J9200, J9300 Installation Instructions Jeep Wrangler TJ

J9200, J9300 Installation Instructions Jeep Wrangler TJ
#J9200, J9300 Installation Instructions
Jeep Wrangler TJ
2" & 3" Body Lift Kits
Read and understand all instructions and warnings prior to installation of product
and operation of vehicle.
Zone Offroad Products recommends this system be installed by a professional technician. In addition to these instructions, professional knowledge of disassembly/ reassembly procedures and post installation checks must be known. Minimum tool requirements
include the following: Assorted metric and standard wrenches, hammer, hydraulic floor jack and a set of jack stands. See the "Special
Tools Required" section for additional tools needed to complete this installation properly and safely.
»»P
roduct
Safety Warning
Certain Zone Offroad Products are intended to improve off-road performance. Modifying your vehicle for off-road use may result in
the vehicle handling differently than a factory equipped vehicle. Extreme care must be used to prevent loss of control or vehicle rollover. Failure to drive your modified vehicle safely may result in serious injury or death. Zone Offroad Products does not recommend
the combined use of suspension lifts, body lifts, or other lifting devices.
You should never operate your modified vehicle under the influence of alcohol or drugs.
Always drive your modified vehicle at reduced speeds to ensure your ability to control
your vehicle under all driving conditions. Always wear your seat belt.
»»T
echnical
Support
Live Chat provides instant communication with Zone tech support. Anyone can access
live chat through a link on www.zoneoffroad.com .
www.zoneoffroad.com may have additional information about this product including the
latest instructions, videos, photos, etc.
Send an e-mail to tech@zoneoffroad.com detailing your issue for a quick response.
888.998.ZONE Call to speak directly with Zone tech support.
»»P
re-Installation
Difficulty Level
easy 1
2
3 4 5 difficult
Estimated installation: 6 hours
Special Tools Required
None
Tire/Wheel Fitment
2" Lift: 32x10.50 Tire/15x8, 3.5"
BS Wheel
3" Lift: 33x12.50 Tire/15x8, 3.5"
BS Wheel
Notes
1.Special literature required: OE Service Manual for model/year of vehicle. Refer to manual for proper disassembly/reassembly procedures of OE and related components.
2.Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the OE manual.
3.Larger rim and tire combinations may increase leverage on suspension, steering, and related components. When selecting combinations larger than OE, consider the additional stress you could be inducing on the OE and related components.
4.Secure and properly block vehicle prior to installation of Zone Offroad Products. Always wear safety glasses when using power
tools.
5.Zone Offroad Products body lifts are designed to be used on vehicles in good operating condition. It is not recommended that body
lifts be used on vehicles in poor physical shape. This includes rusted body mounts, damaged or worn frame-to-body mounting
brackets, and poor mechanical condition. Perform a visual inspection of the vehicle before beginning installation.
rev061313
»»Zone Offroad Products • 491 W. Garfield Ave., Coldwater, MI 49036 • 888.998.ZONE • www.zoneoffroad.
com
Kit Contents
»»
2
3”x2” Body Lift Block
2”x2” Body Lift Block
9
1
Bolt Pack - #203
1
Bolt Pack - #220
2”x3” Body Lift Block
2
2
Bump Stop
2
Threaded Sleeve
1
T-Case Linkage Bracket
1
Steering Support
1
Steering Carrier Bearing Support
1
Fuel Fill Extension (1.50” O.D.)
Radiator Relocation Bracket
6
1
Manual Shift Extension
5/8”x18” Fuel Vent Hose
1
#28 Hose Clamp
2
2
#10 Hose Clamp
Cable tie
3
1Loctite
Manual Shift Extension
1
1
5/16” x 10” Fuel Vent Hose
1
Fuel Filler Extension (1” O.D.)
