WJ 6.5 Critical Path Lift Kit Installatin Instructins Parts Checklist: *BOX 1* 24x12x12 6.5 Frnt spring 96008 (2) 6.5 Rear spring 96009 (2) *BOX 2* 24x14x6 Literature (instructins, steering shimmy checklist, spring warranty sheet) Invice Irn Rck Off Rad lg decal 10001 (2) Irnrckffrad.cm decal (1) Frnt sway bar links 11.25 center t center 92147 (2) Rear sway bar links 14.625 center t center 92149 (2) WJ 4 hle transfer case drp spacer 92026 (2) Frnt cntrl arm munting bracket 92016, 92017 (1 left, 1 right) A-arm spacer 92023 (1) Upper cil spring retainer 92040 (2) Rear lwer cntrl arm w/bushings installed 18.625 C t C (2) #1 - Frnt Track Bar Hardware (1) Track bar bushing half M20919 (4) 12mm track bar bushing sleeve 92035 (2) #2 - Rear Sway Bar Link Hardware (1) 3/4 hurglass bushing M00393 (4) 12mm sway bar blt sleeve 92038 (2) 10mm sway bar blt sleeve 92037 (2) M10 x 60 sway bar link blt (2) M10 X 1.5 hex nut (2) 7/16 USS washer (2) #3 Shcks Hardware (1) 12mm shck blt sleeve 404739 (2) 7/16 washer (6) 5/16 x 1 hex blt (4) 5/16-18 hex nut (4) 5/16 washer (8) #4 - Frnt Sway Bar Link Hardware (1) 3/4 hurglass bushing M00393 (4) 12mm sway bar blt sleeve 92038 (4) #5 - T-Case Drp Hardware (1) M10 x 150mm class 10.9 blt (4) 3/8 USS washer (4) #6 - Frnt Brake Line Spacers, Cil Spring Retainer Hardware (1) Frnt brake line spacer (10mm SBL sleeve) 92037 (2) M6 x 45 Frnt brake line blt (2) 1/4 USS washer (2) 1/2 x 5 scket head cap screw (2) #7 - Frnt Cntrl Arm Brackets Hardware (1) WJ frnt cntrl arm bracket nut plate 2.75 center t center 92097 (4) 7/16 x 1 1/4" gr8 hex blt (8) 7/16 USS washer (8) #9 Shck Hardware (1) Frnt shck barpin 403827 (2) #19 A-arm Spacer Hardware (1) M14 x 80 cl10.9 hex blt (3) 1/2 USS washer (3) #22 LCA Spacers Hardware (1) Lwer cntrl arm bushing spacer 90194 (10) #127-2 5/8 6 Blt IRO Flex End Hardware (2) Inner race 91118 (2) Thrust washer 91119 (2) Ball 91117 (1) 10-32 x 1-3/4 Scket Head Cap Screw (6) 10-32 Nylck Nut (6) 90 Degree ¼ -28 Grease Zerk Fitting (1) #76 - Caster Adjuster Hardware (1) 5/16 x 1 Carriage Blt (4) M10 x 90 Hex Head Blt (1) ¼ USS Flat Washer (4) 3/8 USS Flat Washer (2) 5/16 Hex Nut (4) M10 nylck hex nut (1) *BOX 3* 24x6x6 Shcks IRO Hydr Frnt Shcks SL2900F (2) Rear Shcks LL2973F (2) Detsch Upgrade (Optinal) Frnt shcks DT 8421 (2) Rear shcks DT 8403 (2) Bilstein Upgrade (Optinal) Frnt shcks 33-104652 (2) Rear shcks 33-185569 (2) #17 - Bilstein Shck Hardware (1) Frnt barpin 403827 (2) 12mm Shck sleeve 404739 (6) SBL U-bracket 99000 (2) 1/2 x 1 1/2 Hex blt, gr8 (2) 1/2 Hex nut, gr8 (2) 1/2 Flat washer (2) 1/2 Lck washer, gr8 (2) 7/16 USS Flat Washer (6) M12x60 Hex blt, cl10.9 (2) M12 Hex nut, cl10.9 (2) *BOX 4* 42x15x7 Frnt Irn Y and Passenger Side Lwer Cntrl Arm with bushings installed (1) Optinal: Fixed (Standard 92150 & 92154 r High Clearance 92151 & 92155) Optinal: Adjustable (Standard 92152 & 92156 r High Clearance 92153 & 92157) Lng Arm Male End 92186 (2) #65 Lng Arm Clamping Hardware (1) ¼ 28 x 1.125 Scket head cap screw (4) ¼ 28 Gr8. Nuts (4) Caster Adjust Bracket 92100 (1) Optinal: Fixed Track Bar 92008 (1) Optinal: Adjustable track bar 92001 (1) Track Bar Male End 92004 (1) #29 Track bar jam nut (1)
