Zone Offroad Products 4" Lift Kit Installation guide

Brand: Zone Offroad Products

Model: 4" Lift Kit

Type: Installation guide

»Zone Oroad Products • 491 W. Gareld Ave., Coldwater, MI 49036 • 888.998.ZONE • www.zoneoroad.com

Diculty Level

easy 1 2 3 4 5 difcult

Estimatedinstallation:4-5hours

Tire/Wheel Fitment

35x12.50tire/16x8,4.5"BSwheel

Read and understand all instructions and warnings prior to installation of product

and operation of vehicle.

ZoneOffroadProductsrecommendsthissystembeinstalledbyaprofessionaltechnician.Inadditiontotheseinstructions,profes-

sionalknowledgeofdisassembly/reassemblyproceduresandpostinstallationchecksmustbeknown.Minimumtoolrequirements

includethefollowing:Assortedmetricandstandardwrenches,hammer,hydraulicoorjackandasetofjackstands.Seethe"Special

ToolsRequired"sectionforadditionaltoolsneededtocompletethisinstallationproperlyandsafely.

»Product Safety Warning

CertainZoneSuspensionProductsareintendedtoimproveoff-roadperformance.Modifyingyourvehicleforoff-roadusemayresult

inthevehiclehandlingdifferentlythanafactoryequippedvehicle.Extremecaremustbeusedtopreventlossofcontrolorvehicle

rollover.Failuretodriveyourmodiedvehiclesafelymayresultinseriousinjuryordeath.ZoneOffroadProductsdoesnotrecom-

mendthecombineduseofsuspensionlifts,bodylifts,orotherliftingdevices.

Youshouldneveroperateyourmodiedvehicleundertheinuenceofalcoholordrugs.

Alwaysdriveyourmodiedvehicleatreducedspeedstoensureyourabilitytocontrolyour

vehicleunderalldrivingconditions.Alwayswearyourseatbelt.

»technical SuPPort

Live Chat

providesinstantcommunicationwithZonetechsupport.Anyonecanaccesslive

chatthroughalinkonwww.zoneoffroad.com.

www.zoneoffroad.com

mayhaveadditionalinformationaboutthisproductincludingthelat-

estinstructions,videos,photos,etc.

Sendane-mailto

[email protected]

detailingyourissueforaquickresponse.

888.998.ZONE

 CalltospeakdirectlywithZonetechsupport.

»Pre-inStallation noteS

1.Specialliteraturerequired:OEServiceManualformodel/yearofvehicle.Refertomanualforproperdisassembly/reassemblypro-

ceduresofOEandrelatedcomponents.

2.Adheretorecommendationswhenreplacementfasteners,retainersandkeepersarecalledoutintheOEmanual.

3.Largerrimandtirecombinationsmayincreaseleverageonsuspension,steering,andrelatedcomponents.Whenselectingcombina-

tionslargerthanOE,considertheadditionalstressyoucouldbeinducingontheOEandrelatedcomponents.

4.Postsuspensionsystemvehiclesmayexperiencedrivelinevibrations.Anglesmayrequiretuning,slideronshaftmayrequirere-

placement,shaftsmayneedtobelengthenedortrued,andU-jointsmayneedtobereplaced.

5.SecureandproperlyblockvehiclepriortoinstallationofZoneOffroadProducts.Alwayswearsafetyglasseswhenusingpowertools.

6.Ifinstallationistobeperformedwithoutahoist,ZoneOffroadProductsrecommendsrearalterationsrst.

7.Duetopayloadoptionsandinitialrideheightvariances,theamountofliftisabasegure.Finalrideheightdimensionsmayvaryin

accordancetooriginalvehicleattitude.Alwaysmeasuretheattitudepriortobeginninginstallation.

rev070314

#J1410, J1411 Installation Instructions

2007-2012 Jeep JK

4" Suspension Lift

J1410,J1411Installation-pg.2

Kit Contents

Qty Part

2FrontCoilSpring

2RearCoilSpring

22"BumpStop(frt)

1BoltPack439-FrontBumpStops

2 3/8"-16x2-1/2"boltgrade5

2 3/8"USSatwasher

1 3/8"-16x1"self-tappingbolt

4FrontTrackBarBushing

2TrackBarSleeve-0.750x0.095x1.610

1FrontAdjustableTrackBarAssembly

4LCACamWasher

49/16"SAEWasher

23"BumpStop(rear)

