Installation Instruction
Contents
1. FIGURE 26 Tar LY El 72 Reattach ABS wire clips to original positions 73 Install brakeline relocation brackets as shown there are drv and pass side brackets they will be located into the factory locating tab The the factory brakeline will be mounted towards the center of the vehicle on the inside of the relocation bracket Attach with OE and new 1 4 x 1 hardware BP 768 tighten to 10 ft lbs Fig 27 Note do not disconnect brakeline shown for inst sheet pictures only Q Ti p The hardline portion of the brake line below the mounting tab can be straightened slightly for more slack and better clearance between the sway bar if necessary Fig 28 FIGURE 28 74 Reinstall wheels and torque to factory specifications Lower vehicle to ground 75 Tighten lower and upper rear control arms to 95 ft lbs Lock off control arm jam nuts on the upper arms securely FINAL INSTALLATION STEPS 76 Double check all hardware for proper torgue 77 Check all fasteners after 500 miles and at regularly scheduled maintenance intervals TIME TO HAVE SOME FUN Thank you for choosing BDS Suspension For questions technical support and warranty issues relating to this BDS Suspension product please contact your distributor installer before contacting BDS Suspension directly WE WANT TO SEE YOUR RIDE Grab photos of your BDS equipped truck in action and send them in for a chance to be featured Send it in to our2. Bad Ass Rides customer gallery at bds suspension com bar and post them on the BDS Fan Page on Facebook at facebook com BDSSuspensions Don t forget about your BDS swag BDS offers t shirts hoodies decals and more available on the BDS website or through your local BDS distributor
3. block the rear wheels for safety 2 _ Measure from the center of the wheel up to the bottom edge of the wheel opening and record below LF RF LR RR 3 Disconnect the front track bar from the passenger s side of the front axle Fig 1 Raise the front of the vehicle and support the frame with jack stands behind the front lower control arm pockets Remove the wheels Remove the 3 bolts mounting the transmission skid plate and remove it from the vehicle Disconnect ABS wires from rubber grommets below outer knuckle Fig 2 Disconnect wire from plastic clips on the OE brake line NO pr Ub ge Disconnect brake line brackets from frame Fig 3 and at the axle on newer models Save hardware 7 FIGURE 2 FIGURE 3 8 Remove the OE steering stabilizer Save hardware Leave the stabilizer bracket on tie rod Fig 4 9 Disconnect the sway bar links from the axle and sway bar Fig 5 FIGURE 5 ie 10 Disconnect the steering drag link from the pitman arm Remove the tie rod end nut and dislodge the tie rod end from the pitman arm with the appropriate puller or pickle fork Retain tie rod end nut 11 Make indexing marks on the pitman arm to indicate the position relative to the splines Remove pitman arm from steering box with ap propriate puller Retain hardware Fig 6 FIGURE 6 12 Transfer indexing marks on pitman arm to the new pitman arm Install new pitman arm with OE hardware Tighten to 185 ft lbs 13
4. differently than a factory equipped vehicle FOLLOW US FOR U P TO DATE ROLLOVERS Extreme care must be used to prevent loss of control or vehicle rollover EVE NT COVE RAGE AN D MO RE DRIVE SAFELY If you do fail to drive your modified vehicle safely it may result in serious injury or death DON T MIX SYSTEMS We do not recommend the combined use of suspension lifts body lifts or other lifting devices e STAY SOBER You should never operate your modified vehicle under the influence of alcohol or drugs e OBEY THE LAW Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt RECOMMENDATIONS Visit 560plus com for more information PROFESSIONAL INSTALLATION BDS Suspension recommends that this system be installed by a professional technician PROFESSIONAL KNOWLEDGE Disassembly reassembly procedures and post installation checks must be known to install this system SPECIAL LITERATURE REQUIRED OE Service Manual for model year of vehicle Refer to manual for proper disassembly IO OR HN reassembly procedures of OE and related components VI NC COMPLIANT risk of rollover crashes the x x x National Highway Traffic OE RECOMMENDATIONS Adhere to recommendations when replacement fasteners retainers and keepers are called out Safety Administration in the OE manual NHTSA established the Federal Mot
