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Instructions

1. hardware to 25 ft lbs and the OE bolt to ft Ibs 8 With the front axle supported unbolt the lower front control arm from the front axle mounts 13 Raise the front axle into place Make sure the 9 Using a chisel remove the alignment plates coil spring seats properly on the lower spring from the factory mounts perch 14 Install your new front shocks TM73265005 us ing the previously removed OE hardware 15 Torque the OE shock hardware according to manufacturers specifications 16 Reinstall the OE front sway bar end link into original mounting bracket on the axle using the previously removed OE hardware Torque to manufacturers specifications 17 2007 2010 models only Install the front brake line brackets 35 TM20010 to the frame and secure using the provided 5 16 X 1 bolt s and hardware 10 Reinstall the front lower control arms to the axle mounts using the supplied alignment plates Rotate the plates so that the large lobe is facing MS 3 E bol toward the front of the vehicle Torque to 95 ft or lbs se i 11 Repeat steps 6 through 8 on the remaining side 3 pA a of the vehicle ind 79 Line Drop 12 Carefully lower the front axle to ease in the new mm o a coil spring installation Using the factory isola tors install the coil springs TM3340 60020 into 5 6 X 1 the spring buckets 7 18 2011 2013 models only Install the front brake line brackets 35 T
2. 400 W Artesia Blvd IIE B IZILI Compton CA 90220 Fax 810 747 3912 Ph 877 695 7812 www trailmastersuspension com JEEP WRANGLER 4 DOOR JK 4 SPRING KIT 07 13 WARNING Installation of a Trail Master suspension lift kit will change the vehicle s center of gravity and handling characteristics both on and off road You must drive the vehicle safely Extreme care must be taken to prevent vehicle rollover or loss of control which could result in serious injury or death Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fas tened WARNING Before you install this kit read and understand all instructions warnings cautions and notes in this instruction sheet and in the vehicle owner s manual CAUTION Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components We recommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation Installation of this kit without proper knowledge of the factory recom mended procedures may affect the performance of these components and the safety of the vehicle We strongly recommend that a certified mechanic famil iar with the installation of similar components install this kit WARNING This kit should only be installed on a vehicle that is in good working cond
3. 695 7812 Park vehicle on a clean dry flat level 3 8 16 30 40 surface and block tires so vehicle cannot roll in ei 3 8 24 35 45 ther direction 7 16 14 50 65 4 Park vehicle on a clean dry flat level surface z and block tires so vehicle cannot roll in either direc TR 1 2 20 80 115 9 16 12 105 135 5 Measure ride height with the vehicle supporting 9 16 18 115 150 its own weight on level ground To settle the sus 5 8 11 150 195 pension the vehicle should be driven forward at 5 8 18 160 210 least 10 feet immediately prior to taking these 3 4 16 175 225 measurements Hide height is the measurement from the center of the axle straight up vertical to the fender lip Record this measurement for all four Engine Compartment wheels 1 Disconnect both battery cables Disconnect negative cable first then positive cable Adhere to recommendations when replacement fas teners retainers and keepers are called out in the fac tory service manual When re assembling the vehicle it is recommended by the vehicle manufacturer that cer tain fasteners are replaced in order to maintain proper retention characteristics This system may not include all replacement hardware as recommended by the fac tory service manual Additional replacement hardware should be obtained prior to installation of this system to meet the requirements of the factory service man ual Prepare to Install Front
