Installation Instructions
Contents
1. 4 5 Lift Kit Installation Instructions Jeep ZJ Grand Cherokee 1993 1998 Box 1 22x22x6 ZJ 4 5 Front springs 96015 1 pair ZJ 4 5 Rear springs 96016 1 pair Box 2 36x8x8 Instructions Invoice Iron Rock Off Road logo decal 1 Ironrockoffroad com decal 1 XJ ZJ double shear adjustable track bar 1 Track bar male threaded end 1 Double shear track bar bracket 1 ZJ rear track bar 31 7 center to center 1 Rear sway bar link set 007 1 set Front sway bar links 8 75 center to center 2 ZJ t case drop spacers 2 Standard shocks without shock upgrade Front shocks RC 8170 2 Rear shocks RC 8111 2 Hardware kit 9 shocks Front shock barpin BP7 2 With nitro shock upgrade only Front shocks RC 9170 2 Rear shocks RC 9111 2 Hardware kit 9 shocks Front shock barpin BP7 2 With DT8000 shock upgrade only Front shocks DT 8386 2 Rear shocks DT 8371 2 Hardware kit 9 shocks Front shock barpin BP7 2 With Bilstein shock upgrade only Front shocks BE5 6248 H5 2 Rear shocks BE5 A465 H8 2 Hardware kit 17 Bilstein Shocks WJ ZJ Front Barpin BP7 2 12mm Shock Sleeves 6 SBL U Brackets 2 1 2 x 1 1 2 Hex Bolt 2 1 2 Hex Nut 2 1 2 Flat Washer 2 1 2 Lock Washer 2 M12x60 Hex Bolt 2 M12 Hex Nut 2 Hardware kit 11 front2. Install barpins into front shocks Lubricate shock bushings and barpins with multi purpose grease clamp barpin vertically in a bench vise and push shock onto barpin rotating the shock as you push down 33 Install front shocks using original barpin bolts Tighten upper stud mount nuts just enough to slightly compress the bushings Note Overcompressing these bushings will result in damage to the bushings and premature bushing failure 34 Torque shock barpin bolts to 17 foot pounds 35 Any remaining loose bolts will be tightened after rear suspension is installed Rear Suspension 36 Lift rear of vehicle and support with tall jack stands under the unibody frame Tip break lug nuts loose before lifting vehicle if necessary 37 Ensure that the vehicle is safely supported 38 Remove rear tires 39 Support rear axle with floor jack do not lift vehicle 40 Remove rear shocks 41 Remove rear sway bar links 42 Remove rear track bar most ZJ s require a T55 torx socket for the track bar bolts 43 Loosen all rear upper and lower control arm bolts do not remove Note Bushing damage will occur if you skip this important step 44 Allow axle to droop as much as possible 45 Remove coil spring clamps 46 Using a coil spring compressor remove rear coil springs and install the provided new springs If you do not have a coil spring compressor you can unbolt the lower control arm at the unibody to achieve enough droop to install the sp
3. at attaches track bar to unibody 8 Loosen all front upper and lower control arm bolts do not remove Note Bushing damage will occur if you skip this important step 9 Allow axle to droop as much as possible 10 Remove front coil spring clamps 11 Using a coil spring compressor remove front coil springs and install new ones If you do not have a coil spring compressor you can unbolt the lower control arm at the unibody to achieve enough droop to install the spring Re connect the first lower control arm before unbolting the second 12 If you disconnected the drag link in step 11 re connect it torque to 55 foot pounds and install cotter pin 13 Locate front track bar track bar mounting bracket and hardware kit 20 14 Install jam nut onto threaded end of track bar 15 Adjust the length to 33 3 4 front center to center as a starting point This may need to be adjusted after a short test drive Do not tighten jam nut at this time 16 Install the track bar bracket onto the unibody and torque bolts to 92 ft lbs 17 Lubricate track bar bushings and bushing sleeves with multi purpose grease and install into track bar smaller I D bushing sleeve is installed at axle end without adjusting threads and larger I D sleeve at unibody end with adjusting thread 18 Install the track bar and torque bolt at axle to 74 ft lbs and bolt at bracket to 80 ft lbs 19 Tighten jam nut very tight 20 Locate front sway bar lin
4. brake line relocation kit 1 4 x 1 self drilling sheet metal screw 2 Hardware kit 12 t case drop M10 x 60mm hex bolt 4 3 8 washer 4 Hardware kit 13 rear track bar Track bar bushing half 4 Track bar bushing sleeve 12mm I D 2 M12 x 70mm class 10 9 hex bolt 2 M12 class 10 9 hex nut 1 Hardware kit 20 front track bar Track bar bushing half 4 7 16 I D track bar bushing sleeve 1 7 16 x 2 1 2 lg gr8 hex bolt 1 7 16 gr8 hex nut 1 12mm track bar bushing sleeve 1 7 16 flat washers 2 Iron Rock Off Road Inc 952 210 7185 Website www ironrockoffroad com E mail Contactus ironrockoffroad com 12mm x 80 hex bolt class 10 9 1 12mm hex nut class 10 9 1 7 8 14 jam nut Hardware kit 58 front sway bar links 3 4 I D hourglass shock bushings 4 12mm I D sway bar bolt sleeves 4 12mm x 60mm class 10 9 hex bolt 2 12mm class 10 9 hex nut 2 M10 x 30 cl10 9 hex bolt 2 3 8 USS washer 2 M10 cl10 9 hex nut 2 Sway bar link u bracket 2 Installation Instructions Safety Warning Important Read before installation Installing a suspension lift kit raises the center of gravity of the vehicle This increases the possibility of a rollover accident Avoid sudden maneuvers at high speed and avoid all situations where a side rollover may occur In addition larger tires decrease brakin
5. d may cause unpredictable steering and accelerated tire wear Recommended caster setting 3 75 to 6 0 4 5 degrees is recommended unless a different setting is required for proper driveshaft running length Recommended toe in setting 0 degrees Re torque all fasteners including lug nuts after 100 miles and frequently inspect all safety critical suspension components ZJ 4 5 inch lift install doc Rev 3 1
