Installation Instruction
Contents
1. Ps 491 W Garfield Ave Coldwater MI 49036 0G Phone 517 279 2135 fi Web live chat www bds suspension com stile SS SPENSION aa ioe E mail tech bds suspension com we vA gute k Part 124021 Product Spring Conversion Suspension System Application 1976 1986 Jeep CJ5 CJ7 CJ8 READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE SAFETY WARNING sps Suspension Co recommends this system be installed by a professional technician In addition to these instructions professional knowledge of disassembly reassembly procedures and post installation checks must be known PRODUCT SAFETY WARNING certain BDS Suspension products are intended to improve off road perfor mance 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 modified vehicle safely may result in serious injury or death BDS Suspension Co does not recommend the combined use of suspension lifts body lifts or other lifting devices You should never operate your modified vehicle under the influence of alcohol or drugs Always drive your modified ve hicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt PRE INSTALLATION NOTES l Special literature required OE Service Manual fo2. bar links do so now Use the OE mounting hardware at the sway bar Use the provided 01457 link spacers along with the 5 8 nuts and SAE washers at the new lower mounts Tighten the upper mount to 30 ft lbs and the lower mount until the bushings begin to swell Install the wheels Page6 124021 29 30 31 32 33 34 With the suspension unloaded and hanging cycle the steering lock to lock while manually spinning the wheels Inspect the steering suspension and drive line for proper operation and clearance Pay close attention to the brake lines On narrow track models with OE wheels adjust steering stops as necessary Fig 10 Lower the vehicle to the ground Bounce the front of the vehicle to settle the suspension Torque the spring hanger bolts to 90 ft lbs Torque the shackle bolts to 50 ft lbs Torque u bolts to 85 ft lbs If transfer case drop kit 124000 is installed do so at this time Remove the three bolts on one side of the transfer case that retain the transfer case crossmember to the frame This will allow the crossmember to drop about one inch Insert the supplied spacers and fasten with the supplied 3 8 bolts and washers Reinstall bumper with OE hardware at top mounting points Use new button head bolts at lower mounting location bolt pack 714 Note Washer not required on button head side of bolt Rear Installation 35 36 37 38 Block the front wheels and raise the rear of the vehicle Su
3. ll the provided bushings 3625RB and sleeves 37 1 in the four provided shackle hangers 2 01455 2 01456 18 Install the provided grease fittings in the threaded holes in the hangers 19 Install a 01455 driver s side hanger with 7 16 x 2 bolts and SAE washers from bolt pack 714 Mount the hanger with the forward hole aligned with the rivet hole and rear hanger hole with the old front hanger mount See Fig 5 old rear mount is no longer used Use loctite on the rear bolt and attached the front bolt through the frame with a 7 16 SAE washer and lock nut Ensure that the hanger is square to the side of the frame and tighten all mounting hardware to 60 ft lbs Fig 4 Fig 5 Torque upper steering box mounting bolts to 60 ft lbs 20 Follow manufactures instructions for installing shackles Leave hardware loose Fig 6 Page 4 124021 21 Clean the spring mounting surface on the axle and ensure that the center pin hole is free of corrosion so that the pin head with fit properly Note Take care not to over extend the brake lines 22 Follow manufactures instructions for installing springs Leave hardware loose until vehicle is on the ground Note Some YJ springs will come with a tall center pin head that will not work in OE CJ axle perches New 5 16 x 4 center pins 228002 can be purchased separately if needed 23 Attach the spring to the axle with 1 2 x 2 1 2 wide u bolts high nuts and washers in conj
