Installation Guide for the `99 and newer Grand Cherokee four

INSTALLATION GUIDE
Note: This kit may not come as pictured or
as listed to the right. Due to suspension
revisions, some items may not be necessary,
and will not be included.
Tera Manufacturing, Inc.
5251 South Commerce Dr.
Murray, Utah 84107
Phone/801.288.2585
Fax/801.713.2313
www.teraflex.biz
Installation Guide for the ‘99 and
newer Grand Cherokee four-inch
Suspension Kit
Part #001491466 (S4W)
The TeraFlex 4” WJ Suspension System is engineered to maximize trail performance and highway handling. It will provide room to run 265/75/16 tires.
Qty.
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Item
Front track bar lowering bracket
Bolt (1/2" x 3")
Nut, 1/2" lock
Drop pitman arm
A-Arm spacer block
Bolts (14mm x 80mm) for A-Arm assembly
Front springs
Rear springs
1/2" Lock washers
3/4" Flat washers
5/16" Flat washers
14mm Lock washers
Front bump stop extensions
Bolts (8mm x 75mm) for front bump stop ext.
Front spring retainers (round alum. 3” dia. x 2 1/4” tall)
1/2" X 20 x 1.5" bolts for front spring retainers
Rear bump stop extensions
Bolts, self-tapping (3/8" x 2") for rear bump stop ext.
WJ Quick Disconnects
WJ Transfer Case Lowering Kit
Spacers, aluminum
Washers
Bolts, (10mm x 130mm)
Bolts, (10mm x 40mm)
Torque Specs.
57 - 75 ft. lbs.
78 - 104 ft. lbs.
14 - 19 ft. lbs.
23 - 31 ft. lbs.
27 - 37 ft. lbs.
27 - 37 ft. lbs.
Revised 10 May 07
Think safety first when installing your
new suspension system.
Use these instructions to install the
TeraFlex four-inch suspension system
and lift for WJ Grand Cherokees.
Installation information for the lower
control arms is included at the end of
these instructions.
Recommended tools:
Pitman arm puller
Spring Compressor
5. Position the aluminum spacer
block between the A-arm and the
top of the differential.
6. Secure the A-arm mounting
bracket and spacer to the differential using the three 14mm
x 80mm bolts included with the
kit. Torque to specifications.
Rear Installation
Hint: Connect the spacer to the
A-arm first. Because the ball joint
can be rotated, it will be much
easier to insert all three bolts
through the ball joint first, then
to the spacer and later to the differential.
Preparation
Bump Stops
Optional accessories:
Adjustable upper control arms
1. Raise the rear of the vehicle
with a floor jack and secure by
placing jack stands under the
unibody, not the axle. Removing
the tires will make installation
easier.
11. Install the shocks.
12. Reinstall tires.
Rear installation is complete.
3. Remove the rear springs. Lowering the differential will make
removal of the rear springs
easier. Remove the rubber bump
stop.
4. Raise the differential to ease
removal of the three bolts connecting the ball joint bracket to
the differential.
9. Install the springs starting with
the passenger side. Place the
rubber bump stop removed in
step 3 inside the coil before placing the spring into position.
10. Install the extended rear sway
bar links using the factory bolts.
2. Remove the shocks and remove
the rear sway bar links. Save the
bolts and nuts.
A-arm Spacer Installation
8. Torque bolts to specifications.
7. Two options exist for installing
the rear bump stops:
Vehicles with Up Country suspensions - Remove the existing bump
stop spacer and use a 10mm
bolt included with the kit to
secure the bump stop to the
upper pedestal. The Up Country’s
bump stop extensions will not be
needed.
Vehicles WITHOUT the Up Country
suspension - Drill a 5/16” hole
in the upper pedestal and tap it
using the 3/8” x 2” self-tapping
bolts.
Revised 10 May 07
Front Installation
Preparation
12. Connect the front track bar to
the lower position in the front
track bar lowering bracket using
the factory bolt. Torque bolt to
27-35 ft. lbs.
1. Secure the vehicle on jack stands
and remove the tires.
2. Disconnect the shocks, front
sway bar links, and front track
bar.
Springs
3. Remove the front springs.
4. Pry the rubber bump stop from
the bump stop cup. Remove the
two bolts inside the bump stop
cup.
Front Track Bar Lowering Bracket
9. Use the two bolts used to secure
the motor mounts to connect the
front track bar lowering bracket
to the vehicle. Remove the bolt
nearest the front of the vehicle.
Loosen the second bolt.
10. Position the bracket in place.
When properly positioned, the
new bracket will fit where the
front track bar originally connected to the vehicle and the
holes in the upper portion of the
new bracket will line up with the
locations of the bolts in step 9.
Secure in place using the bolts
removed/loosened in step 9.
5. Place the bump stop spacer
block between the bump stop cup
and frame. Secure it in place
using the 8mm x 80mm bolts
included with the kit. Replace
rubber bump stop into the cup.
