TERAFLEX 1365000, Manual

Page 1: ...you are experienced and capable to personally perform these modifications A factory service manual should be used in conjunction with these installation instructions This product will change the highway handling characteristics of your vehicle exercise caution After altering the suspension it is always advisable to have an alignment done by a competent 4 wheel drive shop or by an alignment shop th...

Page 2: ... OD Flat Washer 45 10 003 003 4 4 4 4 M10 X 1 50 X 70mm Hex Head Bolt 45 21 001 001 2 2 2 2 M10 x 1 5 Fuji Nut 23 07 03 001 2 2 2 2 M10 x 1 5 x 100mm Flat Socket Cap Screw 45 04 003 001 2 2 2 M8 x 1 25mm Yellow Zinc Fuji Nut 23 07 03 002 4 4 4 M8 x 1 25 x 30mm Hex Flange Bolt 45 02 003 016 4 4 4 4 Rear Upper Bumpstop Spacer 56 10 05 044 1 1 2 2 2 2 Nut Wrench Tool 600271 1 1 1 M14 x 1 5 x 80mm Hex...

Page 3: ...Sway Bar Quick Disconnect 1764000 1 1 1 Front Brake Line Anchor Kit 1101255 1 1 1 Rear Brake Line Anchor Kit 1101455 1 1 1 Rear Trail Rate Forged S T Swaybar Kit 1774700 1 1 1 Front Drop Bracket Kit 1938125 1 Rear Control Arm Bracket Kit 1938225 1 1 1 Rear Track Bar Bracket 1963600 1 1 1 JT Driveline Spacer Kit 4801000 1 1 1 JT Extended Travel Accessory Kit 4834100 1 1 1 JT Rear Upper Lower Spring...

Page 4: ...ontinuing refer to Instruction 999370 FOR FRONT TRACK BAR Refer to Instruction 999340 FOR FRONT TRACK BAR BRACKET Refer to Instruction 999341 FOR REAR TRACK BAR Refer to Instruction 999384 FOR FRONT QUICK DISCONNECTS Refer to Instruction 999372 FOR FRONT BRAKE LINE ANCHORS Refer to Instruction 999267 FOR REAR BRAKE LINE ANCHORS Refer to Instruction 999396 FOR REAR TRAIL RATE FORGED S T SWAYBAR Ref...

Page 5: ...FRONT INSTALLATION NOTES FOR REAR TRACK BAR BRACKETS Refer to Instruction 999391 FOR JT DRIVELINE SPACER KIT Refer to Instruction 999401 FOR JT EXTENDED TRAVEL ACCESSORY KIT Refer to Instruction 999402 FOR JT REAR UPPER LOWER SPRING RETAINERS Before continuing refer to Instruction 999389 ...

Page 6: ...RACK BAR BOLT AT THE AXLE REMOVE DRIVER SWAY BAR LINK REMOVE NUT 18mm REMOVE NUT 18mm REMOVE BOLT 18mm REMOVE DISCARD STUD 6mm 4 5 STUD 6mm NUT 18mm BOLT 18mm REMOVE DISCARD BOLT 18mm STUD 6mm HEX REMOVE DISCARD BOLT 18mm REMOVE NUT 18mm REMOVE NUT 18mm SUPPORT THE FRONT AXLE 3 ...

Page 7: ...TUATORS AND VENT HOSE AT THE FRONT AXLE LOOSEN FRONT CONTROL ARM BOLTS NOTE DO NOT REMOVE THE CONTROL ARM BOLTS PRY OPEN REMOVE NUT 15MM 6 7 8 LOOSEN BOLT NUT 18mm LOOSEN BOLT 21mm NUT 24mm NOTE IF INSTALLING ALPINE ARMS REFER TO INSTRUCTION 999373 NOTE IF INSTALLING FRONT DROP BRACKETS REFER TO INSTRUCTION 999309 ...

Page 8: ...INGS NOTE REMOVE ANY PLASTIC RETAINERS FROM WIRING OR HOSES AS NEEDED 9 BOLT NUT 18mm BOLT 18mm 10 REMOVE FRONT SHOCKS INSTALL FRONT SPRINGS AND LOWER BUMPSTOPS NOTE REFER TO PAGE 16 FOR BUMPSTOP AMOUNT 3 1 11 NOTE IF INSTALLING SPEEDBUMP KIT REFER TO INSTRUCTION 999370 ...

Page 9: ...THE JEEP TO THE GROUND BEFORE TORQUING THE CONTROL ARM BOLTS NOTE IF INSTALLING CONTROL ARMS WITH ALPINE IR BUSHINGS THE CONTROL ARM BOLTS CAN BE TORQUED WITH THE JEEP RAISED REFER TO PAGE 15 FOR TORQUE SETTINGS 12 MAKE SURE SPRING IS FULLY SEATED ON PERCH INSTALL THE BUMPSTOP ONTO THE AXLE AND FULLY SEAT THE SPRINGS INTO THE LOWER SPRING PERCH NOTE IF INSTALLING FRONT BRAKE LINE ANCHORS REFER TO ...