4. pport with jack stands under the frame rail just ahead of the spring hangers Remove the wheels Support the rear axle with a hydraulic jack Remove the shocks Retain hardware Remove brakeline junction block above axle tube Install 39 1 sleeve under junction block and reattach with new 1 4 x 1 3 4 bolt and washer Fig 11 124021 Page 7 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Remove the passenger s side u bolts and spring plate from the vehicle Raise the axle just off the springs Remove the rear shackle and front hanger bolt Remove the spring and shackle from the vehicle Discard spring shackle and hardware Remove the two bolts mounting the OE rear shackle hanger to the frame Remove the hanger and hardware Discard hardware and hanger Install the new passenger s side rear 01455 hanger with bushings and sleeves installed to the original hanger location with 7 16 x 1 1 4 bolts and SAE washers from bolt pack 714 Support plate is located toward outside of frame rail Ensure that the hangers are square with the frame and torque the bolts to 60 ft lbs Use loctite on the bolt threads Fig 9 Follow manufactures instructions for installing shackles Leave hardware loose Clean the spring mounting surface on the axle and ensure that the center pin hole is free of corrosion so that the pin head with fit properly Follow manufactures instruction
5. r 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 replacement may result in component failure Longer replacement hoses if needed can be purchased from a local parts supplier 3 Perform head light check and adjustment 4 Re torque all fasteners after 500 miles Always inspect fasteners and components during routine servicing rev 5 21 2013 124021 Page 1 PARTS LIST Bolt Pack 714 Part Qty Description Qty Description 01451 1 Spring Plate drv front 4 7 16 14 x 1 1 4 bolt grade 8 yellow zinc 01452 1 Spring Plate pass front 2 12mm 1 75 x 30mm bhshcs button head 01453 1 Spring Plate drv rear bolt grade 5 clear zinc 01454 1 Spring Plate pass rear 5 7 16 14 x 1 1 2 bolt grade 8 yellow zinc 01455 2 Spring Hanger 3 7 16 14 x 2 bolt grade 8 yellow zinc 01456 2 Spring Hanger 18 7 16 SAE flat washer thru hardened 01457 2 Link Spacer yellow zinc 01492 1 Driver s side spring hanger spacer 2 7 16 14 prevailing torque nut yellow zinc 01493 1 Pass side spring hanger spacer 2 12mm 1 75 Prevailing Torque Nut clear 01499 2 Steering box drop spacer 1 4 4 1 4 28 straight grease zerk 37 1 4 3 4 x 0 109 x 2 985 Sleeve 6 5 8 18 prevailing torque nut clear zinc 3625RB 8 Hanger Bushing 6 5 8 SAE flat washer clear
6. r model year of vehicle Refer to manual for proper disassembly reassembly procedures 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 combinations 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 replacement 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 BDS Suspension components Always wear safety glasses when using power tools 6 Ifinstallation is to be performed without a hoist BDS Suspension Co recommends rear alterations first 7 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 POST INSTALLATION WARNINGS 1 Check all fasteners for proper torque Check to ensure for adequate clearance between all rotating mobile fixed and heated members Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring harness Check steering gea
7. s for installing springs Leave hardware loose until vehicle is on the ground Note Some YJ springs will come with a tall center pin head that will not work in OE CJ axle perches New 5 16 x 4 center pins 228002 can be purchased separately if needed Note If installing shims to correct pinion angle attach shim directly to the leafpack with center pin The thick end of the shim will go toward the front Attach the spring to the axle with 1 2 x 2 1 2 wide u bolts high nuts and washer in conjunction with the new spring plate 01454 see identification figure Snug but do not tighten u bolts Fig 8 Fig 12 Repeat spring removal and installation on the driver s side of the vehicle Install the new BDS shocks Use the OE hardware at the frame and the 5 8 nuts and SAE washers from bolt pack 714 at the new lower mounts Tighten the hardware until the shock bushings begin to swell Install the wheels and lower the vehicle to the ground Bounce the front of the vehicle to settle the suspension Torque the spring hanger bolts to 90 ft lbs Torque the shackle bolts to 50 ft lbs Torque u bolts to 85 ft lbs Check all hardware for proper torque Check hardware after 500 miles Grease front and rear new shackle hangers A front end alignment is recommended The front toe measurement must be adjusted Page 8 124021
