt heads. J2400 Installation - pg. 17

18 Figure Install the factory rubber isolator on the preload spacer by aligning the hole in the spacer with the nub protruding from the isolator. 59. Reinstall the top strut mount assembly to the strut. Align the mark on the coil with the marks on the isolator and top plate (Figure 30). Fasten the assembly with the original strut rod nut. The nut should bottom out of the strut rod when tightened properly. Torque to 50 ft-lbs. Figure Install the new top spacer on the studs at the top of the strut with the original nuts (Figure 31). The spacer is designed to fit snug over the center rubber strut rod mount. Torque nuts to 65 ft-lbs. J2400 Installation - pg. 18

19 Figure Repeat the strut modification to the remaining front strut. 62. Install the struts to the upper strut mounts with 12mm nuts and 12mm flat washers to the welded studs on the top spacers. Torque nuts to 65 ft-lbs. 63. Reinstall all of the components under the hood in the reverse of their removal. 64. Attach the strut to the lower control arm with the original bolt and nut tab. Leave loose until vehicle is on the ground. 65. Install the appropriate new knuckle/hub assembly to the lower control arm by inserting the CV axle end into the hub and then inserting the lower ball joint in the knuckle. Fasten the knuckle to the lower ball joint with the original nut. Leave loose. 66. Attach the knuckle to the upper control arm with the facotry upper control arm nut (Figure 32). Leave loose. Step 62 Note Strut mount hardware is located in bolt pack #743. Figure Fasten the axle shaft to the knuckle with the factory axle nut and torque to 100 ft-lbs. Go back and torque the upper ball joint to 55 ft-lbs and the lower ball joint to 70 ft-lbs. 68. Reattach the ABS wire to the connector at the body. The wire will go back in all the original clips except the one located on the body directly behind the strut (Figure 33). J2400 Installation - pg. 19

20 Figure Attach the first plastic clip from the hub to the provided hole in the new knuckle (Figure 34). The rubber grommets will need to be slid along the ABS wire to adjust the positioning of the clips to compensate for the added lift. Use a silicone based lubricant spray on the wire to aid in moving the grommets. Figure Cycle the knuckle through its full range of steering motion and check the wire for proper length. Attach the wire to the strut body with zip ties if needed. 71. Attach the steering rod to the knuckle and fasten with the original nut. Torque nut to 65 ft-lbs. 72. Lightly grease and install the provided 5/8" OD sway bar link sleeves in the preassembled front sway bar links. Attach the link to the lower control arm with the factory bolt and to the inside of the sway bar with the factory upper bolt, running from inside out (Figure 35). Torque the upper and lower sway bar link bolts to 65 ft-lbs. J2400 Installation - pg. 20

21 Figure Disconnect the front brake lines from the body and install the provided 2" brake line drop brackets with the original brake line bolt. Torque to 10 ft-lbs. Carefully reform the brake hard lines so that the brake line can mount to the stud on the relocation bracket (Figure 36). Fasten the line with a ¼ nut and washer. Torque nut to 10 ft-lbs. Step 73 Note Be sure that the hard line is not rubbing on any metal surface/edge in its reformed position. Brake line hardware is located in bolt pack #704 Figure Attach brake rotor to the hub and retain with the rubber hub o-ring. 75. Attach brake caliper to the rotor/knuckle and fasten with the original bolts. Apply Loctite to the bolt threads and torque to 125 ft-lbs. 76. Install the wheels and lower the vehicle to the ground. Bounce the front of the vehicle to settle the suspension. Torque lug nuts to the proper spec. 77. Center the cams in the slots and torque to front cam bolts to 125 ft-lbs. 78. Torque the lower control arm-to-strut bolt to 125 ft-lbs. 79. Check all hardware for proper torque. 80. Reconnect battery. J2400 Installation - pg. 21

22 Rear Installation 1. Block front wheels for safety. 2. Disconnect the rear track bar (Figure 37) at the axle (it is easiest to do with the vehicle on the ground). Save hardware. Figure Raise the rear of the vehicle with a hydraulic jack. Support the frame rails with jack stands. 4. Remove the wheels. 5. Disconnect the rear brake line mounting brackets from the body (Figure 38). Save bolts. Figure Place a hydraulic jack under the gas tank skid plate. Loosen front 2 skid plate mounting bolts and remove remaining 4 bolts. 7. Lower the rear of the gas tank enough to allow removal of the driver s side upper control arm nut and bolt (Figure 39). Take care not to overextend any wires or hoses. Remove the control arm bolt at the axle and control arm from the vehicle. Save all hardware. J2400 Installation - pg. 22

23 Figure Raise the gas tank back to the original position, reattach and tighten with original hardware. Torque hardware to 60 ft-lbs. 9. Support rear axle with a hydraulic jack. Disconnect the rear shocks and sway bar links (Figure 40). Save all hardware. Discard shocks and sway bar links. Figure Lower the axle and remove the factory rear coil springs from vehicle. Take care not to overextend any lines or hoses. 11. Remove the upper bump stop & bump stop cup (Figure 41). J2400 Installation - pg. 23

24 Figure 41 Step 12 Note Bump stop hardware is located in bolt pack # Install the bump stop cup and provided 2" spacer with a 10mm x 90mm bolt and 10mm flat washer (BP 744). Torque bolt to 35 ft-lbs. Make sure the factory rubber isolator is reinstalled. Reinstall polyurethane bump stop into cup (Figure 42). Figure Disconnect rear sway bar from axle (4 bolts) and reroute around the emergency brake cable lines. The cables will now be above sway bar (Figures 43A, 43B). Reattach sway bar with factory bolts, tighten to 55 ft-lbs. J2400 Installation - pg. 24