Page 10: ... TO THE GROUND BEFORE LIFTING THE REAR 9 TORQUE 59 FT LBS BOLT 18mm TORQUE 66 FT LBS NUT 18mm STUD 6mm HEX KEY 15 TORQUE THE FRONT TIRES TO 130 FT LBS 17 NOTE IF INSTALLING QUICK DISCONNECTS REFER TO INSTRUCTIONS 999372 18 NOTE IT IS EASIEST TO REINSTALL TRACK BAR AFTER JEEP IS BACK ON THE GROUND NOTE IF INSTALLING FRONT TRACK BAR REFER TO INSTRUCTION 999340 NOTE FOR INSTALLING FRONT TRACK BAR BRA...

Page 11: ...www TERAFLEX com 11 Revision B 999376 REMOVE REAR TIRES REAR INSTALLATION SUPPORT REAR AXLE 19 21 20 LIFT AND SUPPORT AT FRAME 22 REMOVE SWAY BAR LINKS BOLT 19mm BOLT 18mm ...

Page 12: ...EN BOLT 21mm NUT 24mm 26 REMOVE THE REAR SHOCKS BOLT NUT 21mm BOLT 21mm 23 BOLT 10mm TEMPORARILY REMOVE BRAKE LINE BRACKETS FROM BOTH SIDES OF THE FRAME NOTE IF INSTALLING ALPINE ARMS REFER TO INSTRUCTION 999373 NOTE IF INSTALLING REAR CONTROL ARM BRACKETS REFER TO INSTRUCTION 999398 NOTE IF INSTALLING EXTENDED TRAVEL ACCESSORY KIT REFER TO INSTRUCTION 999402 ...

Page 13: ...STALLING FALCON SHOCKS REFER TO QUICK START GUIDE INSIDE FALCON SHOCK BOX NOTE IF INSTALLING CONTROL ARMS WITH ALPINE BUSHINGS AND THE JEEP WAS RAISED FOR INSTALLATION LOWER THE JEEP TO THE GROUND AND FINISH INSTALLATION BY TORQUING THE CONTROL ARM BOLTS NOTE IF INSTALLING CONTROL ARMS WITH ALPINE IR BUSHINGS THE CONTROL ARMS CAN BE TORQUED WITH THE JEEP RAISED IN THE AIR REFER TO PAGE 15 FOR TORQ...

Page 14: ...3mm NUT 12mm 32 33 13 11 6 INSTALL UPPER BUMPSTOP SPACER NOTE REFER TO PAGE 16 FOR SPACER AMOUNT TWIST AND PULL DOWN TO REMOVE BUMPSTOP FROM FRAME TWIST AND PUSH UP TO INSTALL BUMPSTOP INTO SPACER TORQUE 40 FT LBS BOLT 15mm NUT 14mm REINSTALL THE BRAKE LINE BRACKETS TO THE FRAME TORQUE 6 FT LBS BOLT 10mm 17 5 11 12 NOTE IF INSTALLING REAR BRAKE LINE ANCHORS REFER TO INSTRUCTION 999396 NOTE IF INST...

Page 15: ...UCTION 999384 NOTE IF INSTALLING REAR TRACK BAR BRACKET REFER TO INSTRUCTION 999391 TORQUE REAR BOLT 21mm 100 Ft Lbs TORQUE REAR CONTROL ARM TORQUE FRONT CONTROL ARMS TORQUE 111 Ft Lbs 95 REF 240 260 Ft Lbs BOLTS 21mm NUTS 24mm TORQUE 111 Ft Lbs 65 REF 180 200 Ft Lbs TORQUE 111 Ft Lbs 90 REF 250 270 Ft Lbs TORQUE 111 Ft Lbs 60 REF 200 220 Ft Lbs TORQUE 103 Ft Lbs 145 REF 230 250 Ft Lbs BOLT 21mm N...

Page 16: ...stalling on a Eco Diesel Jeep the jounce tubes are 1 375 longer so you should subtract 1 375 from the front bump stop stack A minimum of 2 bump stop is needed if 3 5 4 5 Lift Falcon Shocks are installed TeraFlex Bump Stop Strike Pad Extensions allow the use of larger tires and factory fender flares by limiting suspension up travel JT Rubicon models feature high clearance fenders that allow for mor...

Page 17: ...nob High Flow Oil Channel Offset Sleeve Design PiggyBack Reservoir JT Falcon PiggyBack Shocks 4 Door Series 3 1 14 02 31 400 150 JT Falcon Monotube Shocks 4 Door Series 2 1 14 02 21 400 200 Oil Gas Separator 3 4 Chrome Shaft Offset Sleeve Design JT Specific Shock Series 3 3 Upgradable High Flow Oil Channel Offset Sleeve Design PiggyBack Reservoir ...

Page 18: ... 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 s...