Tuff Country 44905 - Jeep TJ Wranlger 97-06 4 EZ-Flex kit w/sway bar quick disconnects - Manual (Page 5)

Also, do not tighten at this point.
20. Working on the passenger side, make sure that the
new track bar relocation bracket is seating square with
the stock track bar location. Using the new track bar
relocation bracket as a guide, carefully drill a 3/8” hole
into the back side of the stock track bar bracket.
21. Locate (1) 3/8” x 1 1/4” bolt, (2) 3/8” flat washers and
(1) 3/8” unitorque nut from hardware bag 44900NB.
Working on the passenger side, secure the new track bar
relocation bracket to the stock track bar pocket using the
new 3/8” x 1 1/4” bolt and hardware into the previously
drilled hole. Special Note: Make sure to use thread
locker or lock tite. Torque to 28 ft lbs.
22. Locate (1) 10 mm x 75 mm bolt, (1) 10 mm nylon lock
nut, (2) 3/8” flat washers and (1) 10 mm lock washer from
hardware bag 44900NB. Working on the passenger side,
install the stock front track bar into the new track bar
relocation bracket and secure using the new 10 mm bolt
and hardware. Special Note: Make sure to use thread
locker or lock tite. Torque to 32 ft lbs. Once the stock
track bar is into the new passenger side track bar
relocation, the stock upper bolt can be torqued to 32 ft
lbs. Special Note: If you are not able to line up the
hole in the stock track bar and the new track bar
relocation bracket, you will have to perform this step
once the weight of the vehicle is on the ground.
See Photo # 5
23. Locate (2) new front brake line extension bracket
from hardware bag 44905NB1. Also, locate (2) 1/4” x 3/4”
bolts, (4) 1/4” flat washers and (2) 1/4” unitorque nuts
from hardware bag 44900NB. Working on the driver side,
install the new front brake line extension bracket to the
stock brake line bracket and secure using the new 1/4”
hardware. Special Note: Make sure to use thread
locker or lock tite. Do not tighten at this point. Repeat
procedure on the passenger side.
24. Locate the stock brake line bracket hardware that
was removed in step # 4. Working on the driver side,
secure the new brake line extension bracket to the stock
brake line bracket location and secure using the stock
hardware. Special Note: Make sure to use thread
locker or lock tite. Torque the stock hardware to 15 ft
lbs and torque the 1/4” bolt that was installed in step # 23
to 15 ft lbs. Repeat procedure on the passenger side.
See Photo # 6
25. Locate (2) 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 front shocks. Tuff
Country EZ-Ride Suspension recommends using a
23” fully extended hydraulic shock. Also, locate (2)
front lower shock clevis mounts, (4) upper shock
grommets and (4) upper shock washers from hardware
bag 44905NB1. Install the new 5/8” lower shock bushing
into the lower eyelet of each shock. The new bushing
should be packaged with your new shocks. Next, install
the new lower clevis mount into the new 5/8” shock
bushing. Special Note: to make the clevis mount
installation easier, it is highly recommended using a
moly or lithium base grease. Next, install the new
shock boot onto the new shocks and install the new
upper shock grommets and washers.
26. Locate the stock lower shock hardware that was
removed from step # 3. Working on the driver side, install
the new shock into the stock lower location and secure
the lower clevis mount to the stock lower location using
the stock hardware. Special Note: Make sure to use
thread locker or lock tite. Torque to 15 ft lbs. Install the
upper shock into the stock upper location and secure
using the stock nut that was supplied in the new shocks.
Torque to 15 ft lbs. Repeat procedure on the passenger
side.
See Photo # 7
(Passenger Side Shown)
27. Locate the stock stabilizer hardware that was
removed from step # 7. Working on the passenger side,
secure the stock stabilizer into the stock location and
secure using the stock hardware. Special Note: Make
sure to use thread locker or lock tite. Torque to 65 ft
lbs.
28. Locate the new driver side sway bar quick
disconnect. Special Note: To tell the driver side quick
disconnect from the passenger side quick
disconnect, once installed on the vehicle, the sert
fitting on the bottom of the quick disconnect will be
facing towards the front of the vehicle. Install the new
driver side quick disconnect to the stock sway bar and
secure using the new hardware. Special Note: Make
sure to install the new tapered sleeve into the stock
sway bar. Torque upper nut to 32 ft lbs. Repeat
procedure on the passenger side.
29. Locate (2) lower sway bar mounting studs. Special
Note: The lower sway bar mounting studs are the
bigger of the two that are in the hardware bag
44905NB1. Working on the driver side, secure the new
lower sway bar mounting studs into the stock lower sway
bar end links location. Torque to 85 ft lbs. Special Note:
When torqueing the lower sway bar mounting stud,
us the new pin for leverage. Repeat procedure on the
passenger side.
See Photo # 8
30. Locate (2) large washers and (2) quick disconnect
pins from hardware bag 44904NB1. Working on the
driver side, attach the new sway bar quick disconnect to
the lower stud and secure using the new large washers
and quick disconnect pin. Special Note: To make
installation easier, use a lithium or moly base grease