Heavy Duty Axle Assemblies for the Jeep Wrangler

Transcription

1 Heavy Duty Axle Assemblies fr the Jeep Wrangler Extreme Duty Tera 60 8 Lug with SlimLck Hubs Extreme Duty Full Flat CRD60 8 Lug Heavy Duty Tera60 5 Lug Unit Bearing Heavy Duty Semi Flat CRD60 5 Lug RHD Applicatins Available!

2 TeraFlex Tera60 and CRD60 Axles TeraFlex develped the first Jeep specific axle in Since then, TeraFlex axles have been refined and develped t be the ultimate Jeep specific replacement axle. Frnt Tera60 The Tera60 high pinin axle has been designed with packaging in mind. The husing has been engineered fr maximum grund clearance and suspensin up travel. Finite element analysis (FEA) tls were used thrughut the many axle develpment stages t ptimize the strength while reducing the weight f the axle cmpnents; ensuring the Tera60 wuld handle the rigrus ff rad it will be subject t. When cmpared t the CRD60 frnt axle, the Tera60 basts several imprvements. The cast ductile irn center sectin is 12% lighter (70.9 lbs vs 80.6 lbs). A new design fr ptimal grund clearance and better packaging fr maximum up travel have been achieved by casting in the upper cntrl arm munt and mving the pinin bearing il galley allwing fr a 2.25 lwer verall prfile. Generus webbing stiffens the husing and minimizes gear deflectin. The center sectin is drilled and tapped fr an air lcker fitting and uses standard Dana 60 bearings and seals. It is cmpatible with 9.75 Dana 60 gears r 10 Super 60 gears. Oversized ductile irn bearing caps retain the desired differential carrier. Page 2

3 A new ductile irn differential cver has been designed fr maximum steering clearance and durability. The bttm sectin f the cver is nearly ¾ thick fr ultimate durability when the trail gets rugh. The cver features a built in seal-breaker t aid in cver remval fr differential service. The DOM (drawn ver mandrel) tubing used in the axle husing has been increased frm 3.00 diameter tube t 3.25 diameter. At the same time, the tube thickness has been reduced frm t The axle tubing is apprximately 14% lighter and 3% mre resistant t bending when cmpared t the CRD60 frnt axle. Strength has been engineered int the axle using gemetry rather than adding mre material. Stamped spring perches replace the fabricated perches fund n the CRD60 t eliminate spring bw. The stamped perches feature threaded inserts fr bump stp extensins, limit strap munting and cil spring retainers. Page 3

4 The steering gemetry has been updated t match the steering axis inclinatin (SAI) f the JK Wrangler. The increased SAI prmtes directinal stability and better return-t-center characteristics with less psitive caster required. The ball jint spread n the new frged inner C is larger, thus increasing lad carrying ability. Cmpatibility with standard Dana 60 ball jints was retained. The FEA ptimized design increases the strength while reducing the weight by nearly 6% (16.1 lbs vs 17.1 lbs). The cast ductile irn uter knuckles feature a cast in high steer arm and brake caliper munt t reduce the number f cmpnents and the weight by mre than 33% (21.4 lbs vs 32 lbs). Additinally, the tie rd arm has been raised slightly and bth steering arms have been cast in at an angle relative t the SAI t accunt fr the caster angle built int the axle. All Tera60 uter knuckles are machined t run a flipped drag link. The factry Jeep Ackerman gemetry and steering arm lengths have been retained. The knuckles are mirrred right t left, prviding the same benefits fr bth right hand drive and left hand drive applicatins. Page 4