1BoltPack763-RearBumpStop/BrakeLineDrop

2 5/16"-18x1-1/4"bolt

2 5/16"-18x7/8"bolt

4 5/16"-18prevailingtorquenut

8 5/16"SAEatwasher

2 1/4"-20x1"selftappingbolt

Qty Part

1BoltPack768-RearBrakeLine

2 1/4"-20x3/4"bolt

2 1/4"-20nylocknut

4 1/4"USSatwasher

2RearBrakeLineBracket

2RearSwayBarLinkw/Bushings

1BoltPack758-RearSwayBarLinks

2 12mm-1.75x60mmbolt

2 12mm-1.75prevailingtorquenut

4 1/2"SAEwasher

4RearSwayBarLinkSleeve-0.625x0.075x1.375

1RearTrackBarBracket

1BoltPack563-RearTrackBarBracket

1 9/16"-12x3"Bolt

1 9/16"-12x3-1/2"Bolt

4 9/16"SAEthru-hardenedwasher

2 9/16"-12Prevailingtorquenut

1 3/8"-16x1-1/4"bolt

2 3/8"SAEthru-hardenedwasher

1 3/8"-16Prevailingtorquenut

*Important* Verify you have all of the kit components before beginning installation.

J1410,J1411Installation-pg.3

INSTALLATION INSTRUCTIONS

Pre-inStallation noteS

1. 2012JKmodelswillrequireexhaustextensionkit,partnumberJ5305forproper

driveshafttoexhaustclearanceoncethissystemisinstalled.Seekitspecic

instructionsforexhaustextensioninstallationprocedure.

»front inStallation

1. Parkthevehicleonaclean,atsurfaceandblocktherearwheelsforsafety.

2. Disconnectthefronttrackbarfromtheaxle(passenger’sside).Savemounting

bolt. Figure 1

Figure 1

3. Raisethefrontofthevehicleandsupporttheframewithjackstandsbehindthe

frontlowercontrolarmpockets.

4. Removethewheels.

5. Removethetransmissionskidplate.Saveskidplateandhardware.

6. Disconnectthefrontbrakelinebracketsfromtheframerails.Savehardware.

RubiconModels

:Disconnectthefrontlockerwirefromthedriver'ssideupper

controlarm.

8. Supportthefrontaxlewithahydraulicjack.Removethefrontshocksfromthe

vehicle.Savelowermountinghardware.

9. Disconnecttheswaybarlinksfromtheaxleandswaybar.Discardlinksand

savehardware.

10. Disconnectthetrackbarfromtheframemountandremoveitfromthevehicle

Figure 2.Savemountinghardware.

11. DisconnectthesteeringdraglinkfromthepitmanarmFigure 2.Removethetie

rodendnutanddislodgethetierodendfromthepitmanarmwiththeappropri-

atepullerorpicklefork.Savetierodendnut.

J1410,J1411Installation-pg.4

Figure 2

12. Lowerthefrontaxleandremovethecoilspringsfromthevehicle.

13. Withtheaxlestillwellsupported,removetheboltmountingthepassenger'sside

lowercontrolarmtotheaxleswingthecontrolarmoutofthepocket.

14. Locatetheperforatedsectionofthelowercontrolarmpocketmountinghole

Figure 3A.Therearportionoftheperforatedsectionmustberemoved.Usinga

rotarygrindingtoolorchisel,removetheperforatedsectionineach(2)mount-

inghole.

Figure 3A

15. Withthelowercontrolarmpocketmodicationcomplete,reattachthelower

controlarmtotheaxlewiththefactoryhardwareandtwoprovidedoffsetcam

plates.Thecamplateswilltbetweenthecamstopsoneachbracketfaceand

theholeinthecamshouldbeoffsettowardtherearFigure 3B,wheretheperfo-

ratedsectionwasremoved.Snughardwarejustenoughtokeepthecamplates

betweenthestops.Theboltwillbetorquedwiththeweightofthevehicleonthe

suspension.

Step 13 Note

Itmaybenecessarytoloosenframe

endofthelowercontrolarmtoal-

lowittoswingdown.