#20 Hose Clamp
2
Bolt Pack 203
QtyDescription
6
7
2
2
2
10
8
2
2
2
1
1
1
1
»»#J9300
#J9200
QtyDescription
7/16” USS flat washer clear zinc
3/8” USS flat washer clear zinc
3/8”-16 x 1-1/4” bolt grade 5 clear zinc
3/8”-16 x 2” bolt grade 5 clear zinc
1/4”-20 x 1” bolt grade 5 clear zinc
1/4” SAE flat washer clear zinc
1/4”-20 prevailing torque nut clear zinc
5/16”-18 x 1-3/4” bolt grade 5 clear zinc
5/16” USS flat washer clear zinc
7/16” SAE flat washer clear zinc
7/16”-14 prevailing torque nut clear zinc
7/16”-14 x 1” bolt grade 5 clear zinc
10mm-1.50 x 60mm bolt grade 8.8 clear zinc
10mm flat washer clear zinc
J9200, J9300 Installation - pg. 2
QtyDescription
2
3”x3” Body Lift Block
9
2”x3” Body Lift Block
1
Bolt Pack - #203
1
Bolt Pack - #221
4
2”x2” Body Lift Block
2
Bump Stop
2
Threaded Sleeve
1
T-Case Linkage Bracket
Steering Support
1
1
Steering Carrier Bearing Support
Fuel Fill Extension (1.50” O.D.)
1
6
Radiator Relocation Bracket
1
5/8”x18” Fuel Vent Hose
2
#28 Hose Clamp
#10 Hose Clamp
2
3
Cable tie
1Loctite
Manual Shift Extension
1
1
5/16” x 10” Fuel Vent Hose
1
Fuel Filler Extension (1” O.D.)
#20 Hose Clamp
2
Bolt Pack 220 (#J9200)
QtyDescription
6
5
1/2”-13 x 5-1/2” bolt
7/16”-14 x 4-1/2” bolt
Bolt Pack 221 (#J9300)
QtyDescription
6
5
1/2”-13 x 6-1/2” bolt grade 5 clear zinc
7/16”-14 x 5-1/2” bolt grade 5 clear zinc
Radiator Brkt (J9200)
Linkage Brkt (J9300)
Steering Support
Linkage Brkt (J9200)
Carrier Bearing
Support
Radiator Brkt (J9300)
01725
Fuel Filler Extension
Shift Extension
(J9200)
Shift Extension (J9300)
J9200, J9300 Installation - pg. 3
INSTALLATION INSTRUCTIONS
1.
Park the vehicle on a clean flat surface and block the wheels for safety. Place
automatic transmissions in park and manual transmissions in neutral.
2.
Remove the negative battery cable first, then the positive battery cable. If
equipped, the Supplemental Restraint System will be deactivated when the battery is disconnected.
»»F
ront/Under
3.
Hood
Remove the four bolts attaching the front plastic cover to the frame and remove
the cover from the frame (Figure 1). Save cover and hardware.
Figure 1
4.
If equipped with factory auxiliary headlights on the front bumper, remove the
two clips and wiring harness from the fenders.
5.
Remove the three screws holding the headlight bezels to the core support and
remove the bezels from the vehicle (Figure 2). Save bezel and hardware.
Figure 2
6.
J9200, J9300 Installation - pg. 4
Remove the radiator overflow hose and overflow bottle from the fan shroud and
remove them from the vehicle. (Figure 3).
Figure 3
7.
Remove the four bolts mounting the fan shroud to the radiator and move the
shroud back toward the engine, off of the radiator (Figure 3). Save hardware.
Figure 4
8.
Remove the six bolts mounting the radiator to the core support (Figure 4). Carefully rest the radiator against the fan. It will be relocated after the lift is installed.
Save hardware.
9.
Remove the air intake hose from the engine compartment by removing the
vacuum line and loosing the hose clamp at the air box and at the throttle body.
10.
Remove the two bolts mounting the steering shaft carrier bearing to the driver’s
side frame rail (Figure 5).
J9200, J9300 Installation - pg. 5
Figure 5
11.
Pull back the carpet on the driver’s side near the center console. Remove the
four bolts with captive washers (Figure 6). This will free the transfer case linkage bracket from the underside of the body. Save hardware.
Figure 6
12.
From underneath, remove the two bolts from the transfer case shift linkage pivot
bushing plate. Remove the pivot plate and bracket from the vehicle. Save all
components.
»»M
anual Transmission Vehicles
The following steps are required for the 3” (J9300) body lift. The shift lever may not need
to be extended with 2” (J9200) body lifts to operate properly. These steps can be delayed
until the end of the installation (2” only) so the shift lever operation can be checked. If
all gears can be fully engaged then the extension is not necessary. The lever can also be
heated and bent if minor interference is detected.
»»1997-2002 M
odels
J9200, J9300 Installation - pg. 6
13.
Ensure that the transmission is in neutral.
14.
Remove the manual shift lever knob and pull the shift boot free from the console
and up off of the lever.
15.
Remove the screws holding the console to the floorboard and remove the console from the vehicle.