5 The standard live spindle unit bearing cnfiguratin ptin is retained fr thse desiring t retain a factry 5 n 5 r a larger 5 n 5.5 wheel blt pattern. Fr ultimate durability and serviceability, a fixed chrmly spindle with serviceable tapered rller bearings and TeraFlex SlimLck lcking hubs is an ptinal upgrade. The wheel blt pattern changes t 8 n 6.5 with 9/16-18 wheel studs. The chrmly spindle is drilled and tapped t accept the factry frnt wheel speed sensrs and fully cmpatible with OEM ABS and stability prgrams. T prtect the sensrs frm the elements, a V-seal is installed n the back f the wheel hub and prevents cntaminatin frm damaging the wheel speed sensr. This V-seal als acts as a secnd defense against cntaminatin entering the wheel hub. OEM wheel speed sensrs are swapped int the new Tera60 axle t reduce verall cst. Bth the unit bearing and fixed spindle axles cme with the TeraFlex Big Brake kit installed. The dual pistn calipers paired with 13.3 rtrs prvide increased stpping pwer ver the stck running gear. The calipers feature a zinc cating while the rtrs have a zinc aluminum cating fr superir crrsin resistance. Available in a standard 67 wide wheel munt t wheel munt width r wide 70 wheel munt t wheel munt width Prfiled inner and uter 35 spline 4340 chrmly axle shafts with rlled splines t minimize fatigue and stress cncentratins The Tera60 shares many f the great features ffered with the CRD60. All bearings and seals are standard, ff-the-shelf parts available and at any aut parts warehuse. Hand built in the USA! Heavy duty ¼ thick brackets with multiple munting hles fr suspensin adjustability Triple-stage pwder cating prcess Prfiled 35 spline 4340 chrmly axle shafts with 1480 series U-Jints and rlled splines t minimize fatigue and stress cncentratins Genuine Dana-Spicer cmpnents where available (gear sets, ball jints, seals, bearings, U- Jints, pinin yke) 1310 pinin yke standard, 1350 ptinal 1 year unlimited mileage warranty against material defects and wrkmanship Page 5

6 A blt n hydraulic steering assist axle bracket and tie rd clamp are available fr purchase separately. These brackets and clamps are designed t wrk with PSC hydraulic assist kits. Munting kit is designed t wrk with PSC s lder style silver cated hydraulic ram. Munting kit is designed t wrk with PSC s new nickel plated hydraulic ram. Because all the OEM steering gemetry has been retained with the Tera60, it utilizes the same 6 ¾ strke ram that a factry Dana 30 r Dana 44 uses. Rear CRD60 The CRD60 is available in a rear axle cnfiguratin nly. In additin t the semi-flat rear CRD60 that has been available, an extreme duty full flat ptin is nw available chrmly spindles press fit and welded t upgraded 3.25 diameter wall DOM axle tubes Oversized uter pinin bearing and remvable seal hlder Heavy duty ¼ thick brackets with multiple munting hles fr suspensin adjustability Triple-stage pwder cating prcess Retains OEM brake backing plates, park brake assembly and caliper New caliper munting brackets t accmmdate the massive 13.5 sltted rtrs with zinc aluminum cating fr superir crrsin resistance Prfiled 35 spline 4140 chrmly axle shafts with rlled splines t minimize fatigue and stress cncentratins Available in a standard 67 wide wheel munt t wheel munt width r wide 70 wheel munt t wheel munt width Genuine Dana-Spicer cmpnents where available (gear sets, seals, bearings, pinin yke) 1310 pinin yke standard, 1350 ptinal 1 year unlimited mileage warranty against material defects and wrkmanship Axle Installatin Installing a Tera60 frnt and CRD60 rear is a straight frward task that can be accmplished in the garage in a weekend. In additin t referencing a factry service manual, several things shuld be nted fr axle installatin. IMPORTANT NOTE! All TeraFlex axle assemblies are shipped dry! All bearings and seals are pre-greased. Freight regulatins dictate that the axles must be shipped dry. Use a quality 80W-90 gear il t fill yur new differentials. As with any Jeep mdificatin, it is imprtant t verify functin befre driving the vehicle. After installing the axle, it is imprtant t cycle the suspensin t ensure the husing desn t cntact the frame r engine. All clearances shuld be checked at all the extremes the suspensin will experience during full articulatin and cmpressin. Cycle the suspensin with the axle fully installed, but withut the springs and bump stps. D nt final tighten the track bar and cntrl arm blts at this time. The tires shuld be installed t verify fender clearance. The clearances need t be checked at the psitins Page 6

