Part# CE-9800XJ, CE-9800XJ1, CE-9800XJ2, and CE-9800XJL Jeep Cherokee XJ Lift Kit Installation Instructions

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1 Part# CE-9800XJ, CE-9800XJ1, CE-9800XJ2, and CE-9800XJL Jeep Cherokee XJ Lift Kit Installation Instructions Please note that modifying the suspension of your Jeep Cherokee will affect the vehicle handling and stability characteristics! You have purchased a RockJock suspension lift system for Jeep Cherokee. This suspension system will provide ample lift to accommodate up to 32" tall tires.* A 4½ back spacing wheel was used for the development of this kit. Other wheel & tire configurations can be used but interference may be an issue. * For clearance, some body and fender trimming may be necessary and/or aftermarket flares/fenders installed. A 32 x 10.5 x 15 tire was used in the development of this kit. 1

2 Kit includes: 1 pr. CE-9807FSP Front Coil Springs 1 pr. CE-9106XJ XJ Johnny Joint Front Lower Control Arms 1 CE-9122F Front Bump Stop Kit 1 CE-9120TJS Front Adjustable Track Bar 1 pr. CE-9095XJ XJ Rear Leaf Springs 1 CE-9031XJK Rear Bump Stop Kit 4 CE-9017 U-bolt for 2 3/4 Tube 4 CE-9019 U-bolt for 3 Tube 4 CE-9020 U-bolt for 3 1/4 Tube Optional Equipment Shown/Available Tools Needed Front Antirock Sway Bar Kit CE-9900XJF Complete Set of Hand Tools Metric and SAE Front Sway Bar Disconnects CE-9141 Drill Front Johnny Joint Upper Control Arms CE-9102 Drill Bit Set Front Shocks RT /16-14 Tap Rear Shocks RT Grease Gun Currectlync Heavy Duty Steering CE-9701 Angle Finder Front Shocks (must use HD Steering) CE-9151 Jack Stands HD Steering Stabilizer CE-9170 Floor Jack Short Tail Shaft Conversion (early 231) CE-9069 Red Loctite Short Tail Shaft Conversion (late 231) CE-9069T HD Short Tail Shaft Conversion CE-9069HD HD Motor Mounts CE-9201 HD 5 Rear Shackles JS-9081 Rear Driveshaft (for use with CE-9069T) CE-97984XJ Rear Driveshaft (for use with CE-9069HD) CE-97984XJH Instructions 1. Read the complete instruction manual before starting installation. Please note that your XJ may have a 2 3/4 or a 3 1/4 axle tube stock. If your rearend has been replaced with an aftermarket rearend, aftermarket rearends are commonly 3 tube. Please verify your tube size to ensure that you have the proper u-bolts prior to starting the kit installation. 2. Park your vehicle on level ground and disconnect front trac bar from the frontend housing.** 3. Lift the vehicle on jack stands by the frame. Ensure vehicle stability before working on the vehicle. 4. Remove wheels and tires from the vehicle. 5. Use red Loctite on all suspension hardware when assembling. Front Installation 6. Remove front drive shaft from the front axle. 7. Place a floor jack under the front axle and remove the front shocks. Place a set of jack stands under the front axle and slowly release the jack allowing the front axle to drop, releasing pressure from the springs. DO NOT OVER EXTEND THE BRAKE LINES!!!!!!! ** Refer to the suplimental instruction sheet specific to this component. 2

3 8. Remove the front springs and factory trac bar from the frame. 9. Drill to 3/8" and then tap the center of the lower spring pad to 7/16-14 thread. 10. Install the front upper bump stop.** 11. Drill the frame side track bar mount hole to 5/8". 12 Install front lower control arms one at a time. If you are replacing your front upper control arms also, you may also do that at this time. You must drill UPPER control arm holes in the frame and the housing out to 7/16"! ** Refer to the suplimental instruction sheet specific to this component. 3

4 13. Install the front springs and lower bump stop.** 14. With the floor jack, raise the front axle and install the front shocks. 15. Install the trac bar on the frame side only.** 16. At this time you can install the front sway bar links or the front Antirock sway bar system.** 17. If you are using the CE-9701 Currectlync heavy duty steering system in conjunction with the longer front shocks (CE-9151), you must relocate the front brake lines on the frame, or use longer lines. To relocate the brake lines, remove the bolt that holds the brake line on the side of the frame and relocate by drilling two new holes on the lower edge of the frame, 1.5" down from stock location. ** Refer to the suplimental instruction sheet specific to this component. 4

5 Rear Installation 18. Place jack stands under the rearend, While supporting the rearend with a floor jack, remove both rear shocks. Slowly lower the floor jack until the rearend sits on the jack stands and remove rear leaf springs. 19. Remove rear drive shaft. 20. If you are installing a short tail shaft conversion kit, CE-9069, CE-9069T, or CE-9069HD (recommended), do so at this time. If using a short tail shaft conversion, you must replace your drive shaft. 21. Install new leaf springs with the supplied u-bolts and new spring plates/bump stops. If your factory bump stops are deteriorated or missing replace with new ones. Trim excess length off of u-bolts at this time. 22. Install rear shocks at this time. 23. Install wheels and tires and place vehicle on the ground. 24. Adjust and install the axle end of the front trac bar. Center the axle under the vehicle by adjusting the length of the bar.** 25. Using an angle finder, measuer the caster angle of the front end and set to 5 degrees. Adjust the upper and lower control arms as necessary to attain the correct angle. 26. Now go over all nuts and bolts - front and rear - and ensure proper torque specifications. 27. Using an angle finder, measure the angle of the rearend and the angle of the drive shaft. The rearend angle must be 2-3 degrees down in relationship to the drive shaft when using a conventional drive shaft, and 1 degree down when using a double cardan style drive shaft. 28. Before re-installing front and rear drive shafts, check for proper length. 29. It will be necessary to adjust the toe and re-center the steeering wheel by adjusting the drag link. 1/8 toe in is the recommended starting point. 5