J1410,J1411Installation-pg.5

Figure 3B

16. Repeatcaminstallationonthedriver'ssideofthevehicle.

17. Makeamarkinthecenterofthelowercoilspringmountpad.Drilla5/16”hole

atthemarkFigure 4.Usingtheprovided3/8"x1"self-tappingbolt,tapthehole

andremovethebolt.Repeatontheotherside.Thisholewillbeusedtoattach

theprovidedbumpstopextensiontotheaxleafterthecoilspringisinstalled.

Figure 4

18. Placeaprovidedbumpstopextensioninsideoneofthenewfrontcoilsprings

andinstallthespringinthevehicle.Makesurethespringisseatedproperlyin

theaxlemount.

19. Attachthebumpstopextensiontotheaxlethroughtheholethatwastapped

earlierwitha3/8”x2-1/2”boltand3/8USSwasher.Torquebolttoapproxi-

mately25ft-lbs.Repeatthespring/bumpstopinstallationontheothersideof

thevehicle.

20. Installthenewshockswiththefactorylowerhardwareandnewupperbushings/

hardware.Torquethelowerboltto60ft-lbsandtheuppernutuntilthebushings

begintoswell.

Step 17 Notes

Hardwareforfrontbumpstopex-

tensionislocatedinhardwarepack

#439.Besuretodrilltheholewith

a5/16"drillbittoensurethatthe

boltcancutthethreadsproperly.

Step 18 Note

Thetallercoilspringsareinstalled

inthefront..

Step 19 Note

Hardwareislocatedinpack#439.

J1410,J1411Installation-pg.6

21. Locatethenewadjustablefronttrackbarassembly.Lightlygreaseandinstall

theprovidedtrackbarbushingsandsleeves(0.750x0.090x1.575)ineachend

ofthetrackbar.

22. Installthenon-adjustableendofthenewtrackbarinthefactorytrackbarframe

mountwiththefactoryhardware.Orientthetrackbarsothatthebendisup.

Figure 5Leavehardwareloose.Thetrackbarwillbeadjustedandinstalledin

theaxlemountafterthevehiclesweightisonthesuspension.

FRAME ENDFRAME END

AXLE END

Figure 5

23. Reattachthedraglinktothepitmanarmwiththefactorytierodendnut.Torque

nutto65ft-lbs.

24. Reconnectthefrontbrakelinebracketstotheoriginalmountsontheframerails

withthefactorybolts.Tightenboltssecurely.Checktheslackinthebrakelines

byturningthewheelsfromlock-to-lock.Itmaybenecessarytoslightlyreform

thebrakelinehardlineattheframedownabout10-15degreestoprovidemore

slackinthelineFigure 6a/b.Carefullybendthehardlinewithyourhands.2011

andnewermodels:Trimthetaboffthelocatingtabonthebrakelinehardline.

Drilla7/32"hole1"belowtheoriginalbrakelinemountinghole.Carefullyre-

formthehardlineandattachthebrakelinetotheframerailwith1/4"selftapping

boltFigure 6c

Figure 6A - Before

Step 21 Note

Thetrackbarbushingsaremade

withahighdurometer(stiff)poly-

urethane.Abenchvise,c-clamp,

orsimilartoolwillbenecessaryto

installthesleevesinthebushings.

Useplentyofgreasetoeaseinstal-

lation.

J1410,J1411Installation-pg.7

Figure 6B - After

Figure 6C

25. Reattachthefactorytransmissionskidplatetothetransmissioncrossmember

andframerailswiththefactoryhardware.Ateachframerailmount,position

two9/16"washersbetweentheframeandtheskidplatebeforeinstallingthe

mountingboltsFigure 7.Thiswillensureadequatedriveshafttoskidplateclear-

ance.Torqueboltsto55ft-lbs.

Figure 7

26. Installthewheelsandtorquelugnutstomanufacturer’sspecications.

J1410,J1411Installation-pg.8

27. Bouncethefrontofthevehicletosettlethesuspension.Adjustthefronttrack

toaligntheholeintheaxlemountwiththeendofthetrackbar.Installthetrack

barinthebracketwiththefactoryhardware.Visuallycheckthethataxleis

centeredunderthevehicleandadjustasnecessary.Torquethetrackbarboltsat

theframeandaxleto125ft-lbs.Lockoffthejamnutsecurely.