7 utlined belw. 1. Full Cmpressin raise the axle assembly slwly until there is cmpnent cntact, ie: the axle husing, cntrl arms, track bar r drag link cntact either the frame r the engine the tires cntact the fenders r ther parts f the bdy the track bar, blt r frame bracket hits the diff cver r axle husing 2. Full Drp lwer the axle assembly slwly until any f the fllwing ccurs: the brake lines r ABS wiring are taut the driveshaft cntacts the transmissin crss member r exhaust n 2012 and newer (gd t check n 2011 and lder JKs) driveshaft binding at pinin r transfer case shcks at full extensin 3. Articulated Left and Right raise ne side t full cmpressin, drp the ther side and vice versa (be sure t cycle the steering right and left at bth extremes): the tire cntacts the fender/bdy, frame r bumper, the shck bttms ut, r the axle husing, track bar r drag link interfere with the frame Recrd key measurements at each extreme. Yu will need t tune yur bump stps, and limit straps (nt required, but recmmended) t prevent damage at the extremes f yur suspensin s range f travel. When the axle is in the full cmpressin psitin, measure the distance between the spring pad n the axle and the metal bump stp cup n the frame. Perfrm the same measurement when the axle is articulated as described in step three. This measurement will mst likely be different. Chse the largest f the three measurements. This is the amunt the frnt bump stps need t be extended. Dn t frget t take tire clearance int accunt. When the axle is drped, it is imprtant that the brake lines, park brake cables (rear axle nly) r ABS wiring are nt ver extended. If the driveshaft cntacts either the transmissin crss member r exhaust, it is imprtant t limit the dwn travel with either a limiting strap r installing a shrter shck. TeraFlex recmmends installing a limiting strap t prevent damage t the shck frm tpping ut. The spring perches n yur new Tera60 feature a limit strap munting pint. After clearances are verified, install the required bump stp extensins, limit straps and springs. With the Jeep n the grund at ride height trque the track bar and cntrl arm blts. The track bar, lwer cntrl arm and rear upper cntrl arm blts shuld be trqued t 125 ft-lbs (169 N-m) while the frnt upper cntrl arm blts shuld be trqued t 75 ft-lbs (102 N-m). Be sure t rute the brake lines and ABS wiring s they will nt be damaged as the suspensin cycles and springs cmpress. Adjust the steering stp blts t bttm ut the same time the steering gear reaches the end f its travel, r befre either tire cntacts the frame, cntrl arm r bumper (whichever happens first). The principles utlined abve are applicable in a rear axle installatin. It is imprtant t cycle the suspensin and check fr clearances at all suspensin extremes t prevent damage t the Jeep. Page 7

8 Differential Oil Fill the differential with 80W-90 gear il t the fill hle n a frnt Tera60. At this pint, the frnt axle is ready t run; hwever, further steps must be taken when filling the rear axle t ensure lng bearing life. The fllwing steps are critical fr the full flat CRD60 rear and recmmended fr the semi-flat axle. Begin by filling the CRD60 axle t the fill level indicatr hle n the differential cver (small brass NPT plug). After filling the rear differential it is necessary t fld the wheel hubs with il fr prper wheel bearing lubricatin. Raise the right rear tire ff the grund at least 6 inches. Wait ne minute. Lwer the right side dwn and tp the differential ff with mre il. Lift the left side f the differential and wait ne minute befre lwering. Again, tp the differential ff with mre il and install the fill and level indicatr plugs. Align the vehicle and duble check the trque n all blts befre test driving. Re-trque all blts after 100 miles and check trque every 3000 miles thereafter r after fur wheeling. Drive Shafts Drive shaft changes are required when installing a Tera60 frnt end r CRD60 rear end. The length change will vary depending n the pinin and transfer case ykes used (1310, 1330, 1350 r even between manufacturers) and the lcatin f the axle under the Jeep. On average, the frnt and rear drive shafts will need t be shrtened between 2 and 2 ½ inches. Refer t yur drive shaft manufacturer s instructins t prperly measure required drive shaft length. A 1310 pinin yke cmes standard n all Tera60 and CRD60 axles but can be upgraded t a 1350 yke. Page 8

9 Basic Frnt Axle Installatin Checklist: Upper and lwer cntrl arms Track bar Sway bar links Trque t 75 ft-lbs Tie rd Trque t 63 ft-lbs Drag link Trque pitman arm side t 77 ft-lbs Trque axle side t 63 ft-lbs Shcks Trque pin t 20 ft-lbs Trque blt t 56 ft-lbs Wheel speed sensrs Brake lines dn t frget the cpper washers n either side f the banj fitting Trque banj blt t 23 ft-lbs Bleed brakes Tires and wheels Trque lug nuts t 135 ft-lbs fr 8 lug Trque lug nuts t ft-lbs fr 5 lug unit bearing Cycle suspensin t check clearances and measure fr bump stps and limit straps Bump stps/extensins and limit straps Springs and spring retainers Trque cntrl arm blts n the grund Lwer cntrl arms t 125 ft-lbs Upper cntrl arms t 75 ft-lbs Trque track bar blts n the grund t 125 ft-lbs Set steering stps Fill with 80W-90 il Wheel alignment Measure fr drive shaft Page 9