5. sway bar Torque hardware to 60 ft lbs ALL MODELS 38 Turn wheel all the way to the driver s side If installing optional stabilizer lightly grease and install bushings into steering stabilizer with sleeves provided Extend cylinder completely and attach stabilizer to trackbar bracket mounting tab New stabilizer requires a 2 x 2 1 2 bolt with washers and nut run bolt from bottom up The OE stabilizer requires OE hardware run bolt from bottom up Do not tighten bolt at this time Fig 15 39 Rotate tie rod bracket up and attach stabilizer with OE nut Fig 16 40 41 42 43 A4 45 46 47 48 FIGURE 15 Cycle steering and check for proper clearance adjust as necessary Tighten 2 hardware to 65 ft lbs u bolts to 25 ft lbs and stabilizer OE 12mm hardware to 55 ft lbs Attach brake line drop brackets 01716 to the side of the frame with OE hardware Attach brake lines to relocation brackets with nuts and washers from bolt pack 704 It may be necessary to reform the 90 degree bend in the brake line to 45 degrees to gain adequate slack at full droop Reattach the brake line to the axle on newer models It may also be necessary to lube the brake line and pull it through the axle mount for additional slack Reattach ABS wire rubber grommets to mounting bracket on steering knuckles Attach ABS wire to brake lines with zip ties Reattach the factory transmission skid plate to the transmission cro
6. 2012 models only Locate and install the 124314 Exhaust Extension Kit with the instructions included in the kit 14 Support the front axle with a hydraulic jack Remove the front shocks from the vehicle Save lower mounting hardware 15 Lower the front axle and remove the coil springs from the vehicle 16 If working on a JK with front axle alignment eccentric bolts at the axle mark the cam position for reference later 17 With the axle well supported remove the lower control arm bolts at the axle and frame Remove both lower control arms from the vehicle Save hardware 18 Using a grinder remove the material from the control arm mounts as shown for control arm clearance Figures 1 2 FIG 7A DRIVERS SIDE SHOWN _ FIG 7B PASSENGER SIDES hd z 3 i Hei HOWN 19 Using the OE hardware install the arms so the bend is up and towards the center Figure 8 The bend is centered It may be necessary to raise or lower the axle to align the control arm bolts Leave hardware loose it will be tightened with the vehicle at ride height FIGURE 8 Driver Side Shown Top View y 4 Bend in towards the center for tire clearance 20 Drill the two small hole in the front face of the OE track bar bracket to 7 16 Drill the single small hole in the back face of the bracket to 1 2 Place track bar relocation bracket over the OE mount Install the provided 69 crush sleeve 0 750 x 0 083 x 1 375 between bracket and OE pock
7. 3 Vs v 6 ed 7 s o PB Er aS gt ea gt 7 y SE 3 sy a Cs amp Y d i SUS wm rs Ee sn as Le r SE ce k SS K 5 _ i re 6 2 lt gt I lt Hw Gpps sus EM SION i i 3 F v i SANNA ON JE af AU wf gir R y a J ree iy a A YN 106 a yg l PANN 5 UNT F NN M WN y at nae ir Pe ur gt n a E 6o ob 9 veo qo A U BDS PART 014446 491 W Garfield Ave Coldwater MI 49036 Phone 517 279 2135 Web live chat www bds suspension com E mail tech bds suspension com LIMITE L WARRANTY 5 Suspension System Jeep Wrangler JK 2007 2014 wt ga a He 3 GWE SS im yne va A i 2 pat a Read And Understand All Instructions And Warnings Prior To Installation