Parts Checklist: *BOX 1* 33x17x8 Instructins Rck-Link decal 13287 (2) Irn Rck Off Rad lg decal 10001 (2) Irnrckffrad.cm decal (1) XJ/ZJ Adjustable duble shear track bar 92185 (1) Track bar male threaded end 92004 (1) XJ/ZJ duble shear track bar bracket 91015 (1) Frnt sway bar link 8.75 center t center 92145 (2) Subframe center sectin 91154 (1) Subframe left uter 91147 (1) Subframe right uter 91151 (1) IRO Bmerang Shackle 91110 (2) T-Case drp spacer 99003 (2) *BOX 2* (24x12x12) Frnt cil spring 96012 (2) U-Blt set - specific t custmer vehicle: Optinal: Frd 8.8 91093 (4 U-blts) 9/16-20 high nut (8) 9/16 hardened flat washer (8) Optinal: Dana 35/44 91094 (4 U-blts) 1/2-20 high nut (8) 1/2 hardened flat washer (8) Optinal: Chrysler 8.25 91095 (4 U-blts) 1/2-20 high nut (8) 1/2 hardened fat washer (8) #10 - Frnt Sway Bar Link Hardware (1) 3/4 hurglass bushing M00393-BK-01 (4) 12mm sway bar blt sleeve 92038 (4) M12 x 70 cl10.9 hex blt (2) M12 cl10.9 hex nut (2) 1/2 x 1 1/2 gr8 hex blt (2) 1/2 gr8 lck washer (2) 1/2 gr8 hex nut (2) Sway bar link u-bracket 99000 (2) #11 - Frnt Brake Line Relcatin Hardware (1) 1/4 x 1 Self drilling sheet metal screw (2) #20 - Frnt Track Bar Hardware (1) Track bar bushing half 80014 (4) 7/16 I.D. track bar bushing sleeve 92036 (1) 7/16 x 2 1/2 lg gr8 hex blt (1) 7/16 gr8 hex nut (1) 12mm track bar bushing sleeve 92035 (1) 7/16 flat washers (2) 12mm x 80 hex blt, class 10.9 (1) 12mm hex nut, class 10.9 (1) 7/8-14 jam nut #30 - Rear Brake Line Bracket Hardware (1) 5/16 x 1 hex blt (1) 5/16 washer (2) 5/16 hex nut (1) XJ rear brake line drp bracket (1) #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) XJ 4 Rck-Link Lng Arm Lift Kit Instructins XJ 84-01 Jeep Cherkee 90 Degree ¼ -28 Grease Zerk Fitting (1) #134 - IRO Shackle Hardware (1) IRO shackle bushing M02247BK-01 (4) IRO bushing sleeve 91100 (2) ¼ Straight grease zerk (2) #168-2-3/8 Flex End Hardware (1) End cap 91138 (2) Inner race 91139 (2) Flex end ball 91140 (1) 8-32 x 1-1/2 scket head cap screw (8) 90 ¼ -28 grease zerk fitting (1) Straight 1/4-28 grease zerk fitting (1) #181-3-Link Cntrl Arm Clamping Hardware (1) 1/4"-28 x 1-1/8 scket head cap screw (4) 3/8-16 x 1 1/4 hex blt grade 8 (1) 1/4"-28 hex nut, grade 8 (4) 3/8-16 nylck flange nut (1) 3/8 Mil Spec Hardened washer (1) #182 - XJ 3-Link Lng Arm Subframe Hardware (1) M14 x 2.0 x 90 hex blt cl10.9 (1) M14 x 2.0 x 100 hex blt cl10.9 (2) M14 x 2.0 x 110 hex blt cl10.9 (2) M10 X 30 cl10.9 hex blt (4) M10 x 80 cl10.9 hex blt (1) M10 x 25 carriage blt (4) M10 X 50 carriage blt (4) M10-1.5 cl10.9 hex nut (4) M10-1.5 cl10.9 nylck flange nut (1) 7/16-14 X 1-1/4 gr8 hex blt (2) M14 Nylck flange nut cl10.9 (4) 3/8 USS flat washer (12) 9/16 F436 hardened washer (5) Shcks IRO Hydr Frnt shck SL2450F (2) Rear shck LL2498F (2) #15 - Shck Hardware (1) 2.5 lng frnt barpin (2) 2.75 lng rear barpin (2) Detsch Upgrade (Optinal) Frnt shck DT 8352 (2) Rear shck DT 8269 (2) #15 - Shck Hardware (1) 2.5 lng frnt barpin (2) 2.75 lng rear barpin (2) Bilstein Upgrade (Optinal) Frnt shck 33-185606 (2) Rear shck 33-186542 (2) #18 - Bilstein Shcks Hardware Frnt barpin 2.5 (2) Rear barpin 2.75 (2) SBL U-bracket (2) 12mm Shck sleeve (2) 1/2 x 1 1/2 gr8 Hex Blt (2) 1/2 gr8 Hex nut (2) 1/2 USS Washer (2) 1/2 gr8 Lck washer (2) 7/16 USS Washer (6) M12x60 cl10.9 Hex blt (2)
Bilstein Shcks Hardware Cntinued M12 cl10.9 Hex nut (2) *BOX 3* (42x15x7) XJ Lng LCA Left 85107 (1) XJ Lng LCA Right 85108 (1) XJ 3-Link Frnt UCA 91205 (1) Angled Lng Arm Male End 91109 (2) 2 3/8 UCA Male End 91191 (1) *BOX 4* IRO Full Length Add-a-Leaf 96013 (2 Leafs) Upper leaf clamp 96021 (4) Lwer leaf clamp 96022 (4) 5/16-24 x 4 Center pin (2) 5/16-24 hex nut (2) ~Optinal Parts~ (instead f Add-a-Leaf) XJ 3.5 leaf spring (90149) (2) Bushing installatin instructins #72 Leaf Spring Bushing Hardware (1) Frnt bushing M20774 (4) Rear bushing M20775(4) Frnt bushing sleeve 91071 (2) Rear bushing sleeve 91070 (2)