Installatin Instructins: Safety Warning: ***Imprtant! Read befre installatin.*** Installing a suspensin lift kit raises the center f gravity f the vehicle. This increases the pssibility f a rllver accident. Avid sudden maneuvers at high speed and avid all situatins where a side rllver may ccur. In additin larger tires decrease braking perfrmance, please drive accrdingly. We recmmend a tire and wheel cmbinatin that make the vehicle's track width wider (wheels with less backspacing). This will lwer the center f gravity and add stability. We als recmmend that 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 and lug nuts 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 Multi-purpse grease (all plyurethane bushings shuld be greased befre installatin) Hand drill with gd quality 7/16 drill bit 1/2-20 fine thread hand tap with tap handle and cutting il. Tuch up paint t match the clr f yur unibdy frame. Rubberized undercating. High strength threadlcker adhesive such as Lctite red. Anti-seize cmpund fr blts. Prepare the parts fr installatin: 1. Lcate hardware kit 3 and the rear shcks. 2. Grease and install the 5/8 I.D. shck bushings included with the shcks (if needed). 3. Grease and install the 12mm shck blt sleeves frm hardware kit 3. The rear shcks use 12mm sleeves at the tp and bttm. 4. Leave the rest f the hardware in the bag fr future use. 5. Lcate hardware kit 9 and the frnt shcks. 6. Lubricate the bushings and the barpins with multi-purpse grease. Clamp the barpin vertically in a bench vise; push the shck dwn nt the barpin, rtating the shck as yu g. Repeat fr ther frnt shck. 7. Lcate the frnt track bar and hardware kit 1. 8. If yu purchased the adjustable track bar lcate the track bar male end and hardware kit 29. Apply anti-seize t male threads and install jam nut nt male end. Install male end int track bar and adjust t 33-9/16 center t center as a starting pint. 9. Grease and install the track bar bushings. 10. Grease and install the track bar blt sleeves. 11. Lcate the rear sway bar links (14.625 center t center) and hardware kit 2. 12. Grease and install the hurglass bushings. 13. Grease and install the sway bar link blt sleeves. Each link gets ne 12mm I.D. sleeve and ne 10mm I.D. sleeve. 14. Leave the rest f the hardware in the bag fr future use. 15. Lcate the frnt sway bar links (11.25 center t center) and hardware kit 4 (If yu purchased JKS Sway Bar Discnnect system, refer t JKS instructins). 16. Grease and install the hurglass bushings. 17. Grease and install the sway bar link blt sleeves. All sleeves are the same (12mm I.D.). 18. Lcate Irn Y lng arm and passenger side lwer cntrl arm. Barpin Installatin 19. If yu purchased adjustable lng arms; lcate male ends and apply anti-seize and install in cntrl arms. Adjust t a length f 32-3/8 center t center as a starting pint. 20. Assemble lcking blts frm hardware kit 65, but d nt tighten at this time. 21. Assemble flex ends per attached flex end instructins (last page). 22. Assemble Caster Adjuster. See Fig 1. a. Slide Caster adjuster n tp f welded n u-shaped bracket as shwn. b. Insert the (4) 5/16 carriage blts frm the inside f the bracket utwards, engaging the square end f the carriage blt int the welded-n bracket. c. Install washers and nuts n the carriage blts finger tight. d. Once Irn Y is installed in vehicle, install washer nt the 10mm blt and slide thrugh the caster bracket assembly and upper cntrl arm bushing. Add the last washer and nylck nut, trque t spec. Transfer Case Drp Kit and Lwer Cntrl Arm Munting Brackets: 19. Lcate the frnt lwer cntrl arm munting brackets, 4 hle transfer case drp spacers, hardware kit 5, and hardware kit 7. 