American Expedition Vehicles AEV-Nth JK Suspension Systems - Manual (Page 4)

IJKS0100R (JK RHD Suspensions).doc Released: 12-Jan-10 page 4 of 14
Step 6: Install New Front Shocks. Install the upper stud-type bushing end of the shocks to the frame
mounting points in the same manner as the originals were removed. To keep the shock rod from
spinning, use a 5mm hex key (‘Allen’ wrench) in the end of the stud and use an open end wrench to turn
the nut. Be sure to only compress the bushings by approximately 1/8”.
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Especially for Premium Systems, the lower end of the front shocks must be spaced outboard of
the stock brackets to keep them from hitting the frame during extreme articulation. To do this properly,
you have a separate pack that includes pair of ‘doubler brackets’ and hardware (Nth99053Ax) that will
preserve the double-shear mounting arrangement with the shocks outboard of the stock bracket. Match
each bracket to the correct side and install as shown in figure 6-1 which shows the passenger side.
Note that the bottom bolt locations fit to existing holes in the stock brackets, but the forward one on the
right side may not exist and require drilling the stock bracket. For the side of the spring seat, use the
self-tapping bolts supplied and drive them in with an air-ratchet, then add a nut to the backside for good
measure.
For +3.5” and most +4.5” systems, complete the shock connection using the supplied spacer
tubes and longer M12 bolts as shown. If yours is a +4.5” system, you were also supplied to with an
additional hardware pack (Nth99051Az = JK Shock Spacer Kit) that can be used to optimize the travel of
the supplied shocks for your 4.5” system – however, you may only use this kit if you have replaced your
front driveshaft with an aftermarket unit with smaller tube diameter. (Note that this hardware pack also
includes four tubes and longer metric bolts to space the rear shocks as well – these are addressed later
in the instructions).
To install shock spacers for 4.5” systems, attach one square ‘extender’ bracket to each doubler
installed above using the new bolts and tubes supplied (i.e. you will not use the long metric bolts and
longer tubes supplied in the doubler bracket pack). Arrange the bolts and 1.375” long tube as shown in
figure 6-2 – this is done to provide clearance to avoid static contact with the shock eye. Add the shock
to the extender by turning the shock body/lower-eye 90 degrees and re-using the stock shock bolt.
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