Of doy System And Operation Of Vehicle a f T Nye ji SUSPENSION Mie GA THANK YOU Your truck is about to be fitted with the best suspension system on the market today That means you will be driving the baddest looking truck in the neighborhood and you ll have the warranty to ensure that it stays that way for years to come Thank you for choosing BDS Suspension ae FOR YOUR SAFETY Certain BDS Suspension products are intended to improve off road performance For your safety and the safety of your passengers take the following precautions e HANDLING Modified vehicles will likely handle
8. et Fig 9A B FIGURE 9A FIGURE 9B 21 Attach track bar bracket to OE mount with 7 16 x 1 bolts washers and nuts in the front two holes Attach the bracket to the back hole with a 1 2 x 1 bolt washer and square nut Use 9 16 x 3 bolt washers and nut through the OE track bar position Do not hook up the track bar at this time Note All hardware is located in bolt pack 562 22 Tighten 9 16 hardware to 95 ft lbs and 7 16 hardware to 45 ft lbs 23 Position the new track bar support bracket on the back side of the track bar bracket by aligning the large hole in the bracket to the top hole in the already installed track bar bracket The tabs on the support bracket will set against the coil mount top in the front and inside surface in the back Install the provided 9 16 x 3 1 2 bolt BP 645 through the track bar bracket and support bracket to help keep the support in place Fig 10 24 25 26 27 28 29 30 31 Make sure the support bracket is setting flush to all mounting surfaces and mark the two holes to be drilling in the coil mount Remove the support bracket and drill 3 8 holes at the marks Reinstall the support bracket on the axle with 3 8 x 1 1 4 bolts nuts and washer BP 645 in the new holes Leave hardware loose Make a mark in the center of the lower coil spring mount pad Drill a 5 16 hole at the mark This hole will be used to attach the provided bump stop exten
9. etween 8 1 2 and 8 3 4 from the center of the bushing to the very end of the disconnect Do not lock off the jam nuts at this point 34 Lightly grease and install the provided sleeves 46 in the new sway bar links assemblies Attach the new sway bar link assembly to the sway bar with a 2 x 3 bolt nut and 2 SAE washers BP 912 The link will mount to the outside of the sway bar and position a 1 3 8 extra thick 1 2 washer BP 912 between the bushing and the sway bar Fig 13 Torque 12 bolt to 65 ft lbs FIGURE 13 iia t 35 Connect the sway bar links to the ball studs on the axle Adjust the sway bar link ends so that they are square on the ball stud and lock off the jam nut securely 36 Locate the existing inner fender bolt up near the front body mount Remove the bolt and attach the new lanyard to the inner fender with the bolt Torque bolt to 10 ft lbs Slide the male clip up the lanyard and attach the female clip to it This will be the stowed position for the lanyard when not in use Fig 14 RUBICON FIXED SWAY BAR LINK INSTALL 37 Install the provided 3 4 ID bushings and sleeves 46 into the new front sway bar links 911110 Attach the links to the inside of the OE axle mount with the OE hardware Attach the link to the outside of the sway bar with the provided 1 2 x 3 bolt nut and washers BP 912 The link will offset toward the inside of the vehicle as it runs from the axle to the