28. Torquethelowercontrolarmboltsattheaxle(andattheframeiftheywere

loosened)to125ft-lbs.

»rear inStallation

1. Blockthefrontwheelsforsafety.

2. Disconnectthereartrackbarfromtheframe(passenger’sside).Savehardware.

Figure 8

3. Raisetherearofthevehicleandsupporttheframewithjackstandsinfrontof

thelowercontrolarmmounts.

4. Removethewheels.

5. Removetheshocks.Savetheupperandlowermountinghardware.

6. Disconnecttheswaybarlinksfromtheswaybarandaxle.Savelowerhardware

forinstallingthenewlinkstotheaxle.Movethefactoryrearswaybarlinks

(withuppermountingnut)tothefrontofthevehicleandinstalltotheaxlewith

theoriginalfrontlinkhardwareandtotheswaybarwiththefactorynutFigure 9.

Torqueupperandlowerhardwareto60ft-lbs.

Step 6 Note

Reminder:Theballjointend

mountstotheoutsideofthesway

barandthebushingendmountsto

theinsideoftheaxletab.

J1410,J1411Installation-pg.9

Figure 9

7. Disconnectbrakelinebracketsfromtheframe,saveboltsFigure 10

Figure 10

8. Disconnecttheparkingbrakecablebracketfromtheundersideofthecab

Figure 11.Removethecablesfromthebracket.

Figure 11

9. Lowertheaxleandremovetherearspringsandupperspringisolators.Save

isolatorsforinstallationwithnewsprings.

Step 9 Notes

Donotover-extendedtheABS

lineswhenloweringtheaxle.It

maybenecessarytotemporarily

removetheplasticretainingclip

attheframetoallowforenough

slack.

RubiconModels

:Itwillbeneces-

sarytoremovetherearlockerwire

fromtheretainingclipatthetopof

thedifferential.

J1410,J1411Installation-pg.10

10. Notetheorientationofthereartrackbar(driver'sversuspassenger'sside).Re-

movethetrackbarboltfromtheaxlemountandremovethetrackbarfromthe

vehicle.Savetrackbar.

11. Locatethenewreartrackbarbracket.Installthebracketoverthefactorytrack

barmountattheaxleFigure 12A.Thesupportwingonthebracketwillreston

theexistingbumpstoppadontheaxleandalignwiththeholesinthebracket.

Aligntheoriginaltrackbarmountholewiththeholeinthebracket.Temporar-

ilyinstalla9/16"x3-1/2"bolt.Usingthebracketasaguide,markthetop

mountingholetobedrilled.Removethebracketanddrilla7/16"holeatthe

mark.

Figure 12A

12. Repositionthereartrackbarbracketontheaxleandplacea0.750x0.090x

1.575sleeveintheoriginaltrackbarmountlocation.Fastenthenewbracketto

thefactorybracket,throughthesleevewitha9/16"x3-1/2"bolt,nutandwash-

ers.Fastenthebracketinthenewupperholewitha3/8"x1-1/4"bolt,nutand

washers.Leavehardwareloose.

13. Positiononeofthenewrearbumpstopextensionsoverthesupportwingofthe

trackbarbracket.Aligntheholesinthespacerandtrackbarbracketwiththe

existingholesintheaxlebracket.Fastenthepartstogetherwith5/16"x1-1/4"

bolts,nutsandwashers.Runtheboltsfromthebottomupandtorqueto25

ft-lbs.Figure 12B

Figure 12B

Step 11,12 Note

Allhardwareneededfortherear

trackbarbracketinstallationis

locatedinhardwarepack#563.

Step 13 Note

Hardwareforthesupport/bump

stopinstallationislocatedinpack

#763

J1410,J1411Installation-pg.11

14. Withthesupportwinghardwaretight,gobackandtorquethe9/16"(95ft-lbs)

and3/8"(35ft-lbs)trackbarbrackethardware.

15. Installthefactoryreartrackbarinthenewaxlebracketwitha9/16"x3"bolt,

nutandwashers.Theboltmustberunfromthefronttorear.Thiswillensure

thereisnocontactbetweentheboltandcoilspring.Leaveboltloose.