Drop Pitman Arm
6. Disconnect the drag link.
7. Remove the stock pitman arm
with a pitman arm puller.
8. Install the new drop pitman arm
and reconnect the drag link.
13. It will be necessary to tap
the hole in the front upper pedestal once the spring has been
removed. Use a 1/2”-20 tap.
14. Install the front springs using
a spring compressor. Be sure
to have the retainers inside
the spring before releasing the
springs.
15. Secure the included aluminum
spring retainers to the underside
of the pedestal using the 1/2”x2”
bolts. Torque bolts.
11. Install the new 1/2” x 3” bolt
supplied in the kit in the upper
position where the original track
bar connected. Torque bolt to 3037 ft. lbs.
Quick Disconnects
16. Install the lower mounting
stud. Place the metal sleeve
where the sway bar originally
connected. The lower mounting
stud inserts where the bolt that
secured the lower end of the
sway bar link was located. The
stud portion points to the outside of the vehicle. Use Loctite
and secure with a nut.
Revised 10 May 07
Hint: A hitch pin inserted in the
mounting stud will make tightening easier. It is important to get
the pin tight. If necessary, ViseGrip type pliers can be used, but
use a piece of leather or similar
material to protect the stud’s
finish.
17. Install the upper mounting stud
into the hole in the end of the
front sway bar. Note: The upper
mounting stud is shorter than the
lower one. Use Loctite on the stud
and fasten securely.
18. The disconnect arm connects
as one piece with one eyelet for
each stud. The arm is secured in
place using washers and hitch
pins. The new arms are offset
one inch outwards at the bottom
mount.
19. Connect shocks. Replace tires.
Transfer Case Lowering Kit
Notes:
20. Starting on one side of the
vehicle, remove the four bolts
that secure the cross member
(factory skid plate) to the frame.
Keep the bolts.
Front Wheel Shimmy
Some kits may experience front wheel
shimmy. Front wheel shimmy is not
a warranty issue but rather a design
limitation to the 1999+ WJ Jeep Grand
Cherokee.
Some customers have found relief
from front wheel shimmy or “death
wobble” by using a 4-5 degree caster
and 0.25 degree toe-in adjustments.
In some cases, customers have found
that the specific tire used on the vehicle has contributed to the shimmy.
Those customers experienced positive
results by changing tires.
In most cases these adjustments will
resolve front end shimmy situations.
If other efforts have been exhausted
and the condition persists, a modification of the front lower control arm triangulation should compensate for the
design limitations of the WJ Grand
Cherokee.
This kit involves adding a simple,
weld-on bracket to the front axle
tube to further spread the mounting
points of the lower control arms. Lower
control arms that are in new condition
can be exchanged at minimal cost.
Less than five percent of units have
required this modification.
Tera Manufacturing assumes no
incurred expenses caused by the correction of this condition.
21. Position the aluminum spacers
in their proper locations between
the frame and crossmember.
22. Secure the transfer case using
the bolts removed in step 20. The
larger bolts removed from the
outer edges of the cross member
will be used to secure the cross
member where the shorter bolts
were. New bolts included with the
kit will be used in the outer bolt
locations.
23. Repeat this process for the
opposite side of the vehicle.
Pitman arm pullers
Avoid using an impact wrench on a
pitman arm puller. The sector shaft has
an aluminum locator and can brake.
Shocks
The RS9255 are a good fit for the
front. The RS9112 fits the lift, but
users may experience some internal
shock noise.
FlexArm System Components Part#001491001 (SW)
All control arms have been set to stock length before leaving the factory. Flex Arms will give years of trouble free service,
when properly maintained.
Proper maintinence includes greasing the arm a minimum of every month and, if used heavily off-road, greased before
and after every trip. The grease zerk in the arm provides grease to the entire arm including bushings and forces out all
contaminants such as dirt and water. Grease is very important especially if the arms are submerged under water at any
time. Failure to grease these Flex Arms will void any applicable warranty.
Install the Flex Arm with the zerk end of the arm towards the frame, with the zerk facing up, out of harms way.
Grease before use!
Retorque lower control arm bolts to 130-145 ft. lbs., and 37-47 ft. lbs. for upper arms.
Remember grease, grease, and more grease.
factory control arm lengths
•all front upper control arms- 15 1/8”
•all rear upper control arms- 13 1/4”
•all TJ lower and ZJ front lower arms- 15 3/4”
•XJ front lower control arms- 16 1/4”
•ZJ rear lower control arms- 16 11/16”
•WJ front lower control arms- 16”
•WJ rear lower control arms- 19”
Adjustments can be made to the front
arms to adjust the caster, and to the
rear to adjust the pinion angle. Flex
Arms may be lenghtened or shortened
if necessary. Adjusting the arms in or
out more than 3/4” from factory settings will void any warrranty.
Revised 10 May 07