Tuff Country 44905 - Jeep TJ Wranlger 97-06 4 EZ-Flex kit w/sway bar quick disconnects - Manual (Page 4)

5. Working on the driver side, remove the stock sway bar
end link from the stock sway bar and the lower stock
location. The stock sway bar end link may be discarded.
Remove the lower stock sway bar end link hardware and
discard. Repeat procedure on the passenger side.
6. Working on the passenger side, remove the stock
hardware that connects the stock front track bar to the
stock location. Save the stock hardware for later re-
installation.
7. Working on the passenger side, remove the stock
hardware that connect the stock stabilizer to the stock
location. Save the stock hardware for later re-installation.
Special Note: Leave the stock stabilizer attached to
the stock tie rod. Also, if you do not have a stock
stabilizer on the vehicle that you are working on, you
may skip this step.
8. Working on the driver side, remove the stock tie rod
end that connects to the stock pitman arm. Save the
stock hardware that connects the stock tie rod end to the
stock pitman arm for later re-installation. Special Note:
Take special care not to tear or rip the stock tie rod
boot. Remove the stock hardware that connects the
stock pitman arm to the stock steering box. Save the
stock hardware for later re-installation. Using a pitman
arm puller, carefully remove the stock pitman arm from
the stock steering box. The stock pitman arm may be
discarded.
9. Working on the driver side lower control arm axle
mount, scribe a mark on the stock alignment cams and
reinforcement bracket. This mark will be used as a
reference when installing the new front EZ-Flex control
arms. Repeat procedure on the passenger side.
10. Working on the driver side, remove the stock lower
control arm from the stock front and rear location and
save the stock hardware for later re-installation. The
stock lower control arm may be discarded. Repeat
procedure on the passenger side.
11. Working on the driver side, remove the stock lower
coil spring clip and save the stock lower coil spring clip
and hardware for later re-installation. Repeat procedure
on the passenger side.
12. Carefully lower down on both hydraulic floor jacks at
the same time allowing enough room for the stock coil
springs to be removed and the new coil springs to be
installed.
13. Locate the new front coil springs. Working on the
driver side, install the new front coil springs into the stock
location. Special Note: Make sure that the new coil
springs seat properly into the lower spring pocket.
Also, the stock bump stop may need to be removed
to make front coil spring installation easier. If you
remove the stock bump stop, make sure to re-install
the stock bump stop back into the stock location
once the new front coil spring has been installed.
Repeat procedure on the passenger side.
14. Locate the stock coil spring clips and hardware that
where removed from step # 11. Working on the driver
side, re-install the stock lower coil clips back into the
stock location. Special Note: Make sure to use thread
locker or lock tite. Torque to 15 ft lbs.
15. Carefully raise up on both hydraulic floor jacks at the
same time until the new coil springs seat properly into the
stock upper coil spring bucket. Special Note: Make sure
that the stock rubber spring isolator pads seat
properly with the stock upper coil spring bucket.
16. Locate (2) new front EZ-Flex control arms. Special
Note: There is not a difference between the front and
rear EZ-Flex control arms. Remove the (2) half’s of the
front EZ-Flex control arms and pack both ends with a
good amount of moly or lithium base grease. Screw the
front EZ-flex control arms back together and set the
length at 16 1/2” from the center of one eyelet to the
center of the other eyelet.
See Photo # 1
17. Locate (4) 90 degree sert fittings and (2) straight sert
fittings from hardware bag 44905NB1. Carefully install
the sert fittings into the new front EZ Flex arms. Special
Note: The 90 degree sert fittings need to be installed
in the outer holes and the straight sert fitting needs
to be installed in the middle hole.
See Photo # 2
18. Locate the stock front lower control arm hardware
that was removed from step # 10. Working on the driver
side, install the new front EZ-Flex control arm into the
stock location and secure using the stock hardware.
Special Note: Make sure that when you install the
new EZ Flex control arms that the sert fittings are
pointing upwards. Slight prying of the stock lower
control arm mounts, raising the axle to ride height
and moving it slightly up and down will make for
easier installation. Also, refer the mark that was
scribed in step # 9 and set the stock cam alignment
bolt to the stock settings and torque the stock front
and rear hardware to 90 ft lbs. Repeat procedure on
the passenger side.
See Photo # 3 (Axle Mount)
See Photo # 4 (Frame Mount)
19. Locate the new front track bar relocation bracket.
Also, locate the stock front track bar hardware that was
removed from step # 6 and (1) .625 x .500” x 1.250” front
track bar crush sleeve from hardware 44900SL. Working
on the passenger side, install the new track bar
relocation bracket into the stock track bar pocket. Secure
the new track bar relocation bracket into the stock pocket
using the stock hardware and crush sleeve into the upper
hole of the new track bar relocation bracket. Special
Note: Make sure to use thread locker or locktite.