10. mobile fixed and heated members e Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring harness e Check steering gear for clearance Test and inspect brake system 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 e Failure to perform hose check replacement may result in component failure Longer replacement hoses if needed can be purchased from a local parts supplier Perform head light check and adjustment Re torgue all fasteners after 500 miles Always inspect fasteners and components during routine servicing CONTENTS OF YOUR KIT 1425H 4 Lift Kit Shown with Optional Adjustable Lower Control Arms 084402R 1 Dropped Pitman Arm 01964B 1 Front Track Bar Bracket W96S 4 Trans Skid Spacer Washer 69 1 75 x 083 x 1 375 Sleeve A187 2 Rear Adjustable Flex UCA 01393B 1 Support Bracket 3396 2 3in x 3in Front Extension 2 7 16 14x 1 bolt 438 1 Front Bump Stop Bolt Pack 3 7 16 SAE washer 1 3 8 16 x 1 1 4 self tapping bolt 2 7716 14 prev torque nut 2 3 8 USS washer 1 9 16 12 x 3 bolt 2 3 8 16 x 3 1 2 bolt 2 9 16 SAE washer 763 1 Rear Bump Stop Bolt Pack 1 9 16 12 prev torque nut 2 5 16 18x 1 1 4 bolt 1 1 2 13 square nut 2 5 16 18x 7 8 bolt 1 1 2 13x 1 bolt 4 5 16 18 prev torque nu
11. oose It will be tight ened once the vehicle is at normal ride heightl Torque frame bolts to 95 ft lbs Q Tip The pinion can be rotated up or down to aid in aligning the control arm mounting holes with the jack FIGURE 24 Bend in for tire clearance Driver Side Shown 67 Install the new rear springs in the vehicle making sure the OE upper rubber isolator is in place Raise the axle to slightly compress the spring 68 Assemble shocks for installation Shock comes with a preinstalled bar pin in the upper eye Grease and install the provided bushing and sleeve 0 625 x 0 075 x 1 475 in the lower eye 69 Install the new shocks to the frame and axle mounts with the OE hardware Tighten upper mounting hardware to 30 ft lbs and lower hard ware to 55 ft lbs 70 Install the provided bump stop spacer on the passenger s side axle just like the driver s side earlier Using the existing holes in the axle bump stop pad fasten the spacer to the axle with 5 16 x 7 8 bolts nuts and 5 16 SAE washers BP 763 Torque bolts to 20 ft lbs Fig 25 FIGURE 25 71 Grease and install sway bar link sleeves 5 8 OD x 12mm ID x 1 375 long sleeves 62147 into the preinstalled bushings in the provided links Attach sway bar links to axle with OE hardware and at sway bar with new 12mm bolts nuts and washers BP758 Run the upper bolt from the outside in The links will mount to the outer surfaces of the sway bar and axle mount tab Fig 26
12. or Wahid LARGER RIM AND TIRE COMBINATIONS These may increase leverage on suspension steering and related components Safety Standard FMVSS When selecting combinations larger than OE consider the additional stress you could be inducing on the OE and related r components No 126 requiring all new passenger vehicles under 10 000 Ibs GVWR include an DRIVE LINE VIBRATION After installation vehicles may experience drive line vibrations Angles may require tuning slider electronic stability control ESC system as on shaft may require replacement shafts may need to be lengthened or trued and U joints may need to be replaced standard equipment Effective August 2012 this law requires aftermarket products to be compliant with these same standards SHOP SAFETY Secure and properly block vehicle prior to installation of components Always wear safety glasses when using power tools WITH A HOIST If installation is to be performed without a hoist we recommend rear alterations first NOT APPLICABLE TO ALL BDS SUSPENSION SYSTEMS AMOUNT OF LIFT Due to payload options and initial ride height variances the amount of lift is a base figure Final ride height dimensions may vary in accordance to original vehicle attitude Always measure the attitude prior to beginning installation AFTER THE INSTALLATION BEFORE YOU DRIVE e Check all fasteners for proper torque e Check to ensure for adequate clearance between all rotating