8. unction with the new 01451 spring plate see identification figures Snug but do not tighten u bolts Note On the passenger s side bracket 01452 the top differential support web may need to be ground slightly to accept the new u bolt position as a result of using the wider YJ spring Fig 7 Fig 8 124021 Page 5 24 25 26 27 28 oe 01454 01453 Passenger Rear Driver Rear a 01452 01451 i Passenger Front Driver Front Repeat spring removal and installation on the passenger s side of the vehicle Note The passenger s side front shackle hanger 01456 will require installation of 01493 passenger s side hanger plate spacer and 7 16 x 1 1 2 bolts with 7 16 washers These spacer plates will provide clearance for the original or certain aftermarket bumpers to be installed A 1 2 x 2 1 2 and 12 x 3 1 4 wide u bolts are required on the passenger s side Fig 9 With both sides complete install the drag link to the pitman arm if it was removed Attach the tie rod with the OE nut and torque to 50 ft lbs Install new cotter pin Note Never loosen the nut to align the cotter pin hole only tighten Install the new BDS shocks Use the OE hardware at the frame and the 5 8 nuts and SAE washers from bolt pack 714 at the new lower mounts Tighten the hardware until the shock bushings begin to swell If installing new sway bar links solid or disconnect or the OE sway
9. with an appropriate puller note the indexing of the pitman arm Install the new pitman arm indexed the same as the original and fasten with the OE hardware and torque to OE specs 9 Disconnect the driver s side spring u bolts and remove along with the OE spring plate Discard u bolts and plate 10 Raise the axle just off the spring Disconnect the front shackles and rear hanger bolt Remove the spring from the vehicle Discard the spring shackles and hanger bolt 11 Remove the two bolts mounting the front shackle hanger to the frame and remove the hanger Discard the hanger and hardware Fig 1 Page2 124021 12 The forward most frame crossmember rivet original covered by the OE shackle hanger must be removed Using a grinder or air chisel remove the head of the rivet and knock the body of the rivet from the frame with a hammer and punch Fig 2 13 Remove lower rear steering box bracket bolt Fig 2 15 Slightly lower steering box and install 4 spacers on top of steering box mounting bracket and underneath crossmember Install new 7 16 x 1 1 2 bolts through original mounting points and spacers Do NOT tighten at this time 16 Install 01492 driver s side steering box spacer above steering box bracket Install 7 16 x 1 1 2 bolt with 7 16 SAE washer at rear most location do not tighten at this time Fig 4 124021 Page 3 gt 01492 aR ve lt 0 17 Coat with grease and insta
10. zinc 39 1 1 0 875 x 0 120 x 0 750 Sleeve 1 1 8 x 1 1 4 cotter pin clear zinc 714 1 Bolt Pack 1 1 4 20 x 1 3 4 grade 5 clear zinc bolt 122120634R 7 1 2 x 2 1 2 x 6 3 4 Round U bolt 1 1 4 SAE Washer clear zinc 123000634R 1 1 2 x 3 x 6 3 4 Round U bolt N12FH 16 1 2 High Nut W12S 16 1 2 SAE flat washer 342701 1 Loctite INSTALLATION INSTRUCTIONS Note Installation of YJ specific lift springs will increase the wheel base slightly over 1 These instructions detail installation of spring hangers spring plates and related parts Shackles and leaf springs are not included in this kit refer to manufac tures instructions for installation of these items Front Installation l Park the vehicle on a clean flat surface and block the rear wheels for safety Raise the front of the vehicle and support with jack stands under the frame rails behind the spring hangers Remove the wheels To aid installation of front brackets remove front bumper Support the front axle with a hydraulic jack Remove the OE shocks Retain the shock hardware NO 72 F WNW Disconnect the sway bar links from the sway bar and the spring plates Retain the upper hardware discard the lower hardware Note The sway bar link stud at the sway bar is tapered and will require and pickle fork for removal 8 Ifinstalling a new dropped pitman arm disconnect the drag link from the pitman arm Retain hardware Remove the pitman arm nut and remove the pitman arm
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