10 Basic Rear Axle Installatin Checklist: OEM park brake backing plate and mechanism Trque blts t 45 ft-lbs Inner spindle nut (with pin) Trque t 50 ft-lbs while rtating hub, then back the nut ff ¼ turn, final adjust as necessary t align pin with hle in lck washer by slwly tightening until the pin indexes in the lck washer. Nte: the lck washer can be flipped ver and reinstalled fr alternate indexing. Grease wheel hub seals Lck washer Wheel hub and uter bearing Page 10

11 Outer spindle nut Trque t ft-lbs Caliper munting bracket, brake pads, caliper Apply thread lcking cmpund and trque caliper munting bracket blts t 55 ft-lbs Apply silicne t hub face, install axle shaft Trque 7 16 blts in crisscrss pattern t 95 ft-lbs Trque caliper blts t 26 ft-lbs Brake rtr Upper and lwer cntrl arms Track bar Sway bar links Trque t 75 ft-lbs Shcks Trque bar pin blts t 37 ft-lbs Trque blt t 56 ft-lbs Wheel speed sensrs Park brake cables Tires and wheels Trque lug nuts t 135 ft-lbs fr 8 lug full flat, fr 5 lug Page 11

12 Cycle suspensin t check clearances and measure fr bump stps and limit straps Bump stps/extensins and limit straps Springs and spring retainers Trque upper and lwer cntrl arm blts n the grund t 125 ft-lbs Trque track bar blts n the grund t 125 ft-lbs Fill with 80W-90 Oil Wheel alignment Measure fr drive shaft Initial Break In and Maintenance Break In New gear sets and bearings need time t break in. Prper gear break in prcedures shuld be fllwed t help ensure years f quiet, truble free peratin. D nt g ver 60 mph fr the first 100 miles r s. After the first 20 miles, stp and let the differential cl befre driving again. This cycle shuld be repeated a few times. Avid twing r heavy use fr the first 500 miles. When twing a heavy lad fr the first time, the same 20 mile drive/cl cycle shuld be fllwed. Change the il after 500 miles t remve any metal particles frm the initial break in. This is an excellent time t inspect the gear set t catch any ptential prblems early n. Maintenance Wash the axle with a mild car wash detergent t maintain the pwder cat finish. Maintenance parts are available frm TeraFlex, any TeraFlex dealers r many majr aut parts warehuses. The tables belw cntain the list f standard parts used in TeraFlex Tera60 and CRD60 axles. Page 12

13 Tera60 Frnt Axle Standard Parts Descriptin TeraFlex Part Number Spicer Part Number Parts Warehuse Number Pinin Seal Pinin Nut Pinin Nut Washer Outer Pinin Bearing Cup X HM88510 Outer Pinin Bearing Cne (cup and cne) HM88542 Inner Pinin Bearing Cup X HM Inner Pinin Bearing Cne (cup and cne) HM Carrier Bearing Cup X 382S Carrier Bearing Cne (cup and cne, 2 ea.) 387A 1480 Series Axle U Jint SPL55-3X SPL55-3X Inner Axle Seal Spindle Bearing and Seal Kit * SBK-3 L > Spindle Needle Rller Bearing * B2414 L > Outer Axle Shaft Seal (Needle * Bearing) L > Outer Axle Shaft Seal (Spindle) * L > Stub Shaft Thrust Spacer (Plastic) * Inner Wheel Bearing * L > Inner Wheel Bearing Cup * JLM L > Inner Wheel Bearing Cne * JLM506849A Outer Wheel Bearing* SET38 L > Outer Wheel Bearing Cup * LM L > Outer Wheel Bearing Cne * LM Inner Spindle Nut * Spindle Lck Washer * Outer Spindle Nut * Wheel Hub Seal* /16-18 Wheel Stud (8 Lug) * /2-20 Wheel Stud (5 Lug)^ Brake Pads AC Upper Cntrl Arm Bushing AA * Parts apply nly t Fixed Spindle Axle ^ Parts apply nly t Unit Bearing Axle Page 13

