TJ Wrangler Long Arm Suspension Kit Instructions
Contents
1. TeraFlex Inc 5680 W Dannon Way West Jordan UT 84081 Phone 801 288 2585 Fax 801 713 2313 www teraflex com INSTALLATION GUIDE Installation Guide for the TJ Long Arm Suspension System Kit Part 001447000 STL x 4 le Te eo g This kit is designed specifically for use with TeraFlex lifts and suspensions It replaces standard length control arms with new longer control arms The upgrade will improve on road driving comfort as well as off road performance There have been some in line changes made to the Long Arm kit that will require the modifica tion of the factory skid plate or the purchase of the TeraFlex s new Belly Up skid plate Part BUT 03 Please be sure that you understand what is required before you begin the installation of this kit INSTALLATION WARNING We recommend that certified technicians perform this installation Attempts to install this product without proper training or experience may jeopardize the safety of you and the vehicle These instructions are meant only as a guideline for the installation procedure and are not meant as the definitive source The Factory Service Manual should be used in conjunction with this instruction guide when installing the components Read this instruction guide thoroughly before beginning the installation process Be sure you have all needed parts and know where they will be installed Read each step completely as you go If any parts are missing from the2. left 1 0075R brake line ext bracket right 1 0076 1 4 28 lock nut 2 0077 1 4 28x3 4 2 TFQD67 U bracket w hardware 2 QDU U bracket amp stud 2 0083 3 8 lock nut 2 0084 3 8 flat washer 2 QD12 tapered insert 2 QD10 sleeve 2 00425 3 8 x1 75 bolt 2 00QD132 link w bushings amp zerks 2 INSTALLATION 1 Prior to starting the installation remove the stock sway bar links 2 After removing the sway bar links identify the left and right quick disconnects One way to tell is that the bolt head will point away from the vehicle in its final position Place the sleeve on the threaded bracket bolt and screw the quick disconnect assembly into the hole vacated by the previous bolt 4 Attach the sway bar stud to the lower mount bracket on the axle 3 Once the assembly has been inserted into place please make sure that the grease zerk points downward away from the vehicle Add the washer and nut and secure with a 9 16 wrench 5 Insert the stainless steel stud in the hole vacated by stock sway bar arm so that the threaded end of the stud points away from the vehicle Driver side Passenger side 6 Use the pin for leverage when tighten ing the nut with a 3 4 wrench Revised 9 May 06 help keep it secure 15 Once the securing stud is ready you can attach the disconnected sway bar arm out of the way against the frame Brake Line Extension installation 7 Now you can attach the
3. 3 year warranty to be free of defects in materials and workmanship This warranty does not cover or include product finish improperly installed or applied products improperly maintained products products or components used for racing or competition or damage due to abuse or neglect products that fail due to the use of larger tire and wheel combinations All returns must be accompanied by an original invoice It is the customer s responsibility to remove the product from the vehicle Shipping charges are the responsibility of the customer Tera Manufacturing will pay the return freight This warranty is for the replacement or repair of defective TeraFlex products only and does not include freight charges labor charges for removal of or installation of TeraFlex or related products or components costs incurred due to down time of the vehicle or lost profits due to vehicle down time A returned goods authorization number RGA must accompany any returned products For more information please contact a TeraFlex customer service representative Revised 9 May 06 TeraFlex Front Sway Bar Discon nects for TJs Part 00 1 143 0 10 Please make sure that your kit includes the following items before starting installation Part Description Quantity CPQDFT component hardware bag 1 00QD11 nut 1 2x20 2 00QD4 lower stud 3 4 2 00QD5 upper stud 5 8 2 00QD9 stud pin 2 00380 3 4 QD washer 2 00478 1 2 lock washer 2 0075L brake line ext bracket
4. kit please call 801 288 2585 for replace ment Take every precaution to make this installation a safe procedure Make safety the number One priority with any suspension or lift installation Read all safety warranty and maintenance information included at the end of the instruction guide Please make sure that your kit includes the following items before starting installation Part Description Quantity 250L2 Long arm bracket left 1 250R2 Long arm bracket right 1 BOLT 3 8 16x1 3 8 16x1 SELF TAP BOLT 6 977 26 Lower FlexArm TJ Fr amp Rr 4 QDFT Sway bar quick disconnect kit 1 SBSPT Steering box skid plate kit 1 CHANGES The main bracket in TeraFlex s Long Arm Kit has had some changes to the rear lower control arm mount that improves the overall geometry of the suspension and allows the use of TeraFlex s popular modular control arms Another advantage is that this new bracket design makes it possible to upgrade to the triangulated four link LCG suspen sion without changing and discarding your long arm bracket In the future the rear Suspension can be upgraded to the triangulated 4 link while the front suspension can be done either at the same time as the rear or at a later date Revised 9 May 06 PASSENGER SIDE INSTALLATION 1 Lift vehicle off ground and secure with jack stands 2 If the TJ is equipped with factory side steps remove them 3 Starting on the passenger side first remove the front and rear lower con trol
