Tuff Country 44905 - Jeep TJ Wranlger 97-06 4 EZ-Flex kit w/sway bar quick disconnects - Manual (Page 7)

the stock location. Special Note: Make sure that the
stock rubber spring isolator pad seats flush with the
upper stock frame bracket on both sides.
49. Locate (2) new rear EZ-Flex control arms. Special
Note: There is not a difference between the front and
rear EZ-Flex control arms. Remove the (2) half’s of the
rear EZ-Flex arms and pack both ends with a good
amount of moly or lithium base grease. Screw the rear
EZ-flex arms back together and set the length at 16 1/2”
from the center of one eyelet to the center of the other
eyelet.
See Photo # 1
50. Locate (4) 90 degree sert fittings and (2) straight sert
fittings from hardware bag 44905NB1. Carefully install
the sert fittings into the new rear EZ-Flex arms. Special
Note: The 90 degree sert fittings need to be installed
in the outer holes and the straight sert fitting needs
to be installed in the middle hole.
See Photo # 2
51. Locate the stock rear lower control arm hardware that
was removed from step # 45. Working on the driver side,
install the new EZ-Flex control arm into the stock location
and secure using the stock hardware. Special Note:
Make sure that when you install the new EZ-Flex
control arms that the sert fittings are pointing
upwards. Slight prying of the stock lower control arm
mounts, raising the axle to ride height and moving it
slightly up and down will make for easier installation.
Torque the stock hardware to 90 ft lbs. Repeat
procedure on the passenger side.
See Photo # 13 (Frame Mount)
See Photo # 14 (Axle Mount)
52. Locate the new rear track bar relocation bracket,
(1) .6875” x .558” x 1.50” crush sleeve from hardware
bag 44900SL. Also, locate the stock rear track bar
hardware that was removed from step # 44. Working on
the driver side, install the new rear track bar relocation
bracket over the stock track bar location and secure
using the stock hardware and new crush sleeve into the
stock location. Special Note: Make sure to use thread
locker or lock tite. Do not tighten at this point.
53. Locate (2) 5/16” x 1 1/4” bolts, (4) 5/16” flat washers,
(2) 5/16” unitorque nuts and (2) 5/16” lock washers from
hardware bag 44900NB. Working on the driver side,
using the new track bar relocation bracket as a guide,
carefully drill (2) 5/16” holes into the bottom and the top
of the stock track bar bracket. Secure the new track bar
bracket to the stock track bar bracket using the new 5/16”
bolts and hardware. Special Note: Make sure to use
thread locker or lock tite and torque to 18 ft lbs.
54. Locate (1) 12 mm x 75 mm bolt, (2) 1/2” flat washers,
(1) 12 mm nylon lock nut and (1) 12 mm lock washer
from hardware bag 44900NB. Install the stock rear track
bar into the new rear track bar relocation bracket and
secure using the new 12 mm x 75 mm bolt and hardware.
Special Note: Make sure to use thread locker or lock
tite. Once the stock track bar is secure to the new track
bar relocation bracket, torque the stock and new 75 mm
bolt to 75 ft lbs. Special Note: If you are not able to
line up the hole in the stock rear track bar and the
new rear track bar relocation bracket, you may have
to perform this step once the weight of the vehicle is
on the ground.
See Photo # 15
55. Locate (2) new rear sway bar end links. Locate (8)
PB4902 poly bushings from hardware bag 44905NB1.
Locate (4) .6875” x .558” x 1.50” crush sleeve from
hardware bag 44900SL. Install the new bushings and
sleeves into each end of the new sway bar end links.
Special Note: Make sure to use a lithium or moly
base grease when inserting the bushings and
sleeves into the new rear sway bar end links.
56. Locate the stock rear sway bar end link hardware that
was removed from step # 43. Working on the driver side,
install the new rear sway bar end link into the stock upper
and lower location and secure using the stock hardware.
Special Note: Make sure to use thread locker or lock
tite. Also, do not tighten at this point. Repeat
procedure on the passenger side. Once both the driver
and passenger side end links are connected, torque all
(4) stock bolts to 85 ft lbs. Special Note: If you are not
able to install the new rear sway bar end links into
the stock location, you may have to perform this step
once the weight of the vehicle is on the ground.
See Photo # 16
57. Locate (2) 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 front shocks. Tuff
Country EZ-Ride Suspension recommends using a
26” fully extended hydraulic shock. Also, locate (2)
rear upper shock clevis mounts from hardware bag
44905NB1. Install the new shock boots onto the new
shocks. Install the new 5/8” upper and lower shock
bushing into the upper and lower eyelet of each shock.
The new bushing should be packaged with your new
shocks. Next, install the new upper clevis mount into the
new 5/8” upper shock bushings. Special Note: to make
the clevis mount installation easier, it is highly
recommended using a moly or lithium base grease.
58. Locate the stock upper and lower shock hardware
that was removed from step # 42. Working on the driver
side, install the new shock into the upper and lower stock
location and secure using the stock hardware. Torque the
upper hardware to 15 ft lbs. and the lower hardware to
65 ft lbs. Repeat procedure on the passenger side.
59. Carefully remove both hydraulic floor jacks from
under the rear differential.