13. rail Fig 19 l FIGURE 18 oO FIGURE 19 RELOCATE UNDER CROSSMEMBER Support the rear axle with a hydraulic jack Remove the shocks Retain the upper and lower mounting hardware Remove the sway bar links Retain lower mounting bolt nut Discard links Fig 20 Lower the axle and remove the rear springs Note Do not overextend the brake lines or ABS wires Remove these from their retaining clips temporarily if necessary Fig 21 FIGURE 20 FIGURE 21 58 Install new provided track bar bracket 01967 over the OE track bar axle mount The support wing on the bracket will set over the existing bump stop pad on the axle Mark the hole to be drilled on the top of the factory track bar mount and drill to 3 8 Reinstall bracket with the provided crush sleeve 54587 in original track bar position and loosely fasten with a 9 16 x 3 1 2 bolt nut and washers BP 563 Install a 3 8 x 1 1 4 bolt nut and washers in the newly drilled hole BP 563 Leave hardware loose Fig 22 59 60 61 62 63 64 65 66 FIGURE 22 Position one of the new rear bump stop extensions over the support wing of the track bar bracket so that the existing holes in the factory bump stop pad are aligned with the holes in the track bar support and the bump stop Fasten the bump stop and track bar bracket support to the factory bracket with 5 16 x 1 1 4 bolts nuts and washers BP 763 Run the bolts from the bottom up and to
14. rings 4 door 124310 Box Kit Non Rubicon Part Qty Description A168 2 Front Disconnect Assembly 01302 2 Disconnect Stud 46 2 750x 120 x 1 450 Sleeve 912 1 Bolt Pack 2 1 2 13 x 3 bolt grade 5 2 1 2 13 prevailing torque nut 8 1 2 SAE flat washer 2 1 2 20 prevailing torque nut 2 1 3 8 OD x 1 2 ID x 3 16 washer 01316 2 13 5in Lanyard 124314 Box Kit 2012 Only Part Qty Description 01839 1 Exhaust Extension Drv 01840 1 Exhaust Extension Pass 814 1 Bolt Pack 8mm x 70mm bolt 8mm x 60mm bolt BRN N 5 16 SAE washer 2 Door Coil Springs Part Qty Description 034311 2 Front Coil Springs taller 2 door 034319 2 Rear Coil Springs 2 door 124339 Box Kit Part Qty Description A182 2 Rear LCA w rubber bushings 124331 Box Kit Part Qty Description A181 2 Front LCA w rubber bushings TIRES AND WHEELS SPECIAL TOOLS 37x12 50 on 16x8 with 4 5 backspacing Pitman arm puller TECH TIPS TROUBLESHOOTING INFORMATION FOR YOUR VEHICLE 1 Will not fit 2wd models 2 Exhaust modification may be required INSTALLATION INSTRUCTIONS PRE INSTALLATION NOTES 1 Stock wheels cannot be re installed due to interference with the rear sway bar links 2 _ If Fox 2 0 series shocks are being installed BDS front 104002 and rear 104006 stainless steel brake lines are recommended INSTALLATION INSTRUCTIONS 1 _ Park the vehicle on a clean flat surface and
15. rque to 25 ft lbs Fig 23 FIGURE 23 With the support wing bump stop hardware tight torque the 3 8 35 ft lbs and 9 16 100 ft lbs track bar bracket hardware Install the axle end of the factory rear track bar into the new relocation bracket Fasten the track bar in the bracket with a 9 16 x 3 bolt nut and washers BP 563 The bolt must be run from the front to rear to provide proper coil spring clearance Leave track bar bolt loose Note Make sure the track bar is oriented correctly With the axle well supported remove the lower control arm bolts at the axle and frame Remove both lower control arms from the vehicle Save hardware Using the OE hardware install the control arms with the bend up for maximum ground clearance The bend is centered on the arm Leave all hardware loose It will be tightened with the vehicle at ride height Note the orientation of the stock upper control arms Disconnect the upper control arms from the frame and axle Retain hardware Adjust center to center length of the rear upper control arms to 17 7 8 4 door or 18 3 8 2 door Note These are a preliminary measure ment The arms may need to be fine tuned to adjust the pinion angle Install the arms similar to the factory orientation with the bend in towards the center of the vehicle and the adjustable flex end mount in the frame pocket with the grease fitting pointing down Fig 24 Use factory hardware and leave the axle hardware l
