Tuff Country 44905 - Jeep TJ Wranlger 97-06 4 EZ-Flex kit w/sway bar quick disconnects - Manual (Page 6)

on the inside of the lower bushing, this will help the
new quick disconnect slid over the lower stud.
Repeat procedure on the passenger side.
See Photo # 9
Follow Step # 31 — 34 to secure the new quick
disconnect out of the way when off roading.
31. Working on the driver side, disconnect the lower eye
let of the quick disconnect. Push the new quick
disconnect towards the front of the vehicle and hold it
against the stock frame rail. Scribe a mark on the side of
the stock frame rail in the center of the bushings.
32. Carefully drill a 5/16” hole in the side of the stock
frame where the mark was scribe in step # 31. Using a
tap wrench and a 3/8” tap, thread the hole in the side of
the frame rail. Special Note: Take special care that the
tap is perpendicular to the frame.
33. Locate (1) quick disconnect securing stud. Special
Note: The securing stud is the smaller of the two
studs. Secure the securing stud into the side of the stock
frame rail. Special Note: Make sure to use thread
locker or lock tite on the stub. Also for easier
installation, use the quick disconnect pin to help
tighten the quick disconnect stud to the side of the
frame rail.
See Photo # 10
34. Once the quick disconnect securing stud is in place,
you can attach the new sway bar end link up and out of
the way. Secure the new sway bar end link with the large
washer and quick disconnect pin to the quick disconnect
securing stud.
See Photo # 11
(Passenger Side Shown)
35. Repeat steps 31 — 34 on the passenger side.
36. Locate the new pitman arm, the stock pitman arm
hardware that was removed in step # 8. Install the new
pitman arm to the stock steering box and secure using
the stock hardware. Special Note: Make sure to use
thread locker or locktite. Torque to 135 ft lbs.
See Photo # 12
37. Locate the stock tie rod hardware that was removed
form step # 8. Install the stock tie rod to the previously
installed pitman arm a secure using the stock hardware.
Torque to 75 ft lbs.
See Photo # 12
38. Carefully remove both hydraulic floor jacks from
under the front differential.
39. Check and double check to make sure that all steps
for the front end where performed properly. Install the
tires and wheels and carefully lower the vehicle to the
ground.
If you where not able to attach the front track bar to
the newly installed front track bar bracket in step #
22. Perform step # 22 now that the weight of the
vehicle in on the ground.
Congratulations, front end installation complete.
Rear end installation.
40. 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 tires and
wheels from both sides.
41. Place a pair of hydraulic floor jacks under the rear
differential. Place one on the driver side and one on the
passenger side.
42. Working on the driver side, remove the top of the
stock shock from the stock location and save the stock
upper shock hardware. Remove the stock hardware that
connects the lower shock to the stock location. 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 rear shocks, please contact Tuff Country or
your local Tuff Country dealer and order the proper
shocks. Tuff Country EZ-Ride Suspension
recommends using a 26” fully extended hydraulic
shock. Repeat procedure on the passenger side.
43. Working on the driver side, remove the stock sway
bar end link from the stock sway bar and the upper stock
location. The stock sway bar end link may be discarded.
Save the stock hardware for later re-installation.
44. Working on the driver side, remove the stock rear
track bar from the stock location and save the stock
hardware for later re-installation. The stock plastic piece
that wraps around the outer part of the stock track bar
bracket may be discarded.
45. Working on the driver side, remove the stock lower
control arm and save the stock front and rear mounting
hardware for later re-installation. Repeat procedure on
the passenger side.
46. Carefully lower down on both hydraulic floor jacks at
the same time allowing enough room for the stock coil
springs to be removed and the new coils springs to be re-
installed. Working on the driver side, remove the stock
coil spring. Repeat procedure on the passenger side.
47. Locate (2) new rear coil springs, working on the driver
side, install the new rear coil spring into the stock
location. Repeat procedure on the passenger side.
48. Carefully raise up on both hydraulic floor jacks at the
same time, until the new coil springs seat properly into