20. Lift frnt f vehicle and supprt with jack stands under the frnt axle. **Tip: break lug nuts lse befre lifting vehicle. 21. Ensure that vehicle is safely supprted. 22. Remve frnt tires. 23. Place a flr jack under the center f the transmissin/transfer case crssmember fr supprt. 24. On ne side remve the 4 blts that hld the crssmember t the unibdy. 25. Lwer the crssmember away frm the unibdy enugh t install the transfer case drp spacer and the crrect left r right side lwer cntrl arm munting bracket. It may be necessary t lsen the blts n the ther side f the crssmember. 26. Install the t-case drp spacer and bracket using the 2 lng existing blts and the 2 new blts and washers. 27. Align the lwer cntrl arm munting bracket t the vehicle. 28. Tighten blts 29. Using the bracket as a guide, drill the fur 7/16 munting hles at the frnt f the bracket. 30. Take the bracket ut and remve any burrs frm the drilled hles and paint any expsed metal.
31. Insert the nut plates thrugh the hle in the unibdy frame and mve them int psitin abve the drilled hles. 32. Spray the area where the cntrl arm munting bracket meets the unibdy frame with rubberized undercating t seal ut any misture between the bracket and the unibdy. 33. While the undercating is still wet, re-install the munting bracket and transfer case spacer. Use washers under all blts. 34. Trque all 8 new 7/16 blts t 65 ft punds. 35. Trque all 8 transfer case crssmember blts t 35 ft punds. 36. Repeat fr the ther side. 37. Re-trque all 16 blts. Frnt Suspensin: 38. Lift frnt f vehicle supprt with tall jack stands under the unibdy frame r transfer case crssmember. 39. Ensure the vehicle is safely supprted. 40. Place a flr jack under the frnt axle fr supprt, d nt lift vehicle. 41. Remve the frnt shcks. 42. Remve the track bar. 43. Remve frnt sway bar links. 44. Lcate hardware kit 6. 45. Install frnt brake line spacers between frnt brake line and axle where the brake line meets the shck munt. Use new M6 blts and washers. 46. Remve all frnt upper and lwer cntrl arms. 47. With the axle hanging as lw as pssible, remve cil springs and lwer cil spring islatrs. 48. Lcate Irn Y cntrl arm and 2 cntrl arm bushing spacers (large 1/4 thick washers). 49. Install Irn Y cntrl arm n the driver s side. First install the axle end lwer bushing int the axle with 2 spacers n the utbard side, then rtate up t install the arm nt the upper cntrl arm bushing n the axle. Use existing lwer cntrl arm blts, and new m10 x 90 blt washers, and lcknut fr the upper cntrl arm. Finally install the back side int the new lwer cntrl arm munting bracket. D nt tighten blts at this time. 50. Install passenger side lwer cntrl arm using 2 cntrl arm bushing spacers n the utbard side f the axle end. D nt tighten blts at this time. 51. Lcate the cil spring retainers (apprx 2 diameter x 5 lng aluminum cylinders) and the remainder f hardware kit 6. The cil spring retainers blt nt the frnt upper cil spring perch t keep the cil springs frm falling ut under extreme drp. 52. Using yur 1/2-20 fine thread hand tap, tap the existing hle in the center f each frnt upper cil spring perch (n need t drill). 53. Apply a liberal cating f high strength threadlcker adhesive (such as Lctite red) t the threads f bth 1/2" x 5 scket head cap screws. Apply anti-seize cmpund t the unthreaded shaft f the blt (nt the threads). 54. Psitin the cil spring retainer nt the upper cil spring pad and install the blt. Trque t 60 inch lbs. Repeat fr ppsite side. 55. Snap the cil spring islatr nt the new spring. 