16. Installthenewrearspringsinthevehicle,makingsurethefactoryupperrubber

isolatorisinplace.Raisetheaxletoslightlycompressthespring.

17.

Installthenewshockswiththefactoryhardware. Tightenuppermounting

hardwareto30ft-lbs,andlowerhardwareto55ft-lbs.

18. Installtheremainingbumpstopspaceronthepassenger'ssideaxleusingthe

existingholesintheaxlebumpstoppad.Fastenthebumpstoptotheaxlewith

5/16”x7/8”bolts,nutsand5/16”SAEwashers.Torqueboltsto20ft-lbs.

Figure 13

19. Installbrakelinerelocationbracketstotheoriginalbrakelinemountingpointon

theframe.Attachthebracketwiththefactorybolt.Attachthebrakelinetothe

INSIDEsurfaceofthedropbracketwitha1/4"x3/4"bolt,nutandwashers

Figure 14A/B.Torquehardwareto10ft-lbs.

Figure 14A

Step 15 Note

Makesurethatthetrackbaris

orientedcorrectlywheninstalling

inthenewbracket.

Step 17 Note

Wheninstallingthepassenger's

sideshockmakesurethattherear

trackbarispositionedabovethe

shocksoitcaneasilybeinstalled

intheframemountlateroninthe

installation.

Step 18 Note

Allhardwareneededfortherear

bumpstopspacerinstallationis

locatedinhardwarepack#763.

Step 19 Notes

Allhardwareneededfortherear

brakelinedropinstallationislo-

catedinhardwarepack#768.

Thefactorybrakelinebracketmust

bemountedtotheinsideofthenew

dropbrackettoprovidedenough

clearancebetweenthebrakeline

andtheswaybar.SeeFigure14B.

Thehardlineportionofthebrake

line(belowthemountingtab)can

bestraightenslightlyformoreslack

andbetterclearancebetweenthe

swaybarifnecessary.

J1410,J1411Installation-pg.12

Figure 14B

20. Locatethenewrearswaybarlinkswithpreinstalledbushings.Lightlygrease

andinstall0.625x0.075x1.375sleevesineachbushing.Attachtheswaybar

linkstotheoutsideoftheaxlemountwiththeoriginalhardwareandtothe

outsideoftheswaybarwith12mmx60mmbolts,nutsandwashers.Runthe

upperboltsfromtheoutsidein.Torqueallswaybarlinkhardwareto60ft-lbs.

21. Installwheelsandtorquelugnutstofactoryspecications.Lowervehicleto

ground.

22. Installthereartrackbarinthefactoryframemountwiththeoriginalhardware.

Torqueboltto125ft-lbs.

»PoSt-inStallation

1. Doublecheckallhardwareforpropertorque..

Checkallfastenersafter500milesandatregularlyscheduledmaintenanceintervals.

Step 20 Note

Allhardwareneededfortherear

swaybarlinkinstallationislocated

inhardwarepack#758.

Step 22 Note

Itmaybenecessarytoslightly

compresstherearsuspensionby

pushingdownonthebumpertoaid

ininstallingthetrackbarbolt.

Post-Installation

Warnings

1. Checkallfastenersforproper

torque.Checktoensurefor

adequateclearancebetweenall

rotating,mobile,xed,andheated

members.Verifyclearancebetween

exhaustandbrakelines,fuellines,

fueltank,oorboardsandwiring

harness.Checksteeringgearfor

clearance.Testandinspectbrake

system.

2. Performsteeringsweepto

ensurefrontbrakehoseshave

adequateslackanddonotcontact

anyrotating,mobileorheated

members.Inspectrearbrakehoses

atfullextensionforadequateslack.

Failuretoperformhosecheck/re-

placementmayresultincomponent

failure.

3. Performheadlightcheckand

adjustment.

4. Re-torqueallfastenersafter500

miles.Alwaysinspectfastenersand

componentsduringroutineservic-

ing.

Zone Offroad Products 4" Lift Kit Installation guide

Brand: Zone Offroad Products

Model: 4" Lift Kit

Type: Installation guide

Download PDF

report

Zone Offroad Products 4" Lift Kit Installation guide

Zone Offroad Products 4" Lift Kit Installation guide

Related papers

Other documents