American Expedition Vehicles AEV-Nth JK Suspension Systems - Manual (Page 11)

IJKS0100R (JK RHD Suspensions).doc Released: 12-Jan-10 page 11 of 14
Step 16: Install Rear Track Bar and Tower. Refer to figure 16-1 as illustration of the completion of this
step for a +3.5” installation. Place the tower over the axle and on top of the factory track bar bracket.
Adjust the position so that the outboard flange of the bracket is flush against the outboard side of the
stock bracket. Use a marking pencil to trace the outline of the oval hole of the tower onto the top side of
the stock bracket. Remove the bracket, center punch in the middle of the marked oval, and drill a ½”
hole.
16-1
Replace the bracket and place two ½” large-diameter washers between the tower and the drilled
hole, then connect using the short ½” bolt, nut and two small-diameter washers, and tighten to 35 ft-lbs,
making sure that the tower is fully seated to the axle tube and flush against the side of the stock bracket.
Next place the 9/16” bolt through the forward portion of the stock bracket and the tab of the tower; add a
washer on the front side (inside the stock bracket) and the locking nut – tighten to 45 ft-lbs. Finally, add
the two u-bolts with washers and nuts and tighten all four incrementally until all are at 40 ft-lbs.
Now reattach the track bar to the new tower. For +3.5” systems, use the lower hole in the tower;
+4.5” systems use the upper hole. Note that both bolts must be inserted from the front of the vehicle to
assure clearance to other components. The factory flag nut that was originally on the axle end may be
swapped to the frame end for easier tightening and better appearance. To hold the flag nut in place
when used on the frame end (where this is nothing to keep it from rotating), simply clamp it to the bracket
with a locking pliers.
Step 17: Install Rear Bump Stop Spacers. ** These plastic spacer blocks are shown in white for
illustrative purposes only – your actual parts should be black ** Each block contains two pairs of
countersunk holes, and you should also have two sets of four flathead bolts that are 3.5” and 4.5” long.
For +3.5” systems, place each block on the striker bracket on the axle (looks like a weak leaf spring
perch) and line up the holes to allow use of the shorter bolts (i.e. 3” spacing thickness). Drop the bolts in
from above and secure with the flanged nuts provided.
For +4.5” systems, place the blocks ‘on edge’ so that the holes for the longer bolts line up with
the axle bracket holes. Make sure that the blocks are biased inboard – that is, more of their width is
closer to the middle of the vehicle – for proper bump stop alignment. Figure 17-1 shows the left-rear
spacer from the front on a LHD JK, while figure 17-2 shows the same spacer from the rear.