American Expedition Vehicles AEV-Nth JK Suspension Systems - Manual (Page 10)

IJKS0100R (JK RHD Suspensions).doc Released: 12-Jan-10 page 10 of 14
old trackbar holes on the bracket) and add a third washer and finally the locking nut – tighten to 35 lb-ft.
NOTE: the damper hole on your bracket may be either 5/8” or ½”. If yours has a 5/8” hole, add the short
spacer sleeve to the bolt before the final washer and nut to center it in the oversize hole.
To prepare the tie-rod end for mounting, first position the mount you loosened and moved earlier
by rotating it rearward/up by approximately 90° (towards the differential cover). Next - with the steering
is set to straight ahead - slide the mount on the tie rod until the eye-eye length for the damper will be
16.0” (OME dampers) or 16.5” (Bilstein dampers) and tighten the clamp bolt to hold it in place. Finally
bolt the damper to the hole in the bracket with the original factory bolt – it will likely be necessary to bend
the clamp downward slightly to make the bolt hole square to the bushing. The tie-rod-end of either
damper should look similar to figure 12-2.
Step 13: Reattach Track Bar. Raise the axle until the axle-end of the track bar can be lined up with the
uppermost holes in the new brackets. It may be necessary to pry the brackets apart to allow the track
bar to drop in easily. Add the factory M14 trackbar bolt and locking nut, but do not tighten at this time –
the final appearance can be seen in figure 12-1 above.
The front suspension is now complete except for final adjustments and torques, which will be performed
at the end. You may now reinstall the new front wheels/tires and if not using a vehicle lift, you may
remove the jackstands and let the front rest on the tires.
REAR SUSPENSION
Step 14: Remove Stock Parts. Place the rear of the frame on jackstands or you may already be using a
vehicle lift that supports the frame directly. Also support the rear axle with a floor jack or jack stands,
then lower the axle or raise the Jeep/frame and remove the following parts:
• rear
wheels/tires
• springs
• shocks
• park brake cable wireform @ floor
Also do the following items only as indicated (not total removal as above)
• Detach brake hoses @ frame (remove retainer bolts only, do not open the hydraulics).
• Detach park brake cables @ axle ends.
• Detach axle breather hose @ axle.
• Detach the track bar @ axle end.
• Loosen all upper and lower control arm bolts.
Step 15: Brake Line Drop Brackets. Similar to the front drop brackets, identify the left and right brackets
and install them to the frame using the original hardware, then gently bend the brake lines down and
reattach them using the remainder of the ¼” hardware provided.
NOTE: Be sure to save all removed hardware and keep it associated with the location on the Jeep
where it came from – all of it will be reused.