16.
Remove the screws mounting the rubber shift boot to the floorboard and pull the
boot up and off of the lever.
17.
Pull the small shift lever dust boot free at the top of the transmission to expose
the shift lever retaining collar.
18.
Push down on the shift lever retaining collar and rotate it counter-clockwise.
Pull the lever up free from the transmission (Figure 7A). Cover the hole in the
top of the transmission with a clean rag.
Figure 7A
19.
Pull the dust boot, retaining collar and spring up on the shift lever as far as possible.
20.
Make an alignment mark along the shift lever just below the first bend. Make a
second “cut” mark perpendicular to the first mark just below the bend (Figure
7B). Note: Make sure the alignment mark is visible on both sides of the cut.
Figure 7B
21.
Cut the lever in two at the cut mark.
22.
Make an alignment mark along the length of the provided manual shift lever
extension. Align the marks on each section of the shift lever with the mark on
the extension and weld the three pieces together. Note: All welding should be
performed by a certified welder.
J9200, J9300 Installation - pg. 7
23.
Install the modified shift lever in the transmission by pushing down on the
retaining collar and turning it clockwise until it locks. Install the shift lever dust
boot on the transmission. The console will be installed later.
»»2003-2006 M
odels
24.
Ensure that the transmission is in neutral.
25.
Pull the shift lever cover free from the center console and up the lever.
26.
Remove the shift lever mounting bolt and remove the lever from the vehicle.
27.
Make an alignment mark and cut line approximately 1” above the coupler end of
the shift lever (Figure 8)
Figure 8
28.
Cut the shift lever on the cut line. Position the provided weld-in extension between the two shift lever halves. Align the marks on the two halves and weld the
extension in place.
29.
Paint all exposed metal to prevent corrosion.
30.
Reinstall the modified shift lever in the vehicle with the OE bolt. Tighten bolt to
25 ft.lbs.
31.
Reinstall the shift lever cover to the console.
»»R
ear
32.
Remove the fuel filler cap and remove the four screws mounting the fuel shroud
to the body. Remove the four screws mounting the filler neck to the shroud.
Remove the shroud from the vehicle.
»»B
ody
J9200, J9300 Installation - pg. 8
Lift
33.
Loosen all body mounting bolts (11 in all) but do not remove.
34.
Remove the body mounting bolts on the passenger’s side of the vehicle and the
front center bolt. Using a hydraulic jack and a wooden block, lift passenger’s
side of the vehicle up just high enough for the body spacers to be placed. The
two 3” diameter spacers go on the mounts located directly behind the front axle
on either side on the vehicle. It will not be possible to install the front center
spacer until the entire vehicle has been lifted. Watch for hoses or wires that may
be binding or stretching while lifting.
35.
Start but do not tighten the new mounting bolts. They are installed in the following locations with the OE bushings;
7/16”-14 x 4-1/2” (7/16” x 5-1/2” for 3” kit) with 3/8” USS washers in the frontcenter and two rear mounts, and 1/2”-13 x 5-1/2” (1/2” x 6-1/2” for 3” kit) with
7/16” USS washers in the three mounts along the frame under the doors.
36.
Repeat installation procedure for the driver’s side of the vehicle and install the
front center mount.
37.
Check body for correct alignment on the frame. Torque 1/2” hardware to 60 ftlbs and 7/16” hardware to 40 ft-lbs. Use Loctite on all body mounting hardware.
Step 35 Note
Body mount hardware is located
in hardware pack #220 for a 2" lift
and hardware pack #221 for a 3"
lift.
»»F
ront
38.
Remove the urethane body support bumpers from the core support. (Fig. 1)
39.
Coat the threads of the provided hexagon bump stops with loctite and thread
them into the provided tapped sleeves.
40.
Install the bump stop/sleeve assembly in the body blocks provided. For 2” kits,
use a 3” tall x 2” wide block. For 3” kits, use 2-2”x2” blocks. (Fig 9A, 9B)
Installation Note
All hardware needed for the installation of the remaining components is located in hardware pack
#203.
Figure 9a
Figure 9B
41.
Mount the support bumper assembly to the original location on the core support
with 3/8” x 1-1/4” bolts for 2” kits or 3/8” x 2” bolts for 3” kits and 3/8” USS
washers. Access the hole in the core support through the headlight hole in the
grill. Use Loctite on the 3/8” mount bolts and torque to 20 ft/lbs.
42.