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 than OEM). 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 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. *2000 and 2001 mdels with autmatic transmissins will require ld style transmissin munt such as Anchr 2625* 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 ply bushings shuld be greased befre installatin) Metal cutting tls such as a 4 ½ angle grinder with thin metal cutting wheel, and a sandpaper flap wheel fr an attractive finish. Pssibly a sawzall with metal cutting blades. Paint and primer (fr uniframe - black r yur chice f clr). Anti-seize cmpund Hand Drill 23/64 drill bit (.359 diameter) 7/16-14 Taper Hand Tap Angle finder String level r laser level Prepare the parts fr installatin: 1. Lcate hardware kit 15 and the rear shcks. 2. Grease and install the barpins int the tp side f the rear shcks. It helps t use a press, r clamp the barpin vertically in a bench vise, and lwer the shck nt the barpin while rtating the shck back and frth. Be sure t thrughly grease the barpin and the shck bushing. If needed yu can grind r file the crners f the barpin t prvide a lead in surface. Remve any sharp edges t prevent damage t the shck bushing. 3. Install the frnt barpins by repeating the prcedure in step 2. 4. Lcate the frnt track bar and hardware kit 20. 5. Thread the jam nut nt the threaded male end, then thread it int the track bar. 6. Adjust the length t 33-3/8 frnt center t center as a starting pint. This may need t be adjusted after a shrt test drive. D nt tighten jam nut at this time. D nt exceed 33-3/4 center t center track bar length. Verify that yu have a minimum f 1 thread engagement. 7. Lubricate track bar bushings and bushing sleeves with multi-purpse grease and install int track bar: smaller I.D. bushing sleeve is installed at axle end (withut adjusting threads), and larger I.D. sleeve at unibdy end (with adjusting thread). 8. Leave the rest f the hardware in the bag fr future use. 9. Lcate the frnt sway bar links, frnt sway bar link u-brackets, and hardware kit 10. (If yu purchased JKS Sway Bar Discnnect system, refer t JKS instructins. 10. Grease and install the hurglass bushings. 11. Grease and install the sway bar link inner sleeves. 12. Leave the rest f the hardware in the bag fr future use. 13. Lcate the rear leaf spring shackle kit. If equipped with ply bushings, grease and install the ply bushings and inner bushing sleeves. 14. Lcate the lwer cntrl arms (larger), male ends (larger, angled), hardware kit 127 and 181. 15. Assemble flex ends int male end. Use hardware kit 127 and attached instructins (2-5/8 ). 16. Lcate the upper cntrl arm (smaller), male end (smaller, straight), and hardware kit 168. 17. Assemble flex end int upper cntrl arm. Use hardware kit 168 and attached instructins (2 3/8 ). 18. Apply a light cat f anti-seize cmpund t the threads, thread male ends int cntrl arms. 19. Adjust cntrl arm lengths per the chart. 20. Install clamping blts. D nt tighten at this time Cntrl arm munting subframe: 21. Lift frnt and rear f vehicle and supprt with jack stands under the uniframe. Leave rm t cut ff the stck lwer cntrl arm munts. 22. Remve the fur transmissin munt nuts frm the transmissin. 23. Raise transfer case slightly and supprt with a jack stand. 24. Remve the factry transmissin munting crssmember. Cntrl Arm Length (Starting Lengths - Center t Center) Lift Height LCA UCA 3 36 1/4 37 4 36 3/8 37 1/8 5.5 36 1/2 37 1/4 6.5 36 5/8 37 3/8 8 37 37 3/4 RIGHT OUTER LEFT OUTER CENTER SECTION