4. Suspension WARNING Compressed coil springs can expand violently causing serious personal injury Before removing the coil springs lower the axle housing as far as possible to al low the coil springs to expand 1 Loosen but do not remove lug nuts on each front wheel 2 Jack the rear of the vehicle with the floor jack under the differential and place jack stands un der the frame just behind the lower control arm frame mounts Leave the jack stands high enough to let the floor jack down and still have the front tires suspended in the air Keep the floor jack under the differential with slight pres sure for support Remove the front wheels WARNING Use extreme caution when lifting vehicle from ground To prevent serious personal injury ensure the lifting de vice is securely placed 3 Disconnect the track bar from the axle and save the hardware for reuse 4 Using the appropriate tool disconnect the steer ing linkage from the pitman arm and save the hardware for reuse 5 Using the appropriate tool remove the OE pit man arm from the vehicle save the OE retain ing nut for reuse 6 Unbolt the front brake line brackets from the frame Save the hardware for reuse 7 Unbolt the front sway bar end links from the axle Save the hardware for reuse 8 Unbolt and remove the front shocks from the vehicle Save the hardware for reuse 9 Unbolt the 1 driver side skid plate bolt and loosen the 2 pas
5. 60mm 10 9 4 Flange Nut M12 8 Flat Washer M12 1 Track Bracket Front 82 TM20032 1 Sleeve 35 TM30024 Front 1 90 TM60025 Hardware bag Front Track Bar 1 Notched Cam front 90 3245 1 Cam Bolt front 90 3718 1 Nut M14 1 5 1 Flat Washer M14 1 90 TM60026 Hardware bag Front Track Bar 2 Bolt 5 16 x 1 2 Flat Washer 5 167 1 90 TM60027 Hardware bag Front Track Bar 3 Bolt 5 16 x 1 3 Nylock Nut 5 16 6 Flat Washer 5 167 1 Nut Plate 35 TM20036 Front Track Bar 1 Track Bracket Rear 82 TM20038 1 Sleeve 35 TM10037 Rear 1 90 TM60028 Hardware bag Rear Track Bar 2 Bolt 3 8 16 x 1 Gr 8 2 Flange Nut 3 8 4 Washer 3 8 1 Bolt 9 16 x 3 Gr 8 1 Bolt 9 16 x 3 1 2 Gr 8 2 Nylock Nut 9 16 4 Flat Washer 9 16 4 Alignment Plate 35 TM20041 2 Bump Stop front 90 TM10001 1 90 TM60007 Hardware bag Front Bump Stop 2 Self Tapping Bolt 3 8 x 2 2 Bump Stop rear 82 TM20012 1 90 TM60008 Hardware bag Rear Bump Stop 4 Bolt M8 1 25 x 20mm 10 9 4 Nylock Nut M8 4 Washer M8 1 Pitman Arm TM3340 50020 Revision Page 1 Notice to Owner Operator Dealer and Installer Vehicles that have been enhanced for off road performance often have unique handling characteristics due to the higher center of gravity and larger tires This vehicle may handle react and stop differently than many passenger cars or unmodified vehicles both on and off road You must drive y
6. Bar 9 16 X 3 1 2 Bolt D L AL K 3 8 x 1 J Bolt p 2 Secure the rear track bar drop bracket 82 TM20038 to the axle using the 2 supplied 3 8 x 1 bolt and hardware 3 Torque the 9 16 track bar drop hardware to 135 ft Ibs and the 3 8 hardware to 40 ft Ibs 35 TM30037 Sleeve 60030 Rear Coil Spring Carefully lower the front axle to ease in the new coil spring installation Using the factory isola tors install the coil springs TM3340 60030 into the spring buckets Raise the rear differential and make sure that the coil springs are in their saddles Assemble the rear sway bar end links 82 TM30025 by install bushings 45359 and sleeve 51792 in the top and bottom of the sway bar end links i 12mm x 60mm Bolt 45359 and Sleeves 3 Link amp 2mm X d 60mm Bolt tj 2 Axle Lp Mount Install sway bar end links 82 TM30025 into the OE frame and sway bar mounting locations us ing the previously supplied 12mm x 60mm bolts and hardware 8 Install the rear brake line drop 35 TM20010 to the OE hole in the frame using the previously removed OE hardware ss om 2 35 TM20010 i 3j Rear Brake hic 41 Line Drop 9 Reconnect the rear brake line drop 35 TM20010 using the supplied 5 16 X 1 bolt and hardware 10 Install the rear bump stop extensions 82 TM20012 to the rear axle bump stop pad using the supplied 8mm X 20mm bolts
7. M20030 drvr and 35 TM20031 pass to the front spring pads and se cure using the provided 1 4 X 1 bolts and hardware 19 Secure the OE brake line brackets to the drop brackets using the previously removed OE hard ware 20 Remove the retaining clips that retain the ABS wire to the OE brackets Wrap the OE ABS lines with the provided protective sleeves 90 4337 and secure with the supplied zip ties 10999 21 Install the new pitman arm TM3340 50020 to the sector shaft Whether re using the existing pitman arm retain ing nut or replacing with a new nut thread lock ing compound must be used 22 Reinstall the Pitman arm retaining nut to the sector shaft and torque to 185 ft Ibs v F N TM3340 50020 Pitman Arm The threads of the sector shaft and the Pitman arm retaining nut MUST be cleaned using brake cleaner or another suitable method to remove the previously applied oil 23 Reinstall the steering drag link to the pitman arm using the previously removed castellated nut Torque the drag link nut to 60 ft lbs Insert new cotter pin 24 Reinstall the front track bar to the front track bar bracket using the supplied 14mm cam bolt 90 3718 notched cam 90 3245 and hardware 25 Reattach the transfer case skid plate using the previously removed hardware Torque the hard ware to 87 ft Ibs 26 Reinstall the wheels and lower the vehicle to the ground Torque the lug nuts to OE specifica t
