Tuff Country 44002 - Jeep JK Performance 4 box kit - Manual (Page 4)

Please follow instructions carefully:
Before installation begins, measure from the center of
the hub, to the bottom of the fender well, and record
measurements below.
Pre-installation measurements:
Driver side front:_______________________________
Passenger side front:___________________________
Driver side rear:________________________________
Passenger side rear:____________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post installation measurements:
Driver side front:______________________________
Passenger side front:__________________________
Driver side rear:_______________________________
Passenger side rear:___________________________
Front end installation:
1. To begin installation, block the rear tires of the vehicle so
that the vehicle is stable and can’t roll backwards. Safely lift
the front of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and the
passenger side. Next, remove the front wheels and tires
from both sides.
2. Place a pair of hydraulic floor jacks under the front
differential. Place one on the driver side and one on the
passenger side.
3. Working on the driver side, remove the stock upper
mounting hardware that connects the stock shock into the
stock location. The stock hardware may be discarded.
Next, remove the stock hardware that connects the stock
shock into the stock lower location and save the stock
hardware for later re-installation. The stock shock may be
discarded. Repeat procedure on the passenger side.
Special Note: New longer front shocks are needed, if
you have not already ordered your new front shocks,
please contact Tuff Country or your local Tuff Country
dealer and order the proper shocks. Tuff Country
recommends using a 26” fully extended nitrogen gas
shock.
Photo # 1
Photo # 2
4. Working on the driver side, remove the stock hardware
that connects the stock track bar to the stock location. Save
the stock hardware for later re-installation. Repeat
procedure on the passenger side.
Photo # 3
Photo # 4
5. Working on the driver side, remove the stock sway bar
end link from the stock axle mount and the stock sway bar.
The stock hardware and the stock end link may be
discarded. Repeat procedure on the passenger side.
Photo # 5
Photo # 6
6. Working on the driver side, remove the stock brake line
bracket hardware that attaches the stock brake line
bracket to the stock frame rail. The stock hardware may be
discarded. Repeat procedure on the passenger side.
Photo # 7
7. Carefully lower down on both hydraulic floor jacks
enough so that the stock coil springs can be removed.
8. Working on the driver side, remove the stock coil spring
from the stock location and discard. Repeat procedure on
the passenger side. Special note: keep the stock spring
isolator in place, we do not want to remove it.
Photo # 8
9. Working on the driver side, remove the stock bump stop
from the stock bump stop cup and discard. Repeat
procedure on the passenger side.
Photo # 9
10. Working on front drive shaft, place a reference mark on
the front drive shaft and the pinion flange. Remove the
stock front drive shaft from the stock front differential and
save the stock hardware for later re-installation. Let the
stock front drive shaft hang.
Photo # 10
Photo # 11
11. Locate the new front bump stops. Working on the
driver side, install the new front bump stop into the stock
location. Repeat procedure on the passenger side. Special
note: using some lithium base grease will help make
installation easier.
Photo # 12
12. Working on the driver side, remove the stock lower
control arm from the axle mount and the frame mount.
Save the stock hardware for later re-installation. The stock
lower control arm may be discarded. Repeat procedure on
the passenger side.
Photo # 13
Photo # 14
13. Locate the new driver and passenger front EZ-Flex
lower control arms. Also, locate the stock lower control arm
hardware that was removed from step # 12. Special note:
Set the length of the new driver and passenger side
front EZ-Flex lower control arms to 23 3/4”. Final
adjustments can be made once the vehicle has been
taken to the alignment shop. Working on the driver side,
following the sticker on the new front EZ-Flex lower control
arm and install into the stock location. Secure using the
stock hardware. Do not tighten at this point. Repeat