25. Using a stud puller, remve the tw crssmember munting studs. If yu d nt have a stud puller, yu can install 2 nuts and tighten ne against the ther then remve using a bx end wrench n the inner nut. 26. Drill and tap the third munting hle n each side (the next hle directly frward frm the tw crssmember munting hles) using the 23/64 (.359 diameter) drill bit and 7/16-14 hand tap. Use plenty f il during drilling and tapping and keep the drill bit and tap as straight as pssible. 27. Install upper cntrl arm int left subframe uter. Make sure the threaded male end is installed in the subframe using the M14 x 90 blt and the arm is riented with the bend hanging dwn t clear the flr. Blt faces frm center ut s it can be remved later if needed. 28. Install subframe uter in vehicle using M10 flange and 7/16 blts, and washers frm hardware kit 182. 29. Install right subframe uter using the same hardware. 30. *2000 and 2001 w/aut trans nly* Remve trans islatr munt. Grind ff lcating pin frm munting plate. Install lder style trans munt. Trque t 78 ft-punds. 31. Using M10 x 25 carriage blts, 3/8 washers, and M10 nuts, lsely assemble the subframe center sectin t the uters (center sectin underneath the uters). ***The text side f the center sectin face frward when installed in the vehicle.*** 32. Trque 7/16 blts t 65 ft punds. Trque M10 blts t 50 ft punds. 33. Trque subframe center sectin blts t 45 ft punds. 34. Trque upper cntrl arm blt at uniframe t 135 ft punds. 35. Lwer the transfer case n t the subframe. 36. Install the fur transmissin munt nuts and trque t 15 ft punds. Frnt Suspensin: 37. Lift frnt f vehicle and supprt with tall jack stands under the unibdy frame r lng arm subframe. 38. Ensure the vehicle is safely supprted. 39. Place a flr jack under the frnt axle fr supprt, d nt lift vehicle. 40. Remve the frnt shcks. 41. Remve the track bar and munting bracket at unibdy. N need t separate track bar frm bracket. 42. Remve frnt sway bar links. 43. On ne side, remve the blt that hlds the brake hse t the unibdy. 44. Any rusted, wrn, cracked, r damaged rubber r steel brake line shuld be replaced. 45. Pull brake line dwn as far as pssible withut ver-stressing r causing a kink in the line. *Nte: Yur brake line may appear different frm the pht. D nt pull t far and damage the brake line. 46. Using tw adjustable wrenches bend brake line bracket munting surface s brake line pints ut tward the brake caliper. See pht. 47. Mark lcatin and drill a 1/4 hle fr the brake line lcating tab. 48. Fasten brake line t unibdy using prvided self drilling sheet metal screw. 49. Repeat fr ther side. 50. Remve upper and lwer factry cntrl arms. 51. Discnnect the driveshaft n the axle side and tape the u-jint s the caps d nt fall ff. Tie the driveshaft ut f the way (use tape, zip tie, mechanic s wire, etc ) fr easier access t the lwer cntrl arm munt. 52. Tie the upper cntrl arm ut f the way. 53. Cut ff factry lwer cntrl arm munts frm the uniframe n the driver s and passenger's side. 54. ***Tip: Our favrite tl fr this is a 4 ½ angle grinder with a thin cutting wheel. Remve in pieces fr ease f access.*** 55. Remve anything n the driver s side that extends inward (tward the transmissin) beynd the uniframe. D nt remve any f the uniframe; just make ne cntinuus edge frm frnt t rear. 56. Clean up any burrs r sharp edges and grind smth fr an attractive appearance. 57. Clean, prime, and paint any expsed metal. 58. Cnnect the upper cntrl arm t the axle using M10 x 80 blt with washer and nylck flange nut. D nt tighten at this time. 59. Install lwer cntrl arms (axle end first) with threaded adjusting end at the uniframe, and bends facing inward t clear the tires, thread clamping blts facing dwn. Use prvided M14 x 100 blts (at axle), M14 x 110 blts (at subframe), 9/16 washers, and nylck nuts. D nt tighten at this time. 60. Install new springs in vehicle being careful t align the springs t the spring buckets n the axle. 61. Using a flr jack lift the frnt axle just enugh t apply sme lad t the cil springs, d nt lift vehicle. 62. Lcate frnt track bar, track bar munting bracket, and hardware kit 20.