5. sway bar arm 12 In order to install the stainless stud to the stud mount for securing the sway bar and arm 8 Slide the polyurethane bushing onto when disconnected you will need a the lower stainless steel stud The use hand drill We suggest drilling a pilot of a lubricant such as WD 40 will make hole with a smaller drill bit Using a this much easier 5 16 bit drill through the pilot hole 13 Use a tap wrench and a 3 8 tap to 1 Remove the Torx bolt that secures the brake line to the frame 2 Using 1 4 bolt and nut supplied secure brake line to the bracket 9 Place the washer on the side opposite the bolt 10 Secure the arm in place using the washer and pin thread the hole for the stainless steel securing stud The 3 8 self tapping bolt could also be used to thread the hole Extra care should be used to make sure the tap is perpendicular to the frame 14 With a pin in the stud twist the 3 Line up bracket with holes in the frame so the bracket extends down 4 With the bracket in place use Torx bolt to secure the bracket to frame A ie securing stud into place A drop of Loc Tite on the stud s threads will P Pe a x 11 Use the connected sway bar arm to determine the proper location for the securing stud Position the arm out of the way and mark the center of the bushing where it rests against the frame This is where we will attach the securing stud Rev
6. view This sticker is to act as a constant safety reminder when operating the vehicle It is your responsibility as the equipment installer to install the provided sticker and to forward the product instructions to the vehicle s owner for review If a Warning to Driver sticker or product installation guide were not included in the kit FREE replacement stickers and instructions are available by request It is the installer s duty to ensure a safe and controllable vehicle after the modifications have been performed WARNING Neither the seller nor the manufacturer will be liable for any loss damage or injury directly or indirectly arising from the use of or inability to determine the use of these products Before using the user shall determine the suitability of the products for its intended use and the user shall assume all responsibility and risk in connection therewith WARNING TO DRIVER This vehicle has been modified to enhance off road performance and has unique handling characteristics Use in harsh environments can cause extreme stress on the components Vehicle should be inspected after being off road to make sure that all the components are in working order and safe to travel on the highway All fasteners should be checked so that they are at the correct torque specifications as the vibration and stresses from off roading may cause critical fasteners to work loose Extra care should be taken to inspect the critical components stee
7. VER SIDE Y A NZ TJ 2003 DRIVER SIDE Diagram 1 AT 2003 rt onan SID S Ty 2002 AND OLDER PASSENGER SIDE is enough clearance cycle the arms through it s full range of movement to make sure that enough material is removed from the skid plate Typical skid plate AO necessary on 97 02 vehicles 10 2003 current TJs The 2003 and newer TJ skid plate s sit closer to the rear of the TJ than previous models this requires more extensive trimming of the factory skid plate than 97 02 models Typical skid plate modifications necessary on 03 current vehicles 11 Position the control arm bracket assembly to the underside of the frame rail Temporarily attach the control arm bracket to the frame using the bolts from the skid plate Use Diagram 1 to properly locate the holes that will be used with the vehicle s model year 12 Make sure that the bracket aligns properly with the holes in the under side of the frame 13 Secure the bracket by tack welding both sides of the bracket to the frame NOTE Make the tack welds about 1 1 2 inches long 14 Connect the front lower long FlexArm to the new bracket then connect the FlexArm to the axle and connect with the stock bolts 15 Connect the new rear lower FlexArm to the bracket and to the axle Lengthen or shorten the control arm to adjust for proper pinion angle Secure with the stock bolts Note With a TeraFlex four inch suspen si
8. arms Note It is important to remove the control arms from only the passenger side at this time This helps to keep the axle positioned correctly The driver s side will follow later 4 Remove the lower control arm mounts from the vehicle Grind the welds away and use a chisel to separate the bracket from the frame 5 Buffing and painting the bracket area will improve appearance and minimize rust 6 Support the transmission and transfer case with a jack 7 Remove the transfer case skid plate or belly pan It will be necessary to either use TeraFlex s BellyUp skid plate part BUT 03 or modify the stock skid plate 8 TeraFlex s new BellyUp Skid Plate Part BUT 03 is recommended to comple ment the Long Arm kit We recommend this because of the time and effort required to make the stock skid plate fit with the long arm bracketry The BellyUp Skid Plate is laser cut from 3 16 thick steel for superior protection and its low profile provides up to an additional 1 5 8 of ground clearance If the new BellyUp skid plate is not purchased the factory skid plate must be modified as to allow enough clear ance for the bracket and rear lower control arms 9 1997 2002 TJs To trim the factory Skid plate lay the long arm bracket on top of the factory skid plate using the correct holes for your TJ see diagram 1 Trim the plate and place the brack ets and arms on top to be sure there TJ 2002 AND OLDER 7 ORI