8. VEHICLE RECORDS Product Information Part Number Date Purchased Purchased From Vehicle Information VIN Vehicle Measurements Axle Center to Fender Lip on level ground at nde 1 C RgRa tone EE Bump Stop to Contact Point on level ground at NENNEN M Tire amp Wheel Information Tire Size Tire Brand Actual Tire Diameter measured Wheel Size Installer Information shop Name Installer Hic Number Fax Number Attach Copy of Purchase Receipt Copy of Vehicle Wheel Alignment Results Before Starting Installation Wheel amp Tire Requirements The factory wheel and tire combination will fit once onm Kit parts are prefaced by the word kit and appear in bold print Torque Specifications oee factory service manual for torque values when reusing OE fasteners 1 Carefully read all warnings and instructions com pletely before beginning TZ see factory service manual for torque values when re using 2 Verify all parts have been received in this kit by OE fasteners checking the parts list at the end of this document Bolt Size Grade 5 ft Ibs Grade 8 ft Ibs 3 Only install this kit on the vehicle for which it 1 4 20 10 10 is specified If anytime during the installation you 1 4 28 10 12 5 encounter something different from what is outlined 5 16 18 17 22 5 in the instructions call technical support at 877 0 16 24 20 25
9. able Miscellaneous 1 Adjust headlights 2 Check all fasteners to ensure they are tight 3 Ensure all wires hoses cables etc are prop erly connected and there is ample slack 4 Align vehicle to OE specifications Retain align ment results Dynamic Vehicle Check 1 Check steering and suspension in all positions to ensure that there is no bind and adequate clearance between all moving fixed and heated members Check operation of clutch brake sys tem and parking brake Check operation of trans mission and transfer case Ensure there is full en gagement in all gears and 4WD ranges Check battery connections and electrical component op erations Test drive vehicle WARNING Re torque all fasteners after 500 miles and after off road use All suspension lift components should be visually inspected and fasteners re torqued during routine vehicle servicing CAUTION Trail Master does not recommend any particular wheel and tire combinations for use with its sus pension lifts and cannot assume responsibility for the customer s choice of wheels and tires Refer to your owners manual for recommended tire sizes and warnings related to the use of over sized tires Larger wheel and tire combinations increase stress and wear on steering and sus pension components which leads to increased maintenance and higher risk for component fail ure Larger wheel and tire combinations also al ter speedometer calibration
10. and hardware T at V n TT x z h e E 20mm Bolts T A 11 Install your new front shocks TM73265006 us ing the previously removed OE hardware 12 Torque the OE shock hardware according to manufacturers specifications 13 Reinstall the rear track bar to the axle mount us ing the previously removed OE hardware 14 Install the rear track bar to the track bar drop bracket using the supplied 9 16 x 3 1 2 bolt and hardware Torque to 135 ft Ibs 15 At full droop cycle the steering from lock to lock while observing the reaction of these components Reposition them if needed 16 Reinstall the rear wheels and lower the vehicle to the ground Torque the lug nuts to factory specifications 17 Recheck the wheel lug torque on all four wheels at this time 18 Recheck all hardware for proper installation and torque at this time 19 On completion of the installation have the head lights re aligned 20 Test drive and note location of steering wheel 21 Adjust drag link to center steering wheel 22 Align vehicle as soon as practical to minimum factory caster and maximum factory toe in specifications 23 After 100 miles recheck for proper torque on all newly installed hardware 24 Recheck all hardware for tightness after off road use After Completing Installation Engine Compartment 1 Connect both battery cables Connect positive cable first then negative c
