Tuff Country 44002 - Jeep JK Performance 4 box kit - Manual (Page 6)

Photo # 32
24. 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 # 33
25. 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 # 34
Photo # 35
26. 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 # 36
27. Locate the new front shocks. 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. Also, locate the stock
lower hardware that was removed in step # 3. Locate (2)
S10074 sleeve from hardware bag 44000NB6. Install the
new poly bushings and S10074 sleeve into the bottom part
of the new shock. Special note: Make sure to use a
lithium or moly base grease prior to inserting the new
bushings and sleeves into the new lower eyelet of the
new shock. This will increase the life of the bushing as
well as prevent squeaking. Working on the driver side,
install the new shock into the stock lower mounting location
and secure using the stock hardware. Make sure to use
thread locker or lock tite and torque to 65 ft lbs. Now install
the new shock into the stock upper location using the new
hardware provided in the new shock. Make sure to use
thread locker or lock tite and torque to 22 ft lbs. Tuff
Country EZ-Ride Suspension highly recommends that
the shocks are installed with shock boots. If shock
boots are not installed, damage may occur to the
piston of the new shock. Repeat procedure on the
passenger side.
Photo # 37
28. Locate (3) S10053 (cross member sleeves) from
hardware bag 44000NB6. Working on the driver side,
remove the (2) stock bolts holding the cross member to the
bottom side of the stock frame rail. Save the stock
hardware for later re-installation. Working on the driver
side, remove the (1) stock bolt holding the cross member to
the bottom side of the stock frame rail. Save the stock
hardware for later re-installation. Install the cross member
using the spacer sleeves and the stock hardware into the
stock locations. Make sure to use thread locker or lock tite
and torque all (3) bolts to 55 ft lbs.
Photo # 38
Photo # 39
29. Carefully remove both hydraulic floor jacks from under
the front differential.
30. Install the tires and wheels and carefully lower the
vehicle to the ground.
31. Check and double check to make sure that all steps
were performed properly and check again.
Front end installation complete!
Rear end installation:
32. To begin installation, block the front tires of the vehicle
so that the vehicle is stable and can’t roll forward. Safely lift
the rear of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and
passenger side. Next, remove the wheels and tires from
both sides.
33. Place a pair of hydraulic floor jacks under the rear
differential. Place one on the driver and passenger side.
34. Working on the driver side, remove the stock shock
from the stock upper and lower location and save the stock
hardware for later re-installation. The stock shock may be
discarded. Special note: New longer rear shocks are
needed, if you have not already ordered your new rear
shocks, please contact Tuff Country or your local Tuff
Country dealer and order the proper shocks. Tuff
Country recommends using a 30” fully extended
nitrogen gas shock. Repeat procedure on the passenger
side.
Photo # 40
Photo # 41
35. Working on the driver side, remove the stock sway bar
end link from the stock upper and lower location. The stock
end link and the stock upper mounting hardware may be
discarded. Save the stock lower mounting hardware for
later re-installation. Repeat procedure on the passenger
side.
Photo # 42
Photo # 43
36. Working on the driver side, remove the clip that
connects the ABS line to the upper control arm mount.
Repeat procedure on the passenger side.
Photo # 44
37. Working on the driver side, remove the stock brake line