American Expedition Vehicles AEV-Nth JK Suspension Systems - Manual (Page 3)

IJKS0100R (JK RHD Suspensions).doc Released: 12-Jan-10 page 3 of 14
• Trans Skid plate (autos only)
2
• Rear Stabilizer End Links
3
1 Be sure to keep the nuts for the upper-end studs matched to the links because they are NOT the same thread as
the bottom-end bolts or the shock lower-end bolts!
2 CAUTION: To avoid damage to the (expensive!) front driveshaft, remove this skid prior to lifting the vehicle – do
not allow it to contact the driveshaft! The weight of the front axle is enough to damage the driveshaft if it contacts
this skid - resulting in vibration issues and/or shortened driveshaft service life. Also, this skid cannot be reinstalled
with the lift – do not attempt to do so even though it seems to fit when the Jeep is sitting on the ground.
3 The rear stabilizer end links will be reused on the front suspension with this system.
Also perform the following items only as indicated (not full removal as above):
• Disconnect front track bar @ axle end.
• Detach brake hoses @ frame (remove retainer bolts only, do not open the hydraulics!).
• Loosen all upper and lower control arm bolts.
CAUTION: Be sure to watch out for the wheelspeed sensor wires that run to each wheel (along the
brake hoses) and make sure to not overextend or otherwise damage them.
Step 4: Install Brake Line Drop Brackets. Determine which of the four supplied brackets is for each
corner of the vehicle and install the fronts to the frame using the bolt that was originally holding the brake
line. Using your hands, gently alter the existing bends in the hard lines so they will reach down to the
new brackets, then use the supplied ¼” bolts and nuts to secure the brake lines to the brackets. Figure
4-1 shows the left front installed and the inner plastic wheelwell pulled back to show how the brake lines
have been re-bent. Additionally on the front brake lines, you will need to also ‘open up’ the bend on the
upper end of the hose as shown in figures 4-2 and 4-3 so there will be enough length for full travel.
4-1 4-2 4-3
Step 5: Install Bump Stop Spacers and Springs. Locate and drill a 3/8” hole in the center of each strike
surface in the middle of the spring seats on the axle (see figure 5-1 next page). Before placing the
springs in the vehicle, you will need to insert one 3”dia. X 3”tall spacer inside the spring from the bottom
end with the counterbored side facing up, then you will bolt the spacer to the drilled hole in the axle after
the spring+spacer is placed. Position the spring’s upper pigtail around the jounce tower on the frame
and raise until the bottom end of the spring can fit over the axle seat – making sure to keep the spacer
inside the spring. Once the spring is in place, use the provided bolts, nuts, and washers to secure the
bumpstop to the drilled hole as shown in figure 5-2. Tighten to 30 ft-lbs and repeat for the other side.