Tuff Country 44000 - Jeep JK EZ-Flex 4 box kit - Manual (Page 5)

procedure on the passenger side.
Photo # 15 / Photo # 16
Photo # 17
(driver side shown)
14. Tuff Country offers a 1/2” spacer for the front of vehicles
that have a bigger bumper or a wench so that the vehicle
will sit level. If this is the case on the vehicle that you are
working on, install the 1/2” coil springs spacer on the driver
and passenger side.
15. Locate the new front coil springs, working on the driver
side, install the new front coil spring into the stock location.
Make sure that the new coil spring seats properly into the
lower coil spring seat. Carefully raise up on the hydraulic
floor jack holding the driver side of the front differential until
it reaches ride height. Repeat procedure on the passenger
side.
Photo # 18
Photo # 19
16. Locate the new driver and passenger side brake line
relocation brackets and hardware that are packaged with
the front extended brake lines. Working on the driver side,
secure the new brake line relocation bracket to the stock
location on the frame rail and secure using the new
hardware provided. Repeat procedure on the passenger
side.
17. Locate the new front driver and passenger side
extended brake lines. Working on the driver side, remove
the stock brake line from the stock hard mount and the
caliper. The stock brake line may be discarded. Install the
new brake line to the hard mount and the caliper using the
stock and new hardware provided with the new brake lines.
Repeat procedure on the passenger side. Using some
shock ties, tie the new extend brake lines to the stock ABS
lines. Special note: There is a driver and passenger
side extended brake line, refer to the photo’s to make
sure that you install the driver side extended brake line
on the driver side and the passenger side extended
brake line on the passenger side. Also, after the
completion of the installation, bleed the brake lines
and top off the brake fluid.
Photo # 20 / Photo # 21
Photo # 22
(driver side shown)
18. Locate the stock front drive shaft hardware that was
removed in step # 10. Install the stock front drive shaft back
to the front differential flange and secure using the stock
hardware. Make sure to use thread locker or lock tite and
torque to 30 ft lbs. Special note: Make sure that the
marks line up that were scribed in step # 10.
Photo # 23
19. Locate the stock front track bar mounting hardware that
was removed in step # 4. Also, locate the new adjustable
front track bar and the joint end. Install the joint end in the
new front track bar and adjust the front adjustable track bar
to 33” from center of eye to center of eye. Working on the
driver side, install the new front adjustable track bar to the
stock location and secure using the stock hardware. Make
sure to use thread locker or lock tite and torque to 75 ft lbs.
Next, install the new front adjustable track bar to the
passenger side stock location and secure using the stock
hardware. Make sure to use thread locker or lock tite and
torque to 75 ft lbs. Special note: With the new front
adjustable track bar, fine tuning of the tracking can be
addressed when the vehicle is getting aligned.
Photo # 24
20. Locate (2) S10142 (large QD stud), (2) S10098 (large
QD stud lock washer) and (2) S10099 (large QD stud jam
nut) from hardware bag 44000NB2. Working on the driver
side, install the new large QD stud to the stock lower sway
bar mounting location and secure using the lock washer
and jam nut. Make sure to sure thread locker or lock tite
and torque to 65 ft lbs. Repeat procedure on the
passenger side.
Photo # 25
21. Locate (2) S10148 (QD “L” brackets), (2) S10094 (small
QD stud) and (2) S10147 (3/8” thin jam nut) from hardware
bag 44000NB2. Working on the driver side, remove the
stock body mount nut and install the new “L” bracket using
the stock hardware. Make sure to use thread locker or lock
tite and torque to 75 ft lbs. Now install the small QD stud
to the “L” bracket and secure using the 3/8” thin jam nut.
Make sure to use thread locker or lock tite and torque to 16
ft lbs. Repeat procedure on the passenger side.
Photo # 26
22. Locate the new driver and passenger side sway bars
end links. Also, locate (2) S10096 (QD pins) and (2)
S10097 (QD over size washers) from hardware bag
44000NB2. Working on the driver side, secure the new
sway bar end link to the bottom QD stud and secure using
the over size washer and pin. Repeat procedure on the
passenger side.
Photo # 27
23. Locate (2) S10143 (12 mm x 70 mm bolts), (2) S10145
(12 mm jam nut) and (2) S10146 (9/16” x 1 3/8” washer)
from hardware bag 44000NB2. Working on the driver side,
secure the top of the new end link to the stock sway bar
and secure using the new 12 mm hardware and washer.
Make sure to use thread locker or lock tite and torque to 55
ft lbs. Repeat procedure on the passenger side.
Photo # 28
Photo # 29
24. If you are going to disconnect the sway bar, remove the
pin from the lower QD stud and swing it up to the small stud
and secure using the pin.
Photo # 30
25. Locate the new front shocks. Special note: New