25 Figure 43A - Before Figure 43B After 14. Mark the gas tank skid plate as shown in Figure 44. Make 2 vertical lines at location where skid plate edge begins and ends flat. Cut with a hand hacksaw only down from edge 1-1/2 and bend tab forward to create additional control arm clearance. Step 14 Caution Do NOT use any power tools, the gas tank is plastic and can be easily damaged. J2400 Installation - pg. 25

26 Figure Grease and install the provided bushings into the new control arm ends. Install the x sleeves into both ends of the control arm. Install grease zerks into both ends. 16. Adjust the preassembled rear control arm to 16-5/8"(center to center), do not lock off jam nut at this time. 17. Install the adjustable end of the control arm into the frame pocket with a 3/16 thick washer (located in bolt pack # 744) between the outside of the frame rail and control arm bushings, make sure the grease zerk faces down (Figure 45). Run the factory bolt from outside to inside, do not tighten at this time. Figure Lower driver s side of axle, install new driver s side coil spring. 19. Disconnect passenger s side upper control arm, rotate axle to reinstall driver s side control arm with original bolt, do not tighten. 20. Lower passenger s side of axle, install new coil spring and new upper control arm. Do not tighten hardware at this time. 21. Grease and install provided bushings and sleeves into the shock eyes. Install spacer washers over sleeve on each side of bushing at lower mounting point. Upper position requires two ¾ washers on the outside of the body and a 7/16 USS washer on inside of the body. (Figures 46A, 46B) J2400 Installation - pg. 26

27 Figure 46A - Upper Mount Figure 46B - Lower Mount 22. Install new whocks into vehicle with factory hardware. Using washers as spacers shown in Figures. 46a and 46b tighten upper bolt to 70 ft.lbs. Lower bolt to 85 ft.lbs. 23. Grease and install 5/8" OD sleeves into the preassembled sway bar end links. Attach sway bar links to the body with the original hardware. Attach to lower mount with new 12mm x 80mm bolt, 12mm flat washer and 7/16 USS washer. The large OD (7/16 USS) washer goes between the bushing and nut. Tighten hardware to 55 ft-lbs. 24. Place the provided track bar relocation bracket over original track bar mounting location on the axle (Figure 47). Mark the 2 holes to be drilled, remove bracket and drill holes to ½. Step 23 Note Sway bar link hardware is located in bolt pack #743. J2400 Installation - pg. 27

28 Figure 47 Step 25,29 Note Track bar bracket hardware is located in bolt pack # Install the track bar bracket with the provided x sleeve between track bar and factory pocket (Figure 48). Attach with original bolt as shown (Figure 48). Attach remaining two positions with ½ x 1-1/4 bolts, ½ SAE washers and a ½ nut. Use the provided nut tab inside the pocket on the bolt that runs from the bottom-up. Tighten factory bolt to 140 ft-lbs and ½ hardware to 65 ft-lbs. Figure 48 Step 26 Note Brake line bracket hardware is located in bolt pack # Install brake line drop brackets at body with the original hardware (Figure 49). Attach the brake line to the relocation bracket with a ¼ nut and washer. Tighten to 10 ft-lbs. J2400 Installation - pg. 28

29 Figure Reinstall wheels and torque to factory specifications. 28. Lower vehicle and bounce to settle suspension. Tighten upper control arm hardware to 55 ft-lbs. Lock off jam nuts securely. 29. Install track bar into relocation bracket with new 9/16 x 3 bolt, nut and 9/16 SAE washers. Tighten to 130 ft-lbs. It may be necessary to push on the body slightly to get the holes to line up, or have an assistant stand on the rear bumper to compress the suspensions slightly. 30. Recheck all fasteners for proper torque. 31. Check all fasteners after 500 miles and at regularly scheduled maintenance intervals. 32. The vehicle will need a complete front end alignment. Fender Trimming Instructions Certain wheel/tire combinations may require trimming of the rear portion of the front inner fenders. Locate the bulge in the rear portion of the inner fender. There is a body pinch weld located behind the bulge in the plastic inner fender. Disconnect the inner fender from the area and pull it back to expose the pitch weld. The pinch weld can be bent over with a large hammer to gain clearance at this point. It is not recommend to cut this area, which can possibly compromise the strength of the pinch weld. By bending the pinch weld over, the strength is retained and clearance will also be increased. Once the pinch weld is modified, paint the area to prevent any corrosion as a result of chipped paint from the pinch weld modification. Black paint is recommended to blend in with the inner fender plastic. Reattach the inner fender and trim the bulge as necessary to gain the proper tire clearance. It may be necessary to section the bulge so it can be laid flat against the pinch weld area. Fasten the inner fender with sheet metal screws as necessary. Post-Installation Warnings 1. Check all fasteners for proper torque. Check to ensure for adequate clearance between all rotating, mobile, fixed, and heated members. Verify clearance between exhaust and brake lines, fuel lines, fuel tank, floor boards and wiring harness. Check steering gear for clearance. Test and inspect brake system. 2. Perform steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating, mobile or heated members. Inspect rear brake hoses at full extension for adequate slack. Failure to perform hose check/ replacement may result in component failure. 3. Perform head light check and adjustment. 4. Re-torque all fasteners after 500 miles. Always inspect fasteners and components during routine servicing. J2400 Installation - pg. 29