14 CRD60 Rear Axle Standard Parts Descriptin TeraFlex Part Number Spicer Part Number Parts Warehuse Number Pinin Seal Pinin Nut Pinin Nut Washer Outer Pinin Bearing Cup Outer Pinin Bearing Cne Inner Pinin Bearing Cup X HM Inner Pinin Bearing Cne (cup and cne) HM Carrier Bearing Cup X 382S Carrier Bearing Cne (cup and cne, 2 ea.) 387A Spindle Bearing and Seal Kit & SBK-3 L > Spindle Needle Rller Bearing & B2414 L > Outer Axle Shaft Seal (Needle & Bearing) L > Outer Axle Shaft Seal (Spindle) & L > Stub Shaft Thrust Spacer (Plastic) & Inner Wheel Bearing & L > Inner Wheel Bearing Cup & JLM L > Inner Wheel Bearing Cne & JLM506849A Outer Wheel Bearing & SET38 L > Outer Wheel Bearing Cup & LM L > Outer Wheel Bearing Cne & LM Inner Spindle Nut & Spindle Lck Washer & Outer Spindle Nut & Wheel Hub Seal & Wheel Bearing and Seal (Semi-Flat Shaft) # SET20 Wheel Speed Sensr Tne Ring # /16-18 Wheel Stud (8 Lug) & # /2-20 Wheel Stud (5 Lug) & Parts apply nly t Full Flat Axle # Parts apply nly t Semi-Flat Axle Page 14

15 Fixed Spindle Frnt Tera60 Explded View Page 15

16 Fixed Spindle Frnt Tera60 BOM Call Out Part Number Descriptin Call Out Part Number Descriptin Full Flat Axle Spindle Frnt with ABS fr JK CRD Teraflex TF60 Diff Cver Icn Badge Blt M x 80mm Lng Grade 12.9 Cap Screw (300635) Tera60 Frnt Passenger Side Axle Shaft with 35 Spline 34.97" Lng (+1.5" Wide in Parentheses) Full Flat Frnt Hub with 8 n 6.5" Blt Pattern (300619) Tera60 Frnt Driver Side Axle Shaft with 35 Spline " Lng (+1.5" Wide in Parentheses) TJ/YJ Full Flat Hub Seal 836S Tera60 Frnt Axle Stub Shaft with 35 Spline fr Full Flat Kit 10.43" Lng TONE RING, 52 TEETH, JK FULL FLOAT U-Jint Frnt T Series Spicer # SPL55-3X WCD 5-806X JK Full Flat Hub Seal t Prtect Speed Sensr Axle Dust Shield fr 3.25" Axle Tubes CRD Bearing Cup and Cne CRD60 Full Flat Inner JK HD Threaded 4140 Chrmly Tie Rd Tube Bearing SET38 CRD60 Full Flat Outer JK HD Tie Rd RH Threaded Frging Nut Spindle Dana 60 Inner Nut M30 X 1.5 RH Jam Nut Washer Frnt Axle Spicer # JK HD Tie Rd LH Threaded Frging Nut Spindle Dana 60 Outer Nut M30 X 1.5 LH Jam Nut Spindle Bearing and Seal Kit D60 AXL WCD Premium JK Steering Ball Jint NEEDLE BEARING SEAL FOR FULL FLOAT STUB SHAFTS JK HD Lng Drag Link Frging NEEDLE ROLLER BEARING, DRAWN CUP WITH OPEN ENDS JK HD Shrt Drag Link Frging Inner Spindle Seal fr Full Flat Axle Shafts Threaded Sleeve with LH and RH Threads fr Adjustable Trackbars Thrust Washer fr Inner