Mountain Off Road 8795-3 - Manual (Page 4)

STEP BY STEP INSTALLATION INSTRUCTIONS:
STEP 1:
On a flat, level, hard surface (concrete) floor, jack up the Jeep® and support the frame with jack
stands six inches behind the stock spring hanger (pivot end of spring). Remove the wheels. Remove the plastic
front frame cover. SEE FIGURE 1.
STEP 2:
Using a second set of jack stands, support the front axle under the rotor/hub area. There should be
a slight bit of weight on the stands. SEE FIGURE 2.
STEP 3:
Remove the front drive shaft. Remove the front bumper. Remove the shackles, bushings and
sleeves from the frame. Set them aside, they will be reused. Remove the pivot bolts from the back of the leaf
springs. Remove the springs. SEE FIGURE 3.
STEP 4:
On the drivers side remove the front upper bolt (OEM*) that retains the steering box to the frame.
Install two of item “C” into the stock shackle bracket. SEE FIGURE 4. Install item “A” onto the frame and into
place, lining up the holes. Install one of item “J ” on one of item “F” and install it thru item “A” and item “C”. Install
one item “J” and one item “I“ on item “F” you just installed. Do not tighten at this time. Install the OEM bolt re-
moved from the frame thru item “A”. Do not tighten at this time. SEE FIGURE 5. Install one item “J” on one of item
“G” and install it thru the back side of item “A”, and the stock shackle hanger. Install one item “J” and one item “I”
on item “G”. Tighten item “F” and “G” to 75 lb. ft. torque. Tighten the OEM bolt to 50 lb. ft. torque. *
OEM-original equip-
ment manufacture.
STEP 5:
On the passenger side install two of item “C” into the stock shackle bracket. Install item “B” into
place, lining up the holes. Install one item “J” over one of item “F” and install it thru item “B” and item “C”. Install
one item “J” and one item “I” on item “F”. Do not tighten yet. Install one item “J” on one of item “G” and install it
thru the back side of item “B” and the stock shackle hanger. Install one item “J” and one item “I” on item “G”.
Tighten items “F” & “G” SLIGHTLY ! This is to hold item “B” in place for the next step only.
STEP 6:
With a 1/2” diameter bit in a power drill, use item “B” as a guide to “mark or dimple” the frame at the
upper back part of item “B”. This should be done inside and outside the frame rail. SEE FIGURE 6. DRILL JUST
ENOUGH TO “DIMPLE” THE FRAME. DO NOT GO ALL THE WAY THRU. Remove item “B” from the frame and
set it aside for now. With a 1/8” bit in the drill, drill the “dimpled” marks in the frame, inside and out as pilot holes.
SEE FIGURE 7. Re-install the 1/2” bit and drill the pilot holes from the outside all the way thru both holes. SEE
FIGURE 8. Install a 3/4” bit in the drill and drill the OUTSIDE FRAME ONLY to 3/4”. SEE FIGURE 9. Install item
“D” into the 3/4” hole (careful, do not drop the spacer tube into the boxed frame!). SEE FIGURE 10. Re-install item
“B” onto the frame as you did above. Install one item “J” over the last of item “F” and start it thru item “B” and item
“D”. Install two items “J” between the inside frame and the inside of item “B”, as you insert item “F” thru them and
the inside of item “B”. SEE FIGURE 11. Install one item “J” on item “F” and one item “I“. Tighten both items “F”
and item “G” to 75 lb. ft. torque.
STEP 7:
Install the front bumper and start the upper bolts. Install the factory lower bolts thru items “A” & “B”
up thru the bumper and into the frame. SEE FIGURE 12A & 12B. After all four bolts are started, tighten them to 65
lb. ft. torque.
STEP 8:
Remove the spring pivot hangers from the frame rails (behind the axle). This can be done with a
hand grinder and cut-off wheel, torch or saw-zall. SEE FIGURES 13A, 13B, & 13C. Be very careful and do not cut
into the frame. Just grind the welds. A chisel and hammer comes in handy for knocking loose the brackets. After
the stock brackets are removed from the frame, grind the welds flush and paint the bare frame with some black
paint.
8795-3 PAGE 4