Parts Checklist: Instructins Irn Rck Off Rad Decal - (2) Rck-Link Decal 13287 - (2) irnrckffrad.cm Decal - (1) Crssmember - 991162 - (1) Shck crssmember - 91173 - (1) Shck crssmember spacer - 91178 - (2) Cil retainer upper spacer - 91193 - (2) Cil retainer middle spacer - 91194 - (6) Cil retainer lwer - 91192 - (2) XJ frnt bumpstp - 52004295 - (2) XJ rear lng uca - 91184 - (2) 2-3/8 flex end male end - 91191 - (2) XJ left rear lng LCA - 91185 - (1) XJ right rear lng LCA - 91186 - (1) Lng Arm Male End; Angled - 91109 - (2) Cil spring pad - 99061 - (2) Left LCA bracket - 85006 - (1) Right LCA bracket - 85005 - (1) Shck munt - 99060 - (2) Rear axle truss custmer specific: Optinal: Chrysler 8.25" 4-link Truss 88208 - (1) Axle munt base 91169 - (1) Axle munt UCA plate inner 91170 - (2) Axle munt UCA plate uter 91171 - (2) Chrysler 8.25 Truss Gusset 88262 - (1) #184 T-Blck Eliminatr (1) Optinal: Frd 8.8" Truss 85060 - (1) Axle munt base 91169 - (1) Axle munt UCA plate inner 91170 - (2) Axle munt UCA plate uter 91171 - (2) Optinal: Dana 60 Over Diff Cradle 88217 (1) Frnt Truss Plate 88218 (1) Rear Truss Plate 88219 (1) UCA Inner Plate 88254 (1) UCA Outer Plate 88255 (1) Optinal: GM Crp. 14 Blt Over Diff Cradle 91196 (1) Frnt Truss Plate 91197 (1) Rear Plate Left 91198 (1) Rear Plate Right 91199 (1) UCA Inner Plate 91200 (1) UCA Outer Plate 91201 (1) Lwer cil spring retainer spacer plate - 99054 - (4) Upper cil spring retainer clamping plate - 99059 - (2) XJ frnt cil spring islatr 52000229 (2) 3/16 steel brake line tubing (5 ft.) - (1) #65 Adjustable LCA Clamping Hardware (2) 1/4"-28 x 1-1/8 scket head cap screw - (4) XJ 4-Link Rear Lng Arm Instructins 1/4"-28 hex nut, gr8 - (4) #127 2-5/8 IRO Flex End (2) 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) #147 XJ/TJ Rear Brake Line (1) 3/16 brake line flare nut - (4) 7/16"-14 x 1.25 hex blt, gr8 - (1) 7/16"-14 hex nut, gr8 - (1) #167 XJ Rear 4-Link Spring/Shck Crssmember (1) 3/8"-16 x 1-1/4 hex blt, gr8 - (8) 3/8" USS washer - (8) 3/8"-16 rivet nut, steel - (8) M8-1.25 x 30 hex blt - (4) 1/4 USS washer - (4) #168 2-3/8 Flex End (4) 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) #169 XJ Upper Rear Cil Retainer (1) 1/2"-13 x 3" gr5 hex blt, fully threaded - (2) 1/2"-13 x 5" gr5 hex blt, fully threaded - (2) #170 XJ Lwer Rear Cil Retainer (1) 1/2"-13 x 1-1/2 carriage blt - (2) 1/2"-13 hex nut - (2) #171 XJ 4-Link Rear Cntrl Arm (1) M14 x 95 hex blt cl10.9 (4) M14 x 100 hex blt cl10.9 (4) M14 nylck nut cl10.9 (8) 1/2 USS washer (16) #172 XJ Rear 4-Link Shck (1) M12 x 1.49 shck sleeve - 404379 - (4) M12-1.75 x 60 hex blt, cl10.9 - (4) 7/16" USS washer - (6) M12-1.75 nylck nut - (4) #173 3/8 Rivet Nut Install Tl (1) 7/16" serrated flange hex nut - (1) 3/8" MIL spec flat washer - (2) 3/8"-16 x 1-1/4 hex blt, gr8 - (1) #174 XJ Rear 4-Link Crssmember (1) 2-hle nut plate - 92097 - (4) 7/16"-14 x 1-1/4 hex blt, gr8 - (8) 7/16 USS washer - (8)
Installatin Instructins: Safety Warning: ***Imprtant! Read befre installatin*** We 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. A custm exhaust will be required. This kit requires a 4 t 8 suspensin lift kit. Maximum rear shck length (extended) is 29.5 center t center with 17 cil springs (ur 8 cils). Shrter cil springs will require shrter shcks. Check all steering/suspensin cmpnents fr wear, replace if 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 parts checklist. Be sure yu have the fllwing tls and supplies: Flr jack and jack stands Basic hand tls Multi-purpse grease Slpe gauge r angle finder. Hand drill with gd quality 7/16 & 17/32 drill bits Anti-seize cmpund fr blts. Axle Axle Rear Upper Cntrl Arms Rear Lwer Cntrl Arms Frame Frame Welder (fr welding brackets t axle) Brake line bender Duble flaring tl (fr brake lines) If equipped with rear uniframe stiffeners: 5/16 drill bit, 3/8"-16 hand tap, tap hlder and cutting il. Yu will nt need the 17/32 drill bit. Prepare the parts fr installatin: 1. Lcate fur cntrl arms, male ends, and hardware kits (65, 127, 168). 2. Build lwer cntrl arms using angled male ends and hardware kits 127: Assemble flex ends per attached instructins (2-5/8 ). 3. Build upper cntrl arms using 2-3/8 flex end male end and hardware kits 168: Assemble flex ends per attached instructins (2-3/8 ). 