Install the headlight bezels with the OE hardware.
43.
Install the air intake tube on the throttle body and air box with the OE clamps.
Attach the vacuum hose to the tube.
44.
Install the six radiator drop brackets to the core support using the OE radiator
mounting hardware.
45.
Mount the radiator on the relocation brackets. If equipped with A/C, mark the
passenger’s side radiator bracket where there is interference with the A/C line.
J9200, J9300 Installation - pg. 9
46.
If equipped with A/C, remove the passenger’s side radiator bracket and trim
where marked. Reinstall the bracket on the radiator with OE hardware and check
for proper A/C line clearance.
47.
Fasten the radiator to the relocation brackets with 1/4” lock nuts and washers.
Torque all radiator mounting hardware to 10 ft-lbs.
48.
Install radiator fan shroud to the radiator with the four OE bolts. Tighen securely.
49.
Install the overflow bottle and overflow hose to the radiator and fan shroud.
50.
Mount the provided steering carrier bearing spacer tube between the steering
carrier bearing and the frame. Attach with the 10mm x 60mm bolt through the
original mounting hole in the carrier bearing, through the tube, and into the
threaded hole in the frame bracket. (Fig. 10) Do not tighten. Use Loctite on
mounting bolts.
Figure 10
51.
Install the side strap on the frame with the OE bolt. Do not tighten.
52.
Mount the side strap to the carrier bearing using a 7/16” x 1” bolt, nut and SAE
washers. (Fig. 11)
Figure 11
J9200, J9300 Installation - pg. 10
53.
Tighten 10mm and 7/16” bolts to 30 ft-lbs.
54.
If equipped with factory auxiliary headlights, reconnect and secure the wiring
harnesses to the fenders with two zip ties.
55.
Install the Jeep front cover with the four OE bolts. Tighten securely.
»»R
ear
56.
Mount the pivot bushing to the relocation bracket (Fig. 12).
Post-Installation
Warnings
1. Check all fasteners for
proper torque. Check to ensure
for adequate clearance between
all rotating, mobile, fixed, and
heated members. Verify clearance
between exhaust and brake lines,
fuel lines, fuel tank, floor boards
and wiring harness. Check steering
gear for clearance. Test and inspect
brake system.
Figure 12
2. Perform steering sweep to
ensure front brake hoses have adequate slack and do not contact any
rotating, mobile or heated members. Inspect rear brake hoses at
full extension for adequate slack.
Failure to perform hose check/replacement may result in component failure. Longer replacement
hoses, if needed can be purchased
from a local parts supplier.
57.
Mount the pivot bushing relocation bracket to the OE bracket as shown in the
figure 12. Torque all mounting hardware to proper specs.
58.
Install the modified bracket assembly in the original location under the floorboard by sliding the linkage rod through the pivot bushing. Fasten the bracket to
the floorboard using the OE hardware. Torque hardware to proper specs.
59.
Check the 4wd lever operation to ensure that there is engagement in all ranges.
Adjust the linkage as necessary.
60.
Remove the rear vent line from the fuel filler assembly by removing the zip tie,
if equipped.
3. Perform head light check and
adjustment.
61.
Remove the two clamps mounting the fuel filler and fuel vent to the fuel tank.
Remove the filler assembly from the vehicle.
62.
Cut the filler hose in half and install the extension and new clamps. Leave
clamps loose for adjustment.
4. Re-torque all fasteners after
100 miles. Always inspect fasteners and components during routine
servicing.
63.
Remove the vent hose and replace with the extended hose and clamp provided.
Note: 03-06 Models use the smaller 5/16 hose. No clamps are needed.
64.
Install the fuel filler assembly on the fuel tank with the original clamps. Adjust
the assembly to the correct position and tighten all hose clamps.
65.
Zip tie the axle vent tube to the fuel vent tube.
66.
Install the fuel filler shroud to the body with the four OE screws.
67.
Install the fuel filler assembly to the shroud with the four OE screws and install
the fuel cap.
68.
Install the rubber shift boot to the floorboard using the stock mounting screws.
69.
Install the console in the vehicle with the stock mounting screws.
70.
Install the outer shift boot over the shift lever and snap it into place in the console.
71.
Install the shift lever knob.
»»P
ost-Installation
72.
Check torque on all hardware.
73.
Reconnect battery cables. Connect positive first, then negative.
74.
Retorque hardware after 500 miles.
J9200, J9300 Installation - pg. 11
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