6. g performance please drive accordingly We recommend a tire and wheel combination that makes the vehicle s track width wider wheels with less backspacing This will lower the center of gravity and add stability We also recommend that this system be installed by a qualified professional Knowledge of suspension component function is necessary for safe installation and post installation inspections Be sure to re torque all suspension components after the first 100 miles of use and frequently inspect all safety critical suspension components Before you begin o Read all safety warnings o Read and understand installation instructions o A coil spring compressor will make installation much easier but is not required You may wish to rent or buy one if you don t have one o Check all steering and suspension components for wear and replace as needed o Contact Iron Rock Off Road with any questions before during or after installation o Ensure that all parts are present and in good condition per attached shipping checklist Front suspension 1 Lift front of vehicle and support with tall jack stands under the unibody frame Tip break lug nuts loose before lifting vehicle if necessary 2 Ensure that vehicle is safely supported 3 Remove front tires 4 Support front axle with a floor jack do not lift vehicle 5 Remove front shocks 6 Remove front sway bar links 7 Remove front track bar and the bracket th
7. ks 8 75 center to center two u brackets and hardware kit 58 21 Install sway bar link u brackets to the sway bar using 1 2 x 1 1 2 grade 8 hex bolts lock washers and nuts Brackets mount to the bottom of the sway bar with the bolt facing up and the lock washer and nut on top of the sway bar Rotate brackets until offset toward outside of vehicle Align brackets torque bolts to 95 foot pounds 22 Lubricate sway bar link bushings and bushing sleeves with multi purpose grease and install into sway bar links 23 Install sway bar links driver s side first using provided M12 x 60mm hex bolt and nut through the u bracket with the nuts toward the outside of the vehicle and the original bolt nut and washer at the axle Torque all nuts to 78 foot pounds 24 Locate hardware kit 11 25 On one side remove the bolt that holds the brake hose to the unibody 26 Pull brake line down as far as possible without over stressing or causing a kink in the line Note Your brake line may appear different from the photo Do not pull too far and damage the brake line 27 Using two adjustable wrenches bend brake line bracket mounting surface so brake line points out toward the brake caliper See photo 28 Mark location and drill a 1 4 hole for the brake line locating tab 29 Fasten brake line to unibody using provided self drilling sheet metal screw 30 Repeat for other side 31 Locate front shocks and hardware kit 9 32
8. nuts to 60 foot pounds 59 Torque front and rear lower control nuts to 120 foot pounds 60 Tighten any jam nuts very tight 61 Torque any remaining loose bolts to spec 62 Install tires 63 Remove vehicle from jack stands 64 Torque wheel lug nuts to spec usually 85 115 foot pounds verify using factory service manual Transfer Case Drop Kit 65 Locate transfer case drop spacers and hardware kit 12 66 Place a floor jack under the center of transfer case crossmember for support 67 On one side remove the two bolts that hold the t case crossmember to the unibody 68 Lower t case crossmember away from unibody 69 Install spacer using new bolts and washers Torque bolts to 50 foot pounds 70 Repeat for the other side Adjustments and Safety Inspection 71 Check all components for clearance for suspension to fully cycle up and down and wheels to turn lock to lock Pay special attention to brake line length and location of all brake lines axle vent hoses and ABS wires Reposition as needed 72 Check front and rear driveshafts for proper running length Slight adjustments can be made by adjusting caster angle otherwise different length control arms or custom driveshafts may be required 73 Go for a short test drive 74 Check if front tires are centered side to side under vehicle Adjust the length of the front track bar as needed 75 A professional front end alignment is required after installation Your toe in will be affected an
9. ring Re connect the first lower control arm before unbolting the second 47 Locate rear track bar and hardware kit 13 48 Lubricate track bar bushings and bushing sleeves with multi purpose grease and install If installing an adjustable rear track bar install jam nut onto threaded end of track bar adjust the length to 31 3 4 center to center 49 Using provided new bolts and nut install the track bar with the bend at the unibody end The bend is for exhaust clearance 50 Torque track bar bolts to 78 foot pounds 51 Install 12mm I D sleeves into lower body end of rear shocks opposite end from shock shaft Lubricate shock bushings and 12mm I D sleeves with multi purpose grease and press the sleeves into the shock bushings 52 Lubricate upper shock bushings and upper shock mounting studs on the vehicle with multi purpose grease 53 Install rear shocks with shock shafts facing up Torque upper nuts to 46 foot pounds and lower nuts to 80 ft lbs 54 Raise vehicle and relocate the jack stands under the front and rear axles so that the vehicle s weight is on the suspension system 55 Ensure that the vehicle is safely supported 56 Install rear sway bar links with nuts facing down Tighten nut until snug but do not compress the bushings the spacer sleeve in the center of the link should still be able to be rotated by hand after tightening 57 Install front and rear coil spring clamps 58 Torque front and rear upper control
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