4. Apply anti-seize t male threads and thread int the cntrl arms. Larger male ends g int the larger (lwer) cntrl arms. 5. Adjust upper arms t 35-1/2 center t center as a starting pint. 6. Adjust lwer arms t 43 center t center n the shrt side t start. 7. Install clamping blts. D nt tighten at this time. 8. With vehicle n level grund, measure pinin angle. Recrd angle here. Disassembly: 9. Lift rear f vehicle and supprt with tall jack stands under the unibdy frame. **Tip: break lug nuts lse befre lifting vehicle.** 10. Ensure that the vehicle is safely supprted. 11. Remve the rear tires. 12. Remve catalytic cnverter, muffler and tailpipe. 13. Remve rear shcks. 14. Remve rear axle. 15. Remve rear leaf springs and shackles. 16. Remve rear bump stps. 17. Remve rear sway bar if equipped. Rear Crssmember: 18. Lcate crssmember and hardware kit 174. 19. With the cntrl arm munts facing the rear, psitin the crssmember s that the frnt blt hle is 12 back frm the rear blt fr the factry frnt crssmember. 20. Center crssmember side t side. 21. Using the crssmember as a template, drill all (8) 7/16" hles. 22. Drill a 1 hle in the side f the uniframe centered between the 7/16" hles. Insert nut plates int frame and secure with 7/16" blts (4 hles per side) 23. Trque all blts t 65 ft-lbs. Rear Spring/Shck Crssmember 24. Place a flr jack underneath the fuel tank fr supprt (d nt lift). 25. Remve hanger blt frm passenger side fuel tank strap. 26. Lcate spring/shck crssmember and hardware kit 167. 27. Psitin crssmember as shwn, aligning bttm hles in crssmember with bump stp hles in uniframe. 28. Center crssmember side t side. 29. Using the crssmember as a template drill the fllwing in the side f the uniframe: *If nt equipped with rear uniframe stiffeners, drill (8) 17/32 hles fr rivet nuts (see rivet nut installatin instructins belw). * **If equipped with rear uniframe stiffeners, drill (8) 5/16 hles and tap with 3/8"-16 hand tap.**
Rivet Nut Installatin: 30. Slide tw small O.D. washers and versized nut nt the blt. As shwn in diagram. 31. Thread blt with nut and tw washers int the rivet nut. 32. Insert assembly int drilled hle. 33. Using a wrench t hld the nut, push inward t prevent the rivet nut frm spinning. 34. Tighten the blt until the rivet nut fully cllapses and lcks int the hle. 35. Be careful nt t strip the threads. 36. Remve blt and check t make sure insert des nt spin when blt is tightened. Prepare the Axle Assembly: 37. Cut ff any brackets attached t the axle tubes. A plasma cutter, xy/acetylene trch, r angle grinder with a cut ff wheel can be used. Be careful nt t cut int the axle tubes. 38. Using an angle grinder, remve any remaining bracketry. Be careful nt t grind away any axle tube material. Measure: 39. Measure the width f the axle and place a mark n the tp f the differential at the center f axle assembly (nt differential) 40. Mark the lcatin f each bracket n the axle. See drawings. C 8.25 and F8.8 Trusses: 41. (C 8.25 Only) Apply medium strength thread lcker t riginal brake line T-Blck blt and install T-Blck Eliminatr (#184) where the riginal brake line T-blck was lcated n the axle. 42. (C 8.25 Only) Slide the gusset int the truss. Stich weld the gusset int the truss. 43. Fully weld the vertical slts in the truss (near the center). Tack weld the ends f the slts first t avid warpage. Grind the frnt sides flush as needed t clear the Upper Cntrl Arm (UCA) base plate. 44. With the truss cl, paint the inside f the truss including abve and belw the gusset t prevent rust. 45. Tack weld truss t the axle with the face f the truss parallel t rear diff cver munting surface and the gusset resting n the axle tubes. ***When tack welding, ensure yur tack welds are strng enugh fr a test fit, but easy t cut apart if necessary. 46. Tack weld upper cntrl arm munt t truss with frnt hle aligned with hle in truss. 47. Tack weld upper cntrl arm munt tabs t base plate with shrter tabs in the center. 48. Weld truss t axle and weld upper cntrl arm munts t truss. ***T avid warping, avid excessive heat buildup. Weld in shrt time increments in ne area then mve t anther part f the axle. Allw time t cl between welds in the same spt. 49. Weld all the way arund UCA munting tabs and UCA base plate. GM 14 Blt and D60 Trusses: 50. Tack weld vertical truss plates t truss tp plate. Vertical plates are inset 3/8 frm uter edge f tp plate. Test fit truss assembly t the axle. Ensure vertical plates cntact axle tubes. 