Warrior 800025 ADD-A-LEAF (1984 – 2001 Jeep XJ Cherokee) User Manual
Warrior For the car
Protecting Your Adventure Lifestyle
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QUALITY • INTEGRITY • INNOVATION • SERVICE
Warrior Products, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone (888) 220-6861
Fax (503) 692-0364
800025
ADD-A-LEAF
INSTALLTION INSTRUCTIONS
Notes:
•
If a torch is used during this installation, protect any heat-sensitive components located in the immediate area by covering them
with a water-saturated cloth. Most under coatings are flammable, but can be extinguished using a water filled spray bottle. Have
this and an ABC rated fire extinguisher at hand.
•
Prior to inserting leafs, be sure all leaf “mating” surfaces are free of grit, grease, undercoating, etc.
•
A factory service manual for this particular year and model should be on hand. The manual will contain fastener torque specs and
any assemble techniques or special tool requirements that are unique to this vehicle.
•
Shock absorber length, depending on the particular vehicle, may not be adequate. Whatever the case, we highly recommend the
installation of a premium grade shock for optimum performance.
•
Prior to disassembly, inspect the stock u-bolts for corrosion and adequate length.
Step 1.
Put the vehicle in neutral, raise the vehicle and support with jack stands on the frame. For front installations, the stands
normally are placed just behind the springs rear hangers. For rear installations the stands are generally placed just in front
of the springs front hangers. Put vehicle in park, or low gear for manual transmissions, and chock the tires remaining on
the floor to prevent accidental movement.
Step 2.
Remove the tires and position floor jack to support the axle. Remove the bottom shock bolts.
Step 3.
Remove nuts/washers from the u-bolts on one side of the axle. If the straps or bend clips must be disturbed, do this before
removing spring eye-bolt. Have c-clamps in place on either side of each strap before center bolt is removed.
Step 4.
Remove the spring eye bolts and nuts and remove the spring.
Step 5.
Unbolt center pin and remove. Un-clamp the leaf spring. CAUTION - Take care when releasing the c-clamps since the
springs are under load and will “spring” apart when released.
Step 6.
Position helper leaf under the next longest leaf of the spring pack. Replace the shorter spring leafs under the helper leaf
and clamp together, being careful to align the center-pin holes in the spring leafs.
Step 7.
Insert the new center-pin supplied with the kit through the spring assembly with the head of the center-pin in the same
location as the stock pin. Re-compress the pack with the c-clamps, not the center-pin, to avoid stripping of nut/bolt
threads. Bolt together, being sure to align leafs. Cut off excess threads on the center pin with a hack saw. If applicable,
re-form straps or install new bend straps. If heat is used on the straps, allow them to cool naturally and thoroughly before
removing the c-clamps.
Step 8.
Replace spring on vehicle and replace with new u-bolts, nuts and washers. Torque u-bolts evenly using a “x” tightening
sequence to the following values.
_”
65-80 ft/lbs
9/16”
75-90 ft/lbs.
5/8”
86-110 ft/lbs.
Do not fully tighten the stock shackle and stationery spring eye bolts. These bolts are not torqued until the suspension is
supporting the vehicle weight.
Step 9.
Repeat the process for the other spring.
Step 10.
Remove jack-stands and lower vehicle to floor. With the suspension supporting vehicle weight, torque the springs’
stationary and shackle eye-bolts.