9. he equipment installer to install the provided sticker and to forward the product instructions to the vehicle s owner for review If a Warning to Driver sticker or product installation guide were not included in the kit FREE replacement stickers and instructions are available by request It is the installer s duty to ensure a safe and controllable vehicle after the modifications have been performed WARNING Neither the seller nor the manufacturer will be liable for any loss damage or injury directly or indirectly arising from the use of or inability to determine the use of these products Before using the user shall determine the suitability of the products for its intended use and the user shall assume all responsibility and risk in connection therewith WARNING TO DRIVER This vehicle has been modified to enhance off road performance and has unique handling characteristics Because of the higher center of gravity and larger tires this vehicle handles and reacts differently than many passenger cars both on and off road You must drive it safely Extreme care should be taken to prevent vehicle rollover or loss of control which can result in serious injury or death Avoid sudden sharp turns or abrupt maneuvers Generally braking performance and capabilities are decreased when significantly larger heavier tires are used especially when used in combination with transfer case low range reduction kits Take this into consideration while dri
10. ignment steering system suspension and drive line systems must be inspected by a qualified professional mechanic at least every 3000 miles TERAFLEX PRODUCT WARRANTY Tera Manufacturing warrants TeraFlex Suspension products to the original retail purchaser to be free of defects in material and workmanship for as long as the original purchaser owns the vehicle on which products were originally installed Failure to complete regular maintenance grease every 3000 miles on TeraFlex FlexArms will void this warranty All other conditions of the standard TeraFlex product warranty apply All TeraLow products are covered by TeraFlex s two 2 year warranty to be free of defects in material and workmanship for two years from date purchased Tera axles are covered by a 12 month warranty to be free of defects in materials and workmanship This warranty does not cover or include product finish improperly installed or applied products improperly maintained products products or components used for racing or competition or damage due to abuse or neglect products that fail due to the use of larger tire and wheel combinations All returns must be accompanied by an original invoice It is the customer s responsibility to remove the product from the vehicle Shipping charges are the responsibility of the customer Tera Manufacturing will pay the return freight if the product meets the terms of warranty This warranty is for the replacement or repair of defect
11. is attached to the frame by the tack welds performed previously 23 Replace skid plate and secure with bolts Tighten securely 24 Check to make sure all bolts are prop erly tightened NOTE It is highly recommended that you apply 1 2 stitch welds to permanently secure the bracketry to the frame ALIGNMENT NOTES After installation of the TeraFlex Long Arm suspension kit it is imperative that the front end alignment angles be checked It is recommended that your TJ be taken to a reputable alignment shop that understands 4WD vehicles and has experience with their alignment param eters Caster might be changed with the installation of our suspension kit It is recommended that the factory specifica tions be maintained Toe in is also important for tire wear Toe in may be affected on a three inch kit and will be affected on a four inch kit It has been recommended that the toe in be set to minimum factory speci fications if you go to the larger tire and wheel set up MAINTENANCE INFORMATION It is the buyer s responsibility to have all suspension drivetrain steering and other components checked for proper tightness and torque after the first 100 miles and every 3000 miles after that NOTICE TO INSTALLER The enclosed Warning to Driver sticker must be installed in the vehicle in driver s view This sticker is to act as a constant safety reminder when operating the vehicle It is your responsibility as t
12. ised 9 May 06 Installation guide for TJ Steering Box Skid Plate Part 004327400 SBSPT Please make sure that your kit includes the following items before starting installation Part Description Quantity OOSBSP2G skid plate 1 0080 3 8 16x1 self tap bolt 1 2 Hold skid plate in place make sure that the holes line up 3 With the skid plate in position replace p1 f N N f d a 4 Sf 2 r 7 6 A x P A Pi 4 NY r 4 z f y 4 IH i Z P w v e H 5 Use a 5 16 drill bit to drill the frame at the location you just marked 6 Screw the self tapping bolt into the the bumper bolt and steering box hole you just made and tighten mounting bolt Note Use flat washers to correct the spacing of skid plate when using stock bumper if necessary 4 With the skid plate in place locate the remaining hole in the ear of the skid plate Using the hole as a guide use a center punch to mark the location you will be drilling INSTALLATION 1 Remove the driver side lower bumper bolt and the bottom steering box mounting bolt Revised 9 May 06 Te NEX PRODUCT INFORMATION It is the buyer s responsibility to have all suspension drivetrain steering and other components checked for proper tightness and torque after the first 100 miles and every 3000 miles after that NOTICE TO INSTALLER The enclosed Warning to Driver sticker must be installed in the vehicle in driver s