51. Tack weld truss t the axle with the face f the truss parallel t rear diff cver munting surface and the tp plate resting n the axle tubes. ***When tack welding, ensure yur tack welds are strng enugh fr a test fit, but easy t cut apart if necessary. 52. Tack weld upper cntrl arm munt tabs t truss with shrter tabs in the center. 53. Fully weld truss assembly, weld truss t axle and weld upper cntrl arm munts t truss. ***T avid warping, avid excessive heat buildup. Weld in shrt time increments in ne area then mve t anther part f the axle. Allw time t cl between welds in the same spt. 54. Weld all the way arund UCA munting tabs. Install Axle Brackets: 55. Supprt the axle assembly n jack stands. Set the pinin angle t 14. This setting wrks well fr lifts ranging frm 4-8", with typical driveshaft cmbinatins. 56. Tack weld lwer cntrl arm munts t the axle with the tp surface at a 10 upward angle. Nte left and right bracket. 57. Tack weld shck munts in place with munting surface exactly vertical. 58. Tack weld spring pads t axle with tp surface exactly hrizntal. 59. Test in vehicle at ride height t verify pinin angle is ideal and make any necessary changes. 60. Fully weld each bracket t the axle tubes. ***Tip: If desired, the spring pads need nt be fully welded t the axle tubes. Abut 1 f weld n each crner is sufficient. This allws yu t easily change the spring pad angle if needed fr suspensin upgrades r installatin f a transfer case slip yke eliminatr. ***Tip: t avid warping, avid excessive heat buildup. Weld in shrt time increments in ne area then mve t anther part f the axle. Allw time t cl between welds in the same spt. 61. Prep and paint 62. Munt rear brake hse t the frnt side f the truss. 63. Run new hard lines frm brake T-fitting t wheel cylinders.
Rear Suspensin: 64. Install upper cntrl arms with bend hanging dwn t clear the flr pan (adjustable threaded end at frame). Use M14 x 100 blts, nuts, and washers (frm hardware kit 171). 65. Install lwer cntrl arms. Adjustable threaded end at frame. *Angled male ends t be angled twards the utside f the vehicle when installed.* *The bends are t be angled upward fr grund clearance, and inward t clear the frame.* Use M14 x 100 blts, nuts, and washers (frm hardware kit 171). 66. Install new cil springs, rtate them until they sit as straight as pssible (lw spt f spring aligned t high side f spring pad). 67. Install new shcks. 68. Raise the vehicle and supprt with jack stands under the rear axle. 69. Bleed brakes at all 4 crners. 70. With full vehicle weight n the suspensin, check if the rear axle is centered as desired in the wheel pening. Adjust lwer cntrl arms t desired axle psitin. Adjust upper cntrl arms t desired pinin angle (see step 8). 71. Trque all cntrl arm nuts t 125 ft-lbs. 72. Tighten all cntrl arm adjusting thread clamping blts. 73. Install tires and place the vehicle n the grund. 74. Trque lug nuts t spec. (Typical specificatin is 85-115 ft-lbs., depending n yur wheels) Adjustments and Final Inspectin: 75. Check all cmpnents fr clearance fr suspensin t fully cycle up and dwn. 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. 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. XJ 4-Link Rear Lng Arm Instructins.dcx Rev 1.0
Fits All Irn Rck Off Rad Lng Arm Systems, WJ A-Arms, and Build Yur Own Flex End Assemblies. 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) 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 2-5/8 IRO Flex End (6 blt) Assembly Instructins 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. (Figure 1) 2. Install this small assembly int the flex end husing. The races are a light press fit, use a wide punch Figure 1 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. 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. 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. Figure 2 13. Re-trque blts t 85 in-lbs. after 5 minutes. Figure 3 Figure 4 *Reference Only* Cmplete jint shwn fully assembled withut husing
2-3/8 IRO Flex End (8 blt) Assembly Instructins 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) 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 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. Figure 1 *Reference Only* Cmplete jint shwn fully assembled withut husing