56. Install new spring in vehicle being careful t align islatr pin with the hle in the spring bucket. 57. Repeat fr ther frnt cil spring. 58. Install new frnt shcks using prvided blts, washers, and nuts. Tighten upper stud munt nuts just enugh t cmpress the bushings. D nt ver-trque nuts. 59. Install new sway bar links. Re-use the existing blts and nuts. Trque t 78 ft. lbs. 60. Install track bar. Trque t 80 ft. lbs. Steep bend at axle side, hanging dwn t clear bracket at full drp. *Nte: The bends in the track bar are fr clearance f the differential and the bracket n the axle. The bent end f the track bar attaches t the axle with the bend n the bttm. The threaded adjusting end attaches t the uni-frame. 61. Any remaining lse blts will be tightened after the rear suspensin installatin. Rear Suspensin: 62. Lift rear f vehicle and supprt with tall jack stands under the unibdy frame. **Tip: break lug nuts lse befre lifting vehicle. 63. Ensure that the vehicle is safely supprted. 64. Remve rear tires. 65. Place a flr jack under the center f rear axle fr supprt (d nt lift vehicle). 66. Remve rear shcks. 67. Remve Sway bar links. 68. Lsen lwer cntrl arm blts. Remve nuts but d nt remve blts. 69. Allw suspensin t drp as much as pssible. 70. Remve cil springs. 71. Lcate a-arm spacer blck and hardware kit 19. 72. Raise rear axle up t a cmfrtable psitin t access the 3 a-arm retaining blts n tp f the differential. 73. Place a jack stand under the pinin t keep the axle frm rtating. 74. Remve the 3 a-arm blts n tp f the differential. 75. Install the a-arm spacer between the a-arm and the tp f the differential using supplied hardware. 76. Trque t 100 ft. lbs. 77. Lcate lwer cntrl arms and 6 cntrl arm bushing spacers (large 1/4 thick washers). 78. If yu purchased adjustable lwer cntrl arms, apply a light cat f anti-sieze t the male threads and assemble male threaded ends with jam nuts. Adjust length t 18 5/8. Install with adjusting threads at uniframe side. 79. Install new lwer cntrl arms with spacers n the inbard side f the bushings, 2 at each axle bushing, 1 at each unibdy bushing. D nt tighten blts at this time. 80. Install new cil springs being careful t align the spring t the islatr. 81. Raise rear axle and install new shcks. Use prvided 7/16 washers n the upper shck munts, place ne washer behind the shck bushing, and 2 washers in frnt f it (tward the utside f the vehicle). 82. Install sway bar links using existing upper blt and the new lwer blt, washer, and nut. Trque t 78 ft. lbs. (upper blt) and 50 ft.lbs. (lwer blt). 83. Raise the vehicle and supprt with jack stands under the frnt and rear axles. 84. Trque all lwer cntrl arm nuts t 120 ft punds. 85. Tighten any adjustable lng arm clamping blts (if equipped) at this time. 86. Tighten frnt track bar jam nut very tight (if equipped). 87. On the frnt axle, set the caster adjuster n the Irn Y t the middle f the range as a starting pint. Trque upper cntrl arm nut t 60 ft punds. Trque the fur lcking nuts t 15 ft punds. 88. Trque any remaining lse blts t spec. 89. Install tires and place the vehicle n the grund. 90. Trque lug nuts t spec. (85-115 ft punds depending n yur wheels) Adjustments and Final Inspectin: 91. 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. 92. Re-center steering wheel by adjusting the drag link (lnger) until the steering wheel is centered.
