Tuff Country 44905 - Jeep TJ Wranlger 97-06 4 EZ-Flex kit w/sway bar quick disconnects - Manual (Page 8)

Special Note: If the vehicle that you are working on
was manufactured from 1997 — 2002, please skip to
step # 73
64. Working on the inside of the vehicle, pull the carpet
back to gain access to the torque shaft bracket mounting
hardware. Special Note: The center console may need
to be removed.
65. Remove the (4) stock mounting hardware screws that
attach the torque shaft bracket to the floor pan.
66. Slide the torque shaft bracket off the torque shaft and
remove the bearing plate and gasket. Save the stock
hardware for later re-installation.
67. Locate the new shifting linkage bracket. Also, locate
(2) 1/4” x 3/4” bolts, (4) 1/4” flat washers and (2) 1/4”
unitorque nuts from hardware bag 44905NB. Attach the
stock bearing plate and gasket to the new shifting linkage
bracket and secure using the new 1/4” x 3/4” bolts and
hardware. Special Note: Make sure to use thread
locker or lock tite. Now install the new shifting linkage
bracket to the stock torque shaft bracket using the (2)
stock bolts that were removed in step # 66. Special
Note: Make sure to use thread locker or lock tite and
torque to 10 ft lbs.
68. Insert the torque shaft into the bearing plate and re-
install the stock torque shaft mounting bracket to the floor
pan using the stock hardware that was removed from
step # 65. Special Note: Make sure to use thread
locker or lock tite and torque to 8 ft lbs. Also, check
and double check to make sure that the torque shaft
is level and the shifting linkage moves freely. If
needed, the end of the shift rod may need to be filed
down to provide proper clearance.
See Photo # 18
69. Re-install the carpet back into the stock location
inside the vehicle. Special Note: If you removed the
center console, re-install the center console.
70. Make sure that the vehicle is on a flat and level
surface, block the front and rear tires and place the
transmission in neutral.
71. Place a jack stand under the transfer case cross
member and remove the (6) stock bolts that secure the
stock transfer case cross member to the bottom of the
stock frame rail. Special Note: There are (3) stock bolts
on each side of the stock transfer case cross
member. The stock bolts may be discarded. Carefully
lower down on the hydraulic floor jack so that the transfer
case cross member lower about 1”.
72. Locate (6) transfer case lower sleeves from hardware
bag 44905SL. Also, locate (6) 12 mm x 55 mm bolts, (6)
12 mm flat washers and (6) 12 mm lock washers.
Working on the driver side, install the transfer case lower
sleeves between the transfer case cross member and the
60. Check and double check to make sure that all steps
for the rear 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 rear track bar to
the newly installed rear track bar bracket in step # 54.
Perform step # 54 now that the weight of the vehicle
in on the ground.
Also, if you where not able to attach the new sway
bar end links in step # 56. Perform step # 56 now that
the weight of the vehicle is on the ground.
Congratulations, rear end installation complete.
Special Note: If the vehicle that you are working on
was manufactured from 1997 — 2002, please follow
step # 61 — # 63 for the transfer case lower kit.
Special Note: If the vehicle that you are working on
was manufactured from 2003 — 2004, please follow
step # 64 — # 72 For the transfer case lower kit and
shifting linkage drop kit.
61. Make sure that the vehicle is on a flat and level
surface, block the front and rear tires and place the
transmission in neutral.
62. Place a jack stand under the transfer case cross
member and remove the (6) stock bolts that secure the
stock transfer case cross member to the bottom of the
stock frame rail. Special Note: There are (3) stock bolts
on each side of the stock transfer case cross
member. The stock bolts mat be discarded. Carefully
lower down on the hydraulic floor jack so that the transfer
case cross member lower about 2”.
63. Locate (6) transfer case lower sleeves from hardware
bag 44900SL. Special Note: There is (3) different size
transfer case lower sleeves. Also, locate (6) 1/2” x 3”
flat head bolts from hardware bag 44900NB. Working on
the driver side, install the transfer case lower sleeves
between the transfer case cross member and the stock
frame rail, (3) per side and secure using the new 1/2” x 3”
flat head bolts. Special Note: Make sure to use thread
locker or lock tite and make sure not to tighten at this
point. Also, the longer sleeve will be installed
towards the rear of the vehicle, the middle sleeve will
go in the middle location and the smaller sleeve will
go towards the front of the vehicle. Repeat procedure
on the passenger side. Once all six bolts have been
installed, torque the new hardware to 80 ft lbs. and
carefully remove the hydraulic floor jack from under the
transfer case cross member. Special Note: Tuff
Country EZ-Ride Suspension recommends not using
and air gun when performing this step, if and air gun
is used the new bolts may strip.
See Photo # 17