Spindle bearing n Full Flat Axle Shafts Pinch Clamp Fr JK Trackbar Adjusting Sleeves Withut Hardware Slimlc Lcking Hub fr 35 Splined Shafts Blt M12 x 1.75P x 70mm Lng Partially Threaded Grade 10.9 Flanged Hex Head Lcking Hub, Bezel Nut M12 x1.75p Serrated Flanged Distrted Thread Lck Nut Lcking Hub, Hub O-Ring HydraPak AS-568A Premium JK Steering Ball Jint Bi-Fld Dust Bt Lcking Hub, Dial Premium JK Steering Ball Jint Dust Bt Retaining Ring Lcking Hub, Blt Ring HD Ball Jint Adjusting Tl Lcking Hub, Dial O-Ring HydraPak AS-568A Ball Jint Set fr Dana 60 Knuckles Lcking Hub, Outer Spline (Engages hub) Outer Right Knuckle fr CRD 60 Axles (12.43 degree SAI) Lcking Hub, Inner Spline (Engages Axle shaft) Outer Left Knuckle fr CRD 60 Axles (12.5 degree SAI) Lcking Hub, Bushing JK Frnt CRD60 Axle 3.25" Husing with Tubes, Inner Knuckles, Brackets Pwder Cated Lcking Hub, Spring JK Frnt CRD60 Passenger Side Spring Pad Lcking Hub, Disengagement Ring JK Frnt CRD60 Driver Side Spring Pad Lcking Hub, Spacer Bracket JK Frnt Lwer Passenger Side Flex Arm Munt fr 3.25" Axle Tubes Blt #8-32 UNC x.75" Lng Black Scket Head Gr JK Frnt Axle Driver/Passenger Shck Bracket fr 3.25" Axle Tubes Snap Ring External fr 1.5" Shaft used n Full Flat Stub Shaft Bracket JK CRD60 Frnt Lwer Driver Side Flex Arm Munt fr 3.25" Axle Tubes JK Frnt PLAIN 13.3" Big Brake Rtr 8 n JK Frnt Trackbar Bracket with Multiple Hles fr 3.25" Axle Tubes Big Brake RAW Caliper JK Frnt Single Caliper 56mm Dia Pistns NO bracket JK Frnt Swaybar Bracket 3.25" Tubes L&R x2 n Axle Blt M8 x 1.25 P x 20mm Lng Flanged Hex Head Zinc Plated Grade JK Frnt Tera60 Upper Passenger Side Flex Arm Bracket fr 3.25" Tube JK Frnt Big Brake Anchr Bracket TF60 HD Differential Cver JK Frnt Big Brake Pads & Clips CRD60 Outer Pinin Seal Blt M x 40mm Lng Grade 10.9 Flanged Hex Head Pinin Nut Washer CRD60/Dana 60 # Wheel Stud 9/16"-18 x 2" Lng Inner Pinin Bearing Cup CRD60/Dana 60 #HM Bushing JK Frnt Upper Axle End FlexArm Bushing with 12mm Hle Inner Pinin Bearing Cne CRD60/Dana 60 #HM Yke Pinin Nut Axle Seal CRD60 Inner Axle Shaft Bearing T60R Pinin HM Vent 5/16" NPT x 1/8" Hse Male Brass Barbed Breather Bearing T60R Pinin HM Plug 1/2" NPT Zinc Plated fr HD Diff Cvers Carrier Bearing Cup CRD60/Dana 60 #382S /8"-16 x1" Scket Head Cap Screw Carrier Bearing Cne CRD60/Dana 60 #387A JK Frnt Lwer Cil Spring Retainer Bracket Dana 60 ARB Air Lcker Blt 3/8"-16 x 1" UNC Lng Hex Head Zinc Plated Page 16

