Tuff Country 44002 - Jeep JK Performance 4 box kit - Manual (Page 8)

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
44000NB6. 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 # 60
51. 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.
52. 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 # 61
53. 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 # 62
54. 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.
55. 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.
56. Locate the new rear shocks. 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. Also, locate (2) new rear
clevis mounts and (2) S10074 from hardware bag
44000NB6. Install the new poly bushing supplied with the
new shocks into each end of the new shocks. Now install the
new S10074 sleeves into the bottom of the new shocks.
Install the new shocks boots onto the new shocks. Special
note: 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. Once the new shock
boots have been installed, install the new clevis mount into
the upper bushing in the upper eyelet. 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.
57. Locate the stock upper and lower shock hardware that
was removed in the step # 34. Working on the driver side,
install the new shock into the stock location and secure using
the stock hardware. Make sure to use thread locker or lock
tite and torque the lower mounting hardware to 75 ft lbs and
the upper mounting hardware to 18 ft lbs. Repeat
procedure on the passenger side.
Photo # 63
58. Locate the stock track bar hardware that was removed in
step # 42. Install the stock track bar to the newly installed
track bar relocation bracket and secure using the stock
hardware. Make sure to use thread locker or lock tite and
torque to 85 ft. lbs.
59. Remove the hydraulic floor jacks from under the rear
differential.
60. Working on the driver side, re-install the stock ABS clip
that was removed from the upper control arm mount in step
# 36. Repeat procedure on the passenger side.
61. Install the tires and wheels and carefully lower the
vehicle to the ground.
62. Check and double check to make sure that all steps were
performed properly. And then check them again.
63. Move back to the stock hardware holding the new front
and rear EZ-Flex lower control arms to the stock mounting
location and add some thread locker or lock tite and torque
the stock hardware to 85 ft lbs.
64. Move back to the stock and new hardware holdng the
new front and rear EZ-Flex upper control arms to the stock
mounting location and add some thread locker or lock tite
and torque to the new and stock hardware to 65 ft lbs.
65. If you have not already done so, please bleed the brake
lines at this point and with proper brake fluid, top off the
break fluid reservoir.