Tuff Country 44001 - Jeep JK EZ-Ride 4 box kit - Manual (Page 7)

side.
40. Locate the new rear 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. 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 # 39 / Photo # 40
Photo # 41
(driver side shown)
41. Remove the emergency brake cable bracket from the
body of the vehicle. Save (1) nut and the other nut may be
discarded.
Photo # 42
Photo # 43
42. Locate (1) BLR06 (emergency brake cable relocation
bracket), (1) 5/16” x 1” bolt, (2) 1/4” USS flat washers and
(1) 5/16” unitorque nuts from hardware bag 44000NB1.
Install the stock emergency brake cable to the new
relocation bracket and secure using the new 5/16” x 1” bolt
and hardware. Make sure to use thread locker or lock tite
and torque to 18 ft lbs. Now secure to new relocation
bracket to the rear stock stud and secure using the stock
hardware that was removed in step # 41. Make sure to use
thread locker or lock tite and torque to 10 ft lbs.
Photo # 44
43. Working on the passenger side, remove the stock track
bar from the stock track bar location. Save the stock
hardware for later re-installation.
Photo # 45
44. Carefully lower down on both hydraulic floor jacks at the
same time allowing enough room to remove the stock rear
coil springs. Working on the driver side, remove the stock
coil spring from the stock location and discard. Also,
remove the stock upper coil spring isolator. Repeat
procedure on the passenger side.
45. Working on the driver side, remove the stock bump stop
from the stock location and discard. Repeat procedure on
the passenger side.
Photo # 46
46. Locate the new rear bump stops. Working on the driver
side, install the new rear bump stop into the stock location.
Repeat procedure on the passenger side. Special note:
using some lithium base grease will help make
installation easier.
47. Locate the new rear track bar relocation bracket. Also,
locate (2) 1/2” x 1 1/2” bolts, (4) 7/16” USS flat washers, (2)
1/2” unitorque nuts, (1) 9/16” x 3” bolt, (2) 1/2” USS flat
washers and (1) 9/16” unitorque nut from hardware bag
44000NB1. Install the new rear track bar relocation
bracket into the stock location and secure using the new
9/16” x 3” bolt and hardware. Do not tighten at this point.
Special note: Make sure the new bracket is on the back
side of the stock cross member. Now secure the
bracket to the cross member using the new 1/2” x 1 1/2”
bolts and hardware. Make sure to use thread locker or lock
tite and torque to 75 ft lbs. Move back to the newly installed
9/16” x 3” bolt and add some thread locker or lock tite and
torque to 85 ft lbs.
Photo # 47
48. Locate the new rear coil spring isolators. Working on
the driver side, install the new isolator into the stock upper
location. Repeat procedure on the passenger side.
49. Locate the new rear coil springs. Working on the driver
side, install the new rear coil springs into the stock location
and raise up on the hydraulic floor jack to ride height.
Repeat procedure on the passenger side.
Photo # 48
50. Locate (2) 3/8” x 1” bolts, (2) 3/8” lock washers, (2) 3/8”
crimp lock nuts and (2) S10152 (rear spring retaining
washers) from hardware bag 44000NB4. Working on the
driver side, attach the new rear spring retaining washer on
the inside of the new coil and secure using the new 3/8” x
1” bolt and hardware. Make sure to use thread locker or
lock tite and torque to 18 ft lbs. Repeat procedure on the
passenger side.
Photo # 49
51. Locate the new rear sway bar end links. Also, locate the
lower sway bar end link mounting hardware that was
removed in step # 36. Working on the driver side, install the
new end link to the lower sway bar end link mount. Special
note: Make sure to install the new mount to the inside
of the stock bracket and secure using the stock
hardware. Do not tighten at this point. Repeat procedure
on the passenger side.
52. Locate (2) S10149 (12 mm x 50 mm bolt), (2) S10144
(12 mm jam nut) and (4) 12 mm flat washers from hardware
bag 44000NB3. Working on the driver side, install the new
end link to the stock sway bar using the new 12 mm
hardware. Special note: Make sure to install the new
end link on the inside of the stock sway bar. Do not
tighten at this point. Move back to the stock hardware
lower hardware and add some thread locker or lock tite and
torque to 55 ft lbs. Now move back to the upper 12 mm
hardware and add some thread locker or lock tite and
torque to 55 ft lbs. Repeat procedure on the passenger
side.