Trail Master Suspension TM3745-40023 w/ Leaf Spring JEEP CHEROKEE (XJ) 4.5 COIL SPRING KIT - Manual (Page 8)

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Prepare to Install Rear
Suspension
1. Block the front tires and raise the rear of the vehicle.
Support the frame with jack stands forward of the
rear springs.
2. Remove the wheels and tires.
3. Remove the shocks on both sides of the vehicle. It
may be necessary that you slightly raise the axle to
unload the shocks for removal.
4. If your vehicle is equipped with factory sway bar,
unbolt the rear sway bar end links from the axle
mount. Save the hardware for reuse.
5. Support the rear axle with a floor jack and remove
the OE U-bolts on the driver side. Slightly loosen
the OE U-bolts on the passenger side.
6. Lower the rear axle. Be sure not to over extend the
rear brake line and rear axle vent line.
7. While supporting the rear leaf spring, remove the
factory spring mounting bolts and remove the leaf
spring from the driver side only at this time.
Install Rear Suspension
1. Assemble the leaf spring rear shackles using the
supplied rear shackles (82-TM20044), shackle
bushings (TM40560), shackle sleeve (TM30032)
and Zerk fitting (90-4303).
2. Install the rear shackle assembly (82-TM20044) to
the rear spring mount using the OE bolts and hard-
ware.
3. Install the new leaf spring (TM3745-60020) into the
new rear shackles and OE front hangers using the
factory hardware. Do not torque at this time.
4. Make sure the pins fit into the holes on the spring
perch. Use your floor jack to raise the axle to the
spring making sure the head on the factory leaf fit
into the holes on the spring perch.
5. Secure the assembly with the supplied U-bolts
(TM3730-50050) and hardware. Do not tighten the
U-bolts at this time. Make sure the spring sits flush
on the axle perch. If there is a gap grinding down
the heads of the bolts may be necessary.
6. Repeat the installation on the other side of the vehi-
cle.
7. When the installation of the remaining side is com-
plete, torque the U-bolts to 95 ft. lbs.
8. Install the new rear shocks (TM73265006) to the OE
mounting locations.
9. Reinstall the sway bar end links to the rear axle us-
ing the previously removed OE hardware.
10. Install the rear brake line drop (35-TM20023) to the
OE hole in the frame using the previously removed
OE hardware.
11. Reconnect the rear brake line drop (35-TM20023)
using the supplied 5/16” X 1” bolt and hardware.
12. Reinstall the wheels and tires and lower the vehicle
to the ground. Torque according to manufacturers
specification. If you are using aftermarket wheels
follow the manufacturers recommended specifica-
tions.
13. Torque the spring mounts at this time. The front
bolts are torqued to 250 ft. lbs. and the rear bolts
are torqued to 185 ft. lbs. Torque the U-bolts to 120
ft. lbs. If the U-bolt threads are too long you can
trim the threads.
14. Recheck the wheel lug torque on all four wheels at
this time.
15. Recheck all hardware for proper installation and
torque at this time.
16. On completion of the installation, have the head-
lights re-aligned.
17. Test drive and note location of steering wheel.
18. Adjust drag link to center steering wheel.
TM3745-60020
Rear Leaf Spring
Rear Leaf Spring kit: TM3745-40023 Installation