63. Install the track bar bracket nt the unibdy with the factry blts. Lsely attach the bracket with the upper tw blts, then align the lwer blt munting hles. Install the lwer munting blts and trque all track bar bracket hardware t 92 ft. lbs. ***NOTE: If the unibdy is rusty, the seam behind the factry bracket may have swelled making installatin f the lwer munting blts difficult. Using a ratchet strap t pull the bracket t align the hles r smthing the seam with a hammer is recmmended. 64. Install the track bar and trque blt at axle t 74 ft. lbs., and blt at bracket t 80 ft. lbs. If necessary use a flr jack and/r the steering wheel t help align the track bar. 65. Raise vehicle slightly and repsitin jack stands under the frnt axle. 66. Re-install cil spring retainer clamps. 67. Install new frnt shcks using riginal barpin blts. Tighten upper stud munt nuts just enugh t slightly cmpress the bushings. Over cmpressing these bushings will result in damage t the bushings and premature bushing failure. 68. Lcate frnt sway bar links (10.75 center t center), tw u-brackets, and the remainder f hardware kit 10. 69. Install sway bar link u-brackets t the sway bar using 1/2 x 1 1/2 grade 8 hex blts, lck washers, and nuts. Brackets munt t the bttm f the sway bar with the blt facing up and the lck washer and nut n tp f the sway bar. Rtate the bracket s it is ffset away frm the center f the vehicle. Align brackets, trque blts t 80 ft punds. 70. Install sway bar links driver s side first using prvided M12 x 70mm class 10.9 hex blt and nut thrugh the u-bracket with the nuts tward the utside f the vehicle, and the riginal blt, nut, and washer at the axle. Tighten all blts t 78 ft punds. 71. Ensure that vehicle is safely supprted. 72. Any remaining lse blts will be trqued after rear suspensin installatin and with full vehicle weight n the suspensin. Rear Suspensin: 73. Lift rear f vehicle and supprt with tall jack stands under the unibdy frame. **TIP: break lug nuts lse befre lifting vehicle. 74. Ensure that the vehicle is safely supprted. 75. Remve rear tires. 76. Remve rear shcks. 77. Allw suspensin t drp as much as pssible. 78. Remve retaining clip frm rear brake line at the unibdy. 79. Push the brake line frward until it can be pulled dwn ut f the bracket. 80. Install rear brake line bracket using 5/16 x 1 blt, nut, and 2 washers. Bracket shuld be riented t extend the brake line dwn and back. 81. Gently bend the steel brake line int its new lcatin in the bracket. Be very careful t nt create a crack r a kink. Any rusted, wrn, cracked, r damaged rubber r steel brake line shuld be replaced. 82. Install brake line retaining clip. If replacing leaf springs: (if installing add-a-leaf kit prceed t step 93) 83. Starting with the driver s side: place a flr jack under the driver s side f the rear axle fr supprt (d nt lift vehicle). 84. Remve leaf spring blts at unibdy and shackle. 85. Remve the u-blts. 86. Allw axle t drp and remve leaf spring. 87. Install new leaf spring. 88. Install frnt blt and rear blts but d nt tighten yet. 89. Clean any debris frm axle seating surfaces. 90. Raise the axle up t the leaf spring, make sure the center pin drps int the axle and the axle seats flat against the leaf spring. Install u-blts. 91. With the vehicles weight n the suspensin, trque U-blts t 90 ft punds and re-trque after 100 miles. 92. Repeat fr passenger side. If installing add-a-leaf kit: 93. Starting with the driver s side, remve u-blts. 94. Allw axle t drp and remve leaf spring clamps and center pin t take apart the leaf spring pack. Nte rientatin f leaves. 95. Install the new highly arched leaf in the spring pack (directly under main leaf in the #2 spt) with the lng end f leaf twards the rear f the vehicle. Use a c-clamp r tw t help install the new center pin. 96. Tighten leaf spring centering pin. 97. Use a c-clamp r tw t help install new leaf spring clamps. 98. Clean any debris frm axle seating surfaces. 