13. ive TeraFlex products only and does not include freight charges labor charges for removal of or installation of TeraFlex or related products or components costs incurred due to down time of the vehicle or lost profits due to vehicle down time A returned goods authorization number RGA must accompany any returned products For more information please contact a TeraFlex customer service representative COPYRIGHT Copyright 2008 All rights reserved TeraFlex Inc Reproduction of this catalog and or any of its contents without written permission is strictly prohibited TeraFlex is a registered trademark of TeraFlex Inc All trade names and logos including but not limited to TeraFlex ee RockGuard Monster and LCG are protected by law and duplication of trade names and or logos are strictly prohibited TeraFlex Inc reserves the right to update discontinue redesign modify finish part number or component build parts if deemed necessary without written notice TeraFlex Inc and any associated dealers are not responsible for misprints or typographical errors that may have inadvertently been made within this instruction sheet Jeep and the Jeep grill are registered trademarks of Chrysler LLC and have no affiliation with TeraFlex Inc Revised 9 May 06
14. on the front control arms should be about 32 5 center to center and rear about 32 Adjust as necessary for the specific vehicle Secure with stock bolts DRIVER S SIDE INSTALLATION 16 Begin installation on the driver s side by removing the lower control arms from the driver s side of the vehicle 17 Grind control arm brackets from the vehicle and touch up as necessary 18 Connect the driver s side control arm bracket to the underside of the frame Make sure the bracket is properly aligned with the holes in the under side of the frame before temporarily Revised 9 May 06 securing with the bolts from the skid plate Use Diagram 1 as reference 19 Secure the bracket by tack welding both sides of the bracket to the frame 20 Connect the front lower long FlexArm to the new bracket then connect the FlexArm to the axle and connect with the stock bolts 21 Connect the new rear lower FlexArm to the bracket and to the axle Lengthen or shorten the control arm to adjust for proper pinion angle Secure with the stock bolts 22 Make sure all bolts are securely fas tened Note With a TeraFlex four inch suspen sion the front control arms should be about 32 5 center to center and rear about 32 Adjust as necessary for the specific vehicle Secure with stock bolts 22 Remove the three skid plate bolts from the underside of each control arm bracket Note The bracket will stay in position because it
15. ring and brake systems During each oil change components such as arms tie rod ends etc should be greased and checked for excessive wear Any worn components should be replaced When returning to the pavement always set or restore tire air pressure to the factory recommendation and connect or engage any disabled sway bar mechanisms Because of the higher center of gravity and larger tires this vehicle handles and reacts differently than many passenger cars both on and off road You must drive it safely Extreme care should be taken to prevent vehicle rollover or loss of control which can result in serious injury or death Avoid sudden sharp turns or abrupt maneuvers Generally braking performance and capabilities are decreased when significantly larger heavier tires are used especially when used in combination with transfer case low range reduction kits Take this into consideration while driving Do not add alter or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the TeraFlex product purchased Mixing component brand is not recommended TeraFlex Inc will not be responsible for any altered product or any improper installation or use of our products We will be happy to answer any questions concerning the design function and correct use of our products It is ultimately the buyer s responsibility to have all bolts nuts checked for tightness after the first 100 miles and then every 3000 miles Wheel al
16. ving Do not add alter or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the Tera Manufacturing product purchased Mixing component brand is not recommended Tera Manufacturing will not be responsible for any altered product or any improper installation or use of our products We will be happy to answer any questions concerning the design function and correct use of our products It is ultimately the buyer s responsibility to have all bolts nuts checked for tightness after the first 100 miles and then every 3000 miles Wheel alignment steering system suspension and drive line systems must be inspected by a qualified professional mechanic at least every 3000 miles TERAFLEX PRODUCT WARRANTY Tera Manufacturing warrants TeraFlex Suspension products to the original retail purchaser to be free of defects in material and workmanship for as long as the original purchaser owns the vehicle on which products were originally installed Failure to complete regular maintenance grease every 3000 miles on TeraFlex FlexArms will void this warranty All other conditions of the standard Tera Mfg product warranty apply All TeraLow products are covered by Tera s two 2 year warranty to be free of defects in material and workmanship for two year s from date purchased Tera axles are covered by a 12 month warranty to be free of defects in materials and workmanship The TeraFlex T Locker is covered by a three
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