* A prfessinal frnt end alignment is required after installatin. We recmmend the fllwing alignment settings: Caster: +3.25 t +6.0 (+4.0 is preferred) Te-in: +.20 degrees (+1/16 t +1/8 measured at the tire) Final Safety Warning: * Re-trque all fasteners including lug nuts 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. WJ 6.5 inch critical path kit install.dc Rev. 3.2
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 Parts Checklist: Outer husing, weld n (may already be attached t yur existing cntrl arm) #127-2 5/8 6 Blt IRO Flex End Hardware Inner race 91118 (2) Thrust washer 91119 (2) Ball 91117 (1) 10-32 x 1-1/4 Scket Head Cap Screw (6) 10-32 Nylck Nut (6) 90 Degree ¼ -28 Grease Zerk Fitting (1) 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 Assembly: 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. 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 six blts t 70 in/lbs., then t 85 in/lbs. 11. Install 90 Degree 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.
Steering Shimmy Eliminatin Checklist Nte: Steering Shimmy is als knwn as death wbble r speed wbble. It is a vilent shaking f the vehicle caused by the frnt tires turning side t side repeatedly until yu slw dwn. It usually ccurs after hitting a bump r pthle a varius speeds abve 30MPH. If yu experience this steering shimmy just remain calm, yu still have steering and braking cntrl. Just gently apply the brakes and slw dwn until the shimmy disappears. Safety Warning: Sme f these adjustments will reduce steering shimmy, but als reduce steering stability and steering respnsiveness. Test drive carefully after every mdificatin, if yu feel any mdificatin is unsafe d nt prceed. Keeping yur vehicle safe t drive is the respnsibility f the persn making the adjustments and the driver. The driver must ntice any unsafe actins f the vehicle and crrect the prblem immediately (e.g. wandering r unrespnsive steering). Irn Rck Off Rad prmtes these mdificatins fr lw speed ff rad use nly, sme f these mdificatins may nt be safe fr use n public r private rads, especially at highway speeds. We recmmend wrking with an experienced alignment shp that has the ability, knwledge, and experience t keep yur vehicle safe t drive at highway speeds. Check all tie rd ends fr wear and replace as needed. Adjust te-in t exactly zer. Nte: a slight te-in is preferred fr stability, te ut will reduce steering shimmy. See safety warning at the tp f this sheet. Adjust caster t 3.0 t 5.5 degrees (mre caster will imprve stability, less caster will reduce steering shimmy). See safety warning at the tp f this sheet. Check steering stabilizer including bushings, replace if cnditin is less than perfect. We have researched extensively and fund the best steering stabilizers available with the least amunt f free play. Balance tires and put the best balanced tires in frnt. The frnt tires MUST be dynamically balanced, meaning they must have wheel weights n bth the inner and uter rim flanges as directed by the balancing machine. If yu dn t like hammer-n weights n the uter flange either fr appearance reasns r because f frequent rck damage, then use stick-n weights fr the uter weights in this case functin must precede frm dn t balance statically with weights just n the inner rim edge. If a tire/wheel requires mre than 6 unces f ttal balance weights (inner and uter cmbined), d nt use it n the frnt axle. Check all suspensin bushings fr wear and lse fasteners including cntrl arms and track bar. Any rubber bushing with cracks, r where the rubber is separating frm the steel shuld be replaced. Check steering gearbx fr wear and adjust r replace as needed. Check wheel bearings fr wear. Check ball jints fr wear. Install dual steering stabilizer kit. Reduce tire air pressure (try 29psi fr OEM size tires, less fr larger tires). Nte: Reducing air pressure t far can cause tires t verheat and blwut at highway speeds. See safety warning at the tp f this page. Check vehicle stance. Hub t fender measurements shuld be minimum ¼ higher in the rear (like OEM stance) fr maximum stability (this transfers weight t the frnt tires). Measure n a level surface with nrmal carg and ½ tank f gas fr maximum accuracy.