99. Raise the axle up t the leaf spring, make sure the center pin drps int the axle and the axle seats flat against the leaf spring. Install u-blts. 100. With the vehicles weight n the suspensin, trque U-blts t 90 ft punds and re-trque after 100 miles. 101. Repeat fr passenger side. 102. Install rear brake line. 103. Grease lwer shck studs, apply anti-seize t upper blts and install rear shcks using riginal hardware. 104. Trque lwer shck blts t 46 ft punds. 105. Trque upper shck barpin blts t 17 ft punds. 106. Install rear tires. 107. Lwer vehicle frm jack stands. 108. With the vehicle n the grund, trque leaf spring and shackle blts t 120 ft punds. Final Trque: 109. With the weight f the vehicle n the springs, trque any lse blts t spec. 110. Trque all frnt lwer cntrl arm nuts t 135 ft punds. 111. Trque upper cntrl arm nut at axle t 60 ft punds. 112. Tighten track bar jam nut very tight. 113. Trque any remaining lse blts t spec.
114. Install tires and place the vehicle n the grund. 115. Trque lug nuts t spec. (85-115 ft punds depending n yur wheels) Adjustments and Final Inspectin: 116. Check all cmpnents fr clearance fr suspensin t fully cycle up and dwn and wheels t turn lck t lck. Pay special attentin t brake lines, axle vent hses, and ABS wires. Repsitin as needed by bending the brackets, relcating, r extending hses and wiring. * A prfessinal frnt end alignment is required after installatin. We recmmend the fllwing alignment settings: Caster: +3.75 t +5.75 (+4.5 is preferred if pssible) Te-in: +1/16 t +1/8 89. Check caster angle. Using a laser level r string level, set the frnt axle level t the rear axle (left side and right). Bunce the Jeep up and dwn t ensure the suspensin is in resting psitin (at exact ride height). Place the angle finder under the axle "C" (r n tp f the upper ball jint). Ensure the angle finder is parallel t the Jeep frnt t rear. This is yur caster angle. 90. Recheck all fasteners and trque any remaining lse nuts r blts t spec. Final Safety Warning: * Re-trque all fasteners after 100 miles, and frequently inspect all safety critical suspensin cmpnents. It is the respnsibility f the installer t be sure all fasteners are prperly tightened after installatin and t ensure the wner knws his/her nging respnsibility. It is the respnsibility f the wner f the vehicle t be sure all safety critical cmpnents are inspected frequently, especially after ff rad r ther demanding use.
Fits All Irn Rck Off Rad Lng Arm Systems, WJ A-Arms, and Build Yur Own Flex End Assemblies. 2-5/8 IRO Flex End (6 blt) Assembly Instructins Befre yu begin: Read and understand installatin instructins. Cntact Irn Rck Off Rad with any questins befre, during, r after installatin. Ensure that all parts are present and in gd cnditin per attached shipping checklist! Have these tls handy: 5/32" allen head scket 3/8" pen end wrench Inch-lb. trque wrench Multipurpse grease/grease gun Parts Checklist: Outer husing, weld n (may already be attached t yur existing cntrl arm) #127-2-5/8 IRO Flex End (6 blt) 2-5/8" flex end race 91118 (2) Thrust washer 91119 (2) 2-5/8" flex end ball 91117 (1) #10-32 nylck nut (7) #10-32 x 1-3/4" scket head cap screw (6) 90 ¼ -28 grease zerk fitting (1) Assembly: Figure 1 1. Insert tw #10-32 scket head cap screws int ne thrust washer and ne plastic race. Spherical bre f race facing away frm thrust washer. (Figure 1) 2. Install this small assembly int the flex end husing. The races are a light press fit, use a wide punch and hammer t assist yu if needed. 3. Apply a thin cating f multi-purpse grease t the mating surfaces f the ball and bth races. 4. Place the ball in the race (inside the flex end). The ball shuld perfectly fit the cntur f the race. (Figure 2) 5. Insert the ther race nt the ball s that the spherical bre is cntacting the ball. Once again, the races are a light press fit, use a hammer and wide punch if needed. (The tw screws shuld be thrugh ne washer and bth races at this pint) 6. Insert the secnd thrust washer n tp f the flex end husing, sliding the blts thrugh the hles. (Figure 3) 7. Start nylck nuts n the tw blts that are in the flex end assembly. Hld the nut and turn the blt. 8. Insert the remaining fur cap screws thrugh the remaining hles and install nuts. (Figure 4) 9. Snug up all f the blts fairly tight. 