17 Unit Bearing Frnt Tera60 Explded View Page 17

18 Unit Bearing Frnt Tera60 BOM Call Out Part Number Descriptin Call Out Part Number Descriptin JK Frnt Unit Bearing with Sensr fr 5 n 5" & 5 n 5.5" Blt Patterns JK HD Lng Drag Link Frging Wheel Stud 1/2"-20 UNF x " Lng JK HD Shrt Drag Link Frging O-Ring 8mm I.D. 1mm Crss Sectin and 10mm O.D. fr Speed Sensr Plug Threaded Sleeve with LH and RH Threads fr Adjustable Trackbars Blt M x 80mm Lng Grade 12.9 Cap Screw Pinch Clamp Fr JK Trackbar Adjusting Sleeves Withut Hardware JK Frnt PLAIN 13.3" Big Brake Rtr Blt M12 x 1.75P x 70mm Lng Partially Threaded Grade 10.9 Flanged Hex Head Big Brake RAW Caliper JK Frnt Single Caliper 56mm Dia Pistns NO bracket Nut M12 x1.75p Serrated Flanged Distrted Thread Lck Nut JK Frnt Big Brake Anchr Bracket Premium JK Steering Ball Jint Bi-Fld Dust Bt Blt M x 40mm Lng Grade 10.9 Flanged Hex Head Premium JK Steering Ball Jint Dust Bt Retaining Ring JK Frnt Big Brake Pads & Clips HD Ball Jint Adjusting Tl Bushing JK Frnt Upper Axle End FlexArm Bushing with 12mm Hle Ball Jint Set fr Dana 60 Knuckles Yke Outer Right Knuckle fr CRD 60 Axles (12.43 degree SAI) Axle Seal CRD60 Inner Axle Shaft Outer Left Knuckle fr CRD 60 Axles (12.43 degree SAI) Vent 5/16" NPT x 1/8" Hse Male Brass Barbed Breather JK Frnt CRD60 Axle 3.25" Husing with Tubes, Inner Knuckles, Brackets Pwder Cated Plug 1/2" NPT Zinc Plated fr HD Diff Cvers JK Frnt CRD60 Passenger Side Spring Pad /8"-16 x1" Scket Head Cap Screw JK Frnt CRD60 Driver Side Spring Pad JK Frnt Lwer Cil Spring Retainer Bracket Bracket JK Frnt Lwer Passenger Side Flex Arm Munt fr 3.25" Axle Tubes Blt 3/8"-16 x 1" UNC Lng Hex Head Zinc Plated JK Frnt Axle Driver/Passenger Shck Bracket fr 3.25" Axle Tubes Teraflex TF60 Diff Cver Icn Badge Bracket JK CRD60 Frnt Lwer Driver Side Flex Arm Munt fr 3.25" Axle Tubes Tera60 Frnt Passenger Side Axle Shaft with 35 Spline 34.97" Lng JK Frnt Trackbar Bracket with Multiple Hles fr 3.25" Axle Tubes Tera60 Frnt Driver Side Axle Shaft with 35 Spline " Lng JK Frnt Swaybar Bracket 3.25" Tubes L&R x2 n Axle Axle Shaft Tera60 Frnt 35 Spline Unit Bearing Stub Shaft 6.76" Lng JK Frnt Tera60 Upper Passenger Side Flex Arm Bracket fr 3.25" Tube Nut 1-1/8"-18 UNEF Sltted Fr Ctter Pin, Frnt Axles TF60 HD Differential Cver Ctter Pin, Frnt Axles fr Nut# CRD60 Outer Pinin Seal Washer Frnt Axle Pinin Nut Washer CRD60/Dana 60 # U-Jint Frnt T Series Spicer # SPL55-3X WCD 5-806X Inner Pinin Bearing Cup CRD60/Dana 60 #HM Axle Dust Shield fr 3.25" Axle Tubes CRD Inner Pinin Bearing Cne CRD60/Dana 60 #HM JK HD Threaded 4140 Chrmly Tie Rd Tube Nut 7/8"-14 UNF 60-Pinin 1310 Yke A Spicer JK HD Tie Rd RH Threaded Frging Bearing T60R Pinin HM Nut M30 X 1.5 RH Jam Nut Bearing T60R Pinin HM JK HD Tie Rd LH Threaded Frging Carrier Bearing Cup CRD60/Dana 60 #382S Nut M30 X 1.5 LH Jam Nut Carrier Bearing Cne CRD60/Dana 60 #387A Premium JK Steering Ball Jint Dana 60 ARB Air Lcker Page 18