11. braking effective ness center of gravity and handling characteris tics Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle All warranty information instruction sheets and other documents regarding the installation of this product must be retained by the vehicle owner Information contained in the instructions and on the warranty card will be required for any war ranty claims The vehicle owner needs to under stand the modifications made to the vehicle and how they affect vehicle handling and perform ance Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury Kit Parts List TM3340 40013 Kit 2 4 Coil Spring TM3340 60020 front 2 4 Coil Spring TM3340 60030 rear 2 Absorber shock front TM73265005 2 Absorber shock rear TM73265006 Box TM3340 40013 1 4 Brake Line Drop 35 TM20010 1 Brake Line Drop 35 TM20030 1 Brake Line Drop 35 TM20031 1 90 TM60005 Hardware bag Brake Line Drop 4 Bolt 5 16 x 1 Gr 8 4 Nylock Nut 5 16 8 Hardened Washer 5 167 1 90 TM60024 Hardware bag Brake Line Drop 2 Bolt 1 4 20 x 1 Gr 8 2 Stover Nut 1 4 20 4 Hardened Washer 1 4 2 Brake Line Sleeving 90 4337 211 Zip Ties 10999 2 Sway Bar End Link Rear 82 TM30025 4 Bushing Rear 45359 4 Sleeve Rear 51792 1 90 TM60029 Hardware bag Rear Sway Bar 4 Bolt M12 1 75 x
12. ions 2 lorque all bolts to factory specifications Re torque all bolts after 500 miles Prepare to Install Rear Suspension 1 Jack the rear of the vehicle with the floor jack under the differential and place jack stands un der the frame just in front of the lower control arm frame mounts Leave the jack stands high enough to let the floor jack down and still have the rear tires suspended in the air Keep the floor jack under the differential with slight pres sure for support 2 Remove the rear wheels 3 Unbolt and remove the rear track bar from the vehicle Save the hardware for reuse 4 Unbolt and remove the rear shocks from the ve hicle Save the hardware for reuse 5 Unbolt and remove the rear sway bar end links from the vehicle 6 Unbolt the brake line bracket from the frame Save the hardware for reuse 7 Unclip the ABS line from the axle 8 Lower the rear differential so that the springs come loose Remove the OE coil springs and the OE isolators Label the springs as to which side they were removed Left and Right so that they are reinstalled in the side in which they were removed NN ER gt E Rear Upper B D Pocket j M ES 4 2 b iw ug j A an T u s c d i Install Rear Suspension Install the track bar drop bracket 82 TM20038 into the track bar mounting position using the previously removed 9 16 X 3 1 2 bolt hard ware and sleeve 35 TM30037 82 TM20038 Track
13. ition Before you install the kit thoroughly inspect the vehicle for corrosion or defor mation of the sheet metal If the vehicle is suspected to have been in a collision or misused do not install this kit Off road use of your vehicle with this kit in stalled may increase the stress applied to the factory components Failure to observe this warning may result in serious personal injury and or severe dam age to your vehicle KIT TM3340 40013 w Nitro Shocks WARNING Many states and municipalities have laws restricting bumper heights and vehicle lifts Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law WARNING The installation of larger tires may reduce the effec tiveness of the braking system WARNING Always wear eye protection when operating power tools WARNING Before you install this kit block the vehicle tires to prevent the vehicle from rolling WARNING DO NOT combine suspension body or other lift de vices Use of vehicle with combined lifts may result in unsafe and or unexpected handling characteris tics Lift height may vary depending on vehicle configura tion engine size additional accessories the factory suspension package and vehicle s condition Trail Master recommends using thread locking com pound on the threads of all kit nuts and bolts unless specified otherwise in these instructions INSTALLATION WORKSHEET SAVE WITH
14. mp stops Products with evident damage caused by abrasion or contact with other items e Damage caused as a result of not following recommendations or requirements called out in the installa tion manuals Products used in applications other than listed in Trail Master Suspension s catalog Components or accessories used in conjunction with other manufacturer s systems e Warranty claims without Proof of Purchase Trail Master Suspension accepts no responsibility for any altered product improper installation lack of or improper maintenance or improper use of our products E Mail info trailmastersuspension com Website www trailmastersuspension com Ph 877 695 7812 12
