2. Zone Offroad Products
  3. 4" Lift Kit

Zone Offroad Products 4" Lift Kit Installation guide

  • Hello! I've reviewed the provided installation instructions for the Zone Offroad Products J1410 and J1411 Suspension Lift kits. This document outlines the steps for installing a 4-inch suspension lift on 2007-2012 Jeep JK models, including details on tire fitment, safety warnings and specific torque specs. I'm ready to answer any questions you might have about the installation process or the product itself.
  • What is the recommended tire and wheel size for this lift kit?
    Is it necessary to have a professional install this kit?
    What additional tool is required for installation?
»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
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detailingyourissueforaquickresponse.
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»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.
7.
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
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
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..
2.
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.
/