19 Full Flat Rear CRD60 Explded View Page 19

20 Full Flat Rear CRD60 BOM Call Out Part Number Descriptin JK Rear CRD60 Axle Husing with 3.25" Tubes, Spindles, Brake Flanges, Brackets, Pwdercated JK CRD60 Rear Upper Passenger Side FlexArm Munt 3.25" Tube JK CRD60 Rear Upper Driver Side FlexArm Munt 3.25" Tube JK Rear CRD60 Bumpstp Pad 3.25" Tube JK Rear CRD60 Trackbar Munt 3.25" Tube JK Rear Axle Passenger Lwer Cntrl Arm Bracket 3.25" Tube JK Rear Axle Driver Lwer Cntrl Arm Bracket 3.25" Tube JK Rear CRD60 Cil Spring Pad 3.25" Tube HD Cver fr CRD60 Differential Seal Hlder 60CRD CRD CRD60 Axle O-Ring Blt 3/8"-16 UNC x 1" Flanged Serrated Head Zinc Plated Plug 1/2" NPT Zinc Plated fr HD Diff Cvers Vent 5/16" NPT x 1/8" Hse Male Brass Barbed Breather Plug 1/8" NPT Allen Head Plug Yke N X U-Blt Type Bracket Spring Retainer RAW JK, Rear Lwer Spring Blt 3/8"-16 x 1" UNC Lng Hex Head Zinc Plated Lck Washer 3/8" Zinc Plated Axle Shaft 35 Spline Full Flat Full Flat Rear Hub with 8 X 6.5" Blt Pattern Rear Anchr Bracket, Big Rtr Kit JK W/Factry Caliper JK Rear PLAIN 13.5" Big Brake Rtr 8 n Wheel Stud 9/16"-18 x 2" Lng Washer Frnt Axle Spicer # Nut Spindle Dana 60 Outer Nut Spindle Dana 60 Inner Blt 7/16"-14 UNC x 1.375" Lng Flange Hex Fr Full Flat Rear Axles TJ/YJ Full Flat Hub Seal 836S JK Full Flat Hub Tne Ring 52 Teeth Rear Bearing Cup and Cne CRD60 Full Flat Inner Bearing SET38 CRD60 Full Flat Outer Blt M12 x 1.75P x 45mm Lng Gr10.9 Flanged Hex Head Nut M12 x1.75p Serrated Flanged Distrted Thread Lck Nut CRD60 Outer Pinin Seal Pinin Nut Washer CRD60/Dana 60 # Inner Pinin Bearing Cup CRD60/Dana 60 #HM Inner Pinin Bearing Cne CRD60/Dana 60 #HM Nut 7/8"-14 UNF 60-Pinin 1310 Yke A Spicer Carrier Bearing Cup CRD60/Dana 60 #382S Carrier Bearing Cne CRD60/Dana 60 #387A Outer Pinin Bearing Cup CRD60 # Outer Pinin Bearing Cne Assembly CRD60 # Dana 60 ARB Air Lcker Page 20

21 Semi-Flat Rear CRD60 Explded View Page 21

22 Semi-Flat Rear CRD60 BOM Call Out Part Number Descriptin JK Rear CRD60 Axle Husing with Tubes, Flanges, Brackets, HD Cver, Pwdercat JK CRD60 Rear Upper Passenger Side FlexArm Munt 3.25" Tube JK CRD60 Rear Upper Driver Side FlexArm Munt 3.25" Tube JK Rear CRD60 Bumpstp Pad 3.25" Tube JK Rear CRD60 Trackbar Munt 3.25" Tube JK Rear Axle Passenger Lwer Cntrl Arm Bracket 3.25" Tube JK Rear Axle Driver Lwer Cntrl Arm Bracket 3.25" Tube JK Rear CRD60 Cil Spring Pad 3.25" Tube HD Cver fr CRD60 Differential Seal Hlder 60CRD CRD CRD60 Axle O-Ring Blt 3/8"-16 UNC x 1" Flanged Serrated Head Zinc Plated Plug 1/2" NPT Zinc Plated fr HD Diff Cvers Vent 5/16" NPT x 1/8" Hse Male Brass Barbed Breather Plug 1/8" NPT Allen Head Plug Yke N X U-Blt Type Bracket Spring Retainer RAW JK, Rear Lwer Spring Blt 3/8"-16 x 1" UNC Lng Hex Head Zinc Plated Lck Washer 3/8" Zinc Plated JK Rear Axle Shaft Assembly with bearing and retainer 32in Lng Axle Shaft D60 JK Rear Standard Length Bth Sides 32" Lng 5 n 5" and 5 n 5.5" Blt Patterns Set 20 Bearing Kit fr CRD60 Rear Wheel Bearings JK Rear Axle Shaft Tne Ring 52 Teeth JK Rear Axle Bearing Retainer fr Semi Flat CRD60 Axles Wheel Stud M12 x 1.5 x 54mm Lng Wheel Stud 1/2"-20 UNF x " Lng JK Rear Axle Nut M12 x 1.5 P Stver Lck Zinc Plated CRD60 Outer Pinin Seal Pinin Nut Washer CRD60/Dana 60 # Inner Pinin Bearing Cup CRD60/Dana 60 #HM Inner Pinin Bearing Cne CRD60/Dana 60 #HM Nut 7/8"-14 UNF 60-Pinin 1310 Yke A Spicer Carrier Bearing Cup CRD60/Dana 60 #382S Carrier Bearing Cne CRD60/Dana 60 #387A Outer Pinin Bearing Cup CRD60 # Outer Pinin Bearing Cne Assembly CRD60 # Dana 60 ARB Air Lcker Page 22