6 30. Drive the vehicle for 1-2 miles at a moderate speed. 31. Once again, go over every nut and bolt in the suspension system and ensure that they are all tight. 32. At this time, grease every one of the bushings on the Johnny Joint control arms, as well as the Johnny Joint trac bar. Repeat this step after 500 miles of driving, then every 10,000 miles. Torque Specifications By Bolt Size 10mm = 50 ft/lbs Factory Trac Bar Bolt at the Axle Housing 7/16 = 60 ft/lbs Upper Control Arms 1/2 = 75 ft/lbs Heavy Front Trac Bar Bolt at the Axle Housing / Rear Leaf Springs 9/16 = 90 ft/lbs Lower Control Arms 5/8 = 125 Trac Bar Bolt at the Frame 85 ft/lbs Lug Nuts ** Refer to the suplimental instruction sheet specific to this component. 6

7 CE-9120TJS & CE-9120TJJ Johnny Joint Adjustable Front Trac Bar for Jeep Wrangler TJ / LJ, and XJ Cherokee Installation Instructions 1. Remove the original trac bar by unbolting it at the housing and then at the frame. Retain the torx bolt and factory nut plate from the housing for reuse (retained with CE-9120TJS only - new housing bolt is provided with CE-9120TJJ). An optional, stronger hex head bolt is available through Jeep to replace this bolt and is highly recommended. Jeep part # Using a 5/8 drill bit, drill out the hole in the trac bar frame bracket on the driver s side of the frame. 3. Install the 5/8 bolt into the new trac bar through the bottom side of the Johnny Joint. The bottom of the Johnny Joint is the side without the large flange sticking out of it. 4. Use the special,.200 thick, washer on top of the factory trac bar bracket 5. Install the new trac bar into the hole that you just drilled out from the bottom side of the trac bar frame bracket. Install the nut on the top and snug it down at this time. 6. Center the front axle assembly under the Jeep by measuring from the side of the frame rail to a tread line in the center of your tire. Make sure you measure to the same place on both sides! You can center the axle by using a ratchet strap if necessary. 7. Adjust the track bar to fit the centered axle assembly. When using the CE-9120TJS trac bar, install the original housing bolt through the housing end of the trac bar and thread it back into the original nut plate, but do not tighten. If you are using the CE-9120TJJ trac bar, it will be necessary to drill out the hole in the housing bracket to 1/2 to accept the new, heavier bolt that is supplied. A new nut plate is supplied for the heavier bolt. Remove the stock nut plate and insert the new one in it s place. In some cases it may be necessary to open up the access hole on the bottom of the trac bar bracket to remove the factory nut plate. Thread the new bolt into the new nut plate, but do not tighten. 8. Remeasure your front axle assembly to make sure it s centered. Readjust it if necessary. 9. Now go back and tighten and torque all of the bolts. 5/8 bolt at the frame = 125 ft. lbs. Stock torx bolt on the housing = 50 ft. lbs. Optional 1/2 bolt on the housing = 75 ft. lbs. Jam nut = really really tight! 10. Confirm that the Johnny Joint is straight and in a relatively neutral position, and that the mount on the housing is straight and not in any kind of bind. If anything is misaligned readjust it and retighten it before use!

8 CE-9122F TJ front bumpstop kit 1/2 thick aluminum bump stop spacer. 1 3/ Grade 8 flat washer - cast into the urethane /8 C thread x 2 1/4 socket head allen bolt w/ lock washer. Upper urethane bumpstop puck. 2 Lower urethane bumpstop puck. 1 thick aluminum bumpstop spacer. 7/16 C thread x 2 1/4 long grade 8 bolt w/ lock washer. Drill and tap 7/16 course thread hole in the top of spring indexing boss on the coil spring pad on the housing. If you have any further questions during the installation of this kit, please contact a Currie technical representative at:

9 Check length of all of the new Johnny Joint control arms prior to installing. Compare the length of your existing control arms to the Currie Arms. When measuring, measure from the center of the thru bolt hole to the center of the thru-bolt hole on the other end. This measurement can also be determined by measuring the overall length of the control arm and subtracting 2" for upper arms and 2 ½ for lower arms. Currie control arms come preset for a TJ with a 4" lift, a transfer case tailshaft shortening kit, and a CV driveshaft. Front upper arms - 15" c-c Rear upper arms /2" c-c All lower arms /4" c-c CE-9800 Johnny Joint Control Arm Set for Jeep Wrangler TJ / LJ Installation Instructions When custom adjusting the arms for your application, you should never have any more than 3/4" of thread showing from beyond the jam nut. If more than 3/4 is showing after you ve adjusted the arms, you should contact Currie Enterprises technical department to discuss your application and installation. The upper control arms are supplied with 7/16" bolts. The upper control arm frame and housing brackets on Jeep TJ s have metric holes. You will need to drill out these metric holes to accommodate the 7/16 bolts. Torque the 7/16" bolts to 60 ft lbs. of torque. Torque all of the 9/16" bolts on the lower control arms to 90 ft lbs. of torque. Grease all fittings with multi-purpose grease and grease regularly. Check all jam nuts on control arms after 100 miles and regularly thereafter. Re-attach emergency brake cables to control arms with zip ties, discarding the original brackets. Make sure there is enough slack in the cable to allow for wheel travel. NOTE 1: Johnny Joint rod ends are fully rebuildable! Contact Currie Enterprises for details, or order online at NOTE 2: The larger washers supplied with the lower control arms are for use with the the front lower arms where they bolt onto the axle housing. Discard the other set of large washers.

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