10. Trque blts evenly, starting at ne blt and cntinuing using a crisscrss pattern. Trque all six blts t 70 in-lbs., then t 85 in-lbs. Figure 2 11. Install 90 grease zerk fitting s that it is easily accessed in the vehicle. 12. Grease flex end until grease cmes ut f the races arund the ball. 13. Re-trque blts t 85 in-lbs. after 5 minutes. *Reference Only* Cmplete jint shwn fully assembled withut husing Figure 3 Figure 4
XJ Plyurethane Leaf Spring Bushing Installatin Shipping Checklist: Hardware Kit # 72 Instructins Main Eye Leaf Spring Bushings (4) M20774 Leaf Spring Shackle Bushings (4) M20775 Main Eye Bushing Sleeve (2) Shackle Bushing Sleeve (2) Installatin Instructins: Befre yu begin: Read and understand installatin instructins. Cntact Irn Rck Off Rad with any questins befre, during, r after installatin. Ensure that all parts are present and in gd cnditin per attached shipping checklist. Yu will need basic wheel bearing multi-purpse grease and a brush. Bushing Installatin: 1. Lcate main eye bushings (M20774) and main eye bushing sleeves (M20775) and separate frm ther parts. 2. Liberally apply grease t the inside f the leaf spring main eye bushing pening. 3. Apply grease t bushing halves n mating surface and sleeves. 4. Press ne bushing half int main eye bushing pening. 5. Press the ther bushing half int the main eye bushing pening n the ppsite side f the first half. 6. Apply grease t the bushing sleeve and slide it int the tw bushing halves. 7. Mimic the main eye installatin fr the shackle bushings using shrtest sleeves and thinner flange bushing halves.
2-3/8 IRO Flex End (8 blt) Assembly Instructins Befre yu begin: Read and understand installatin instructins. Cntact Irn Rck Off Rad with any questins befre, during, r after installatin. Ensure that all parts are present and in gd cnditin per attached shipping checklist! Have these tls handy: 9/64" allen head scket 3/8" pen end wrench Inch-lb. trque wrench Multipurpse grease/grease gun Parts Checklist: Outer husing, weld n (may already be attached t yur existing cntrl arm) #168-2-3/8 IRO Flex End (8 blt) Inner race 91139 (2) Thrust washer 91138 (2) Ball 91140 (1) #8-32 x 1-1/2 scket head cap screw (8) 90 ¼ -28 grease zerk fitting (1) Figure 1 Assembly: 1. Insert tw #8-32 scket head cap screws int ne thrust washer and ne plastic race. Spherical bre f race facing away frm thrust washer. (Figure 1) 2. Install this small assembly int the flex end husing. The races are a light press fit, use a wide punch and hammer t assist yu if needed. 3. Apply a thin cating f multi-purpse grease t the mating surfaces f the ball and bth races. 4. Place the ball in the race (inside the flex end). The ball shuld perfectly fit the cntur f the race. 5. Insert the ther race nt the ball s that the spherical bre is cntacting the ball. Once again, the races are a light press fit, use a hammer and wide punch if needed. (The tw screws shuld be thrugh ne washer and bth races at this pint) 6. Insert the secnd thrust washer n tp f the flex end husing, sliding the blts thrugh the hles. 7. Start nylck nuts n the tw blts that are in the flex end assembly. Hld the nut and turn the blt. 8. Insert the remaining fur cap screws thrugh the remaining hles and install nuts. 9. Snug up all f the blts fairly tight. 10. Trque blts evenly, starting at ne blt using a crisscrss pattern, like trqueing lug nuts. Trque all eight blts t 50 in-lbs., then t 65 in-lbs. 11. Install 90 grease zerk fitting s that it is easily accessed in the vehicle. 12. Grease flex end until grease cmes ut f the races arund the ball. 13. Re-trque blts t 65 in-lbs. after 5 minutes. *Reference Only* Cmplete jint shwn fully assembled withut husing