16. sion to the axle Fig 11 FIGURE 11 Tap hole threads by using the 3 8 x 1 1 4 self tapping bolt provided in bolt pack 438 Remove and reuse for the other coil pad 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 Attach the bump stop extension to the axle through the hole that was drilled earlier using a 3 8 x 3 1 2 bolt and 3 8 USS washer BP 438 Use Loctite on the bolt threads and torgue to approx 25 ft lbs Repeat the spring bump stop installation of the other side of the vehicle Install the new shocks with a 93 sleeve 12mm ID in the lower bushing Attach with OE lower hardware and new upper bushings cup washers and 2 fine thread nut Torque the lower bolt to 65 ft lbs and the upper nut until the bushings begin to swell Attach the drag link to the new pitman arm with the OE tie rod end nut Torgue nut to 55 ft lbs NON RUBICON SWAY BAR DISCONNECT INSTRUCTIONS 32 33 Install the new sway bar link disconnect ball stud to the original sway bar link mount on the axle Attach the stud so that the ball is toward the center of the vehicle Use one 2 SAE washer on each side of the mount and fasten with a 2 nut BP 912 Torque nut to 65 ft lbs Fig 12 FIGURE 12 Locate the new sway bar link assemblies Ensure that they are adjusted to egual length The links should be adjusted b
17. ssmember and frame rails with the factory hardware At each frame rail mount position two 9 16 washers W96S between the frame and the skid plate before installing the mounting bolts Fig 17 This will ensure adequate driveshaft to skid plate clearance Torque bolts to 55 ft lbs FIGURE 17 Install the wheels and torque lug nuts to manufacturer s specifications Lower the vehicle to the ground and bounce the front to settle the suspension Torque the lower control arm hardware to 95 ft lbs Attach the front track bar to the new axle bracket with the provided 9 16 x 3 1 2 bolt nut and washers BP 645 Have an assistant turn the steering wheel to aid in aligning the track bar bolt Run the bolt from front to rear through the bracket track bar and support bracket Torque the track bar bolt to 125 ft lbs Torque the 3 8 support bracket hardware to 35 ft lbs Check all hardware for proper torque REAR INSTALLATION 49 50 51 52 53 54 55 56 57 Block the front wheels for safety Mark track bar to indicate which end goes into the frame Remove the rear track bar from vehicle Retain hardware Raise the rear of the vehicle and support the frame with jack stands in front of the lower control arm mounts Remove the wheels Remove emergency brake cable bracket it will not be reinstalled Fig 18 Relocate cables under frame cross member to allow for maximum droop Disconnect the rear brake line brackets from frame
18. t l 1 2 SAE washer 8 5 16 SAE washer 645 1 Bolt Pack 01928B 2 Rear Bump Stop Extension 1 9 16 12 x 3 1 2 bolt REAR SWAY BAR LINKS 9 16 SAE washer N 9 16 12 prev torque nut 92025 2 Sway Bar Extension nm SB58BK 4 5 8 ID Hourglass Bushing 4 3 8 SAE washer 62147 4 625x 075x 1 375 Sleeve 2 3 8 16 prev torque nut 758 1 Bolt Pack 2 12mm 1 75 x 60mm bolt 2 12mm 1 75 prev torque nut 4 1 2 SAE washer WW 014446 Box Kit REAR TRACK BAR RELOCATION 01967B 1 Rear Track Bar Bracket 54587 1 750 x 090 x 1 575 Sleeve 563 1 Bolt Pack 1 9 16 12 x 3 bolt 2 9 16 SAE washer 1 9 16 12 prev torque nut 1 3 8 16 x 1 1 4 bolt 2 3 8 SAE washer 1 3 8 16 prev torgue nut BRAKE LINE RELOCATION 01716 2 Front Brake Line Relocationt 099000 4 11 5in Nylon Cable Tie JKBL D 1 Rear Brakelline Brkt Drv JKBL P 1 Rear Brakeline Brkt Pass 704 1 Bolt Pack Front Brake Lines 2 1 4 20 prev torque nut 2 1 4 SAE washer 768 1 Bolt Pack Rear Brake Lines 2 1 4 20 prev torque nut 4 1 4 SAE washer 2 1 4 20x 3 4 bolt 124320 Box Kit Rubicon Part Qty Description 911110 2 Fixed Front Sway Bar Link 46 4 750x 120x 1 450 Sleeve SB34BK 4 3 41D Hourglass Bushing B12X3G5 2 1 2x13x3 Bolt N12PT 2 1 2 x 13 Prevailing Torque Nut W12S 4 1 2in Washer D 4 Door Coil Springs Part Qty Description 034411 2 Front Coil Springs taller 4 door 034419 2 Rear Coil Sp
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