15. our vehicle safely Extreme care should always be taken to prevent vehicle rollover or loss of control which can result in seri ous injury or even death Always avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking Trail Master Suspension reminds you to fasten your seat belts at all times and re duce speed We will gladly answer any questions concerning the design function maintenance and cor rect use of our products Please make sure your Dealer Installer explains and delivers all warning notices warranty forms and instruction sheets included with Trail Master Suspension product Application listings in this catalog have been carefully fit checked for each model and year denoted How ever Trail Master Suspension reserves the right to update as necessary without notice and will not be held responsible for misprints changes or variations made by vehicle manufacturers Please call when in question regarding new model year vehicles not listed by specific body or chassis styles or vehicles not originally distributed in the USA Please note that certain mechanical aspects of any suspension lift product may accelerate ordi nary wear of original equipment components Further installation of certain Trail Master Suspension products may void the vehicle s factory warranty as it pertains to certain covered parts it is the con sumer s responsibility to check with their local dealer for warranty coverage before in
16. senger side skid plate bolts 10 Lower the jack carefully remove the OE coil springs and the OE isolators Label the springs as to which side they were removed Left and Hight so that they are reinstalled in the side in which they were removed Install Front Suspension 1 Place the front bump stop extension 90 TM10001 on the lower spring mount Center the extension and mark with a center punch 2 Use the previously applied mark to drill a hole in the lower spring mount using a 5 16 drill bit Pre tap the hole using the supplied 3 8 X 2 self tapping screw 90 TM10001 Bump Stop Extension cim i Front Axle 1 4 EN E gt 3 Install the front track bar relocation bracket 82 TM20032 into the original track bar mounting pocket using the OE bolt and supplied spacer 35 TM30024 4 Secure the track bar relocation bracket to the axle mounting pocket using the supplied 5 16 X 1 bolts and hardware 5 Use the 2 holes in the support leg of the track bar bracket as a guide to center punch and drill TM3340 60020 the mounting holes in the axle upper control arm pis i E J Front Coil mount Drill the holes using a 5 16 drill bit SM Spring 6 Bolt the support leg of the track bar bracket to O the upper control arm mount using the supplied 90 TM10001 5 16 X 1 bolts washers and nut plate 35 A Bump Stop TM20036 i LA z Extension 7 Torque the 5 16
17. stallation of the lift Warranty and Return policy Trail Master Suspension warranties its full line of products to be free from defects in workmanship and materials Trail Master Suspension s obligation under this warranty is limited to repair or replacement at Trail Master Suspension s option of the defective product Any and all costs of removal installation freight or incidental or consequential damages are expressly excluded from this warranty Trail Master Suspension is not responsible for damages and or warranty of other vehicle parts related or non related to the installation of Trail Master Suspension product A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will assume all risk and responsibility for potential dam ages incurred as a result of their chosen modifications Warranty coverage does not include consumer opinions regarding ride comfort fitment and design Warranty claims can be made directly with Trail Mas ter Suspension or at any factory authorized Trail Master Suspension dealer IMPORTANT To validate the warranty on this purchase please be sure to mail in the warranty card Claims not covered under warranty Parts subject to normal wear this includes bushings bump stops ball joints tie rod ends and heim joints Discontinued products at Trail Master Suspension s discretion Bent or dented product e Finish after 90 days Leaf or coil springs used without proper bu

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