Installation Guide for the TeraFlex Elite LCG JK 6” Long Arm

Installation Guide for the TeraFlex Elite LCG JK 6” Long Arm
INSTALLATION GUIDE
Inc. Inc.
Tera TeraFlex,
Manufacturing,
5680
W
Dannon
Way Dr.
5251 South Commerce
West Jordan, UT 84081
Murray,
Utah 84107
Phone/801.288.2585
Phone/801.288.2585
Fax/801.713.2313
www.teraflex.com
Fax/801.713.2313
www.teraflex.biz
TOOL LIST
10mm socket/wrench
12mm socket/wrench
15mm socket/wrench
16mm socket/wrench
18mm socket/wrench
19mm socket/wrench
21mm socket/wrench
¾” socket/wrench
3/8” socket/wrench
5/8” socket/wrench
7/8” socket/wrench
Installation Guide for the
TeraFlex Elite LCG JK 6” Long
Arm Suspension System
These instructions apply to the following kit part numbers
Part #1257600 6” JK LA System w/shocks
Part #1457600 6” JK LA System w/no shocks
Kit Includes:
6” coil springs
6” Shocks (1257600 only)
Front sway bar links
Rear sway bar links
Long front lower control arms
Long front upper control arms
Long rear lower control arms (side specific)
Long rear upper control arms
Frame brackets-2 front/2 rear
Front upper and lower bump stop extensions
Rear upper and lower bump stop extensions
Front spring spacers
Rear spring spacers and guides
Rear trackbar bracket
Rear adjustable trackbar
Front trackbar bracket and frame brace
Heavy Duty drag link and flip kit
Front adjustable Monster trackbar
Front and rear brake lines
Rear spring retainers
Read this first:
Installation of this kit requires removal of the factory control arm mounts from the
frame. The preferred removal method is a combination of a zip wheel and plasma cutter,
with some cleanup grinding required. The new brackets must be welded in place as part
of the installation of the kit. If you are not properly equipped to safely do this level of
fabrication and welding, please contact TeraFlex for the name of a qualified installer in
your area. Plan to spend 20 or more hours for installation.
With proper patience and care it is possible to leave the fuel tank in place during this
installation. The photos accompanying our installation guide show how to cut and
remove the rear brackets without damaging the fuel tank.
To allow for full droop without exhaust modification, you will need to purchase a JE
Reel front drive shaft, Part# 31JK-OE-42F.
7/16” socket/wrench
9/16” socket/wrench
11/16” socket/wrench
13/16” socket/wrench
1 ¼” wrench
1 ½” wrench
Drill with 5/16” drill bit
Grinder with cut off or zip wheel
Welder
Pry bar
Fire extinguisher
Hammer
Jack and jack stands or a hoist
SUPPLIES
Wire brush or wire wheel for a grind
Lock-Tight Primer
Paint
Grease
Zip ties Revised 03 September 2008
FRONT INSTALLATION:
the factory skid plate). Push the new
bracket up tight against the frame.
Mark the frame and the bracket so you
will know were the bracket contacts
the frame.
14.Remove brackets for welding prep.
Clean all marked areas. Make sure
there is no paint or any other possible
contaminants like grease or rust.
15.Reinstall the brackets, make sure the
bolts to the cross member are tight
and the very front edge of the bracket
is touching the frame. If you have the
tranny skid plate bolts, install them
at this time. Fully weld the front long
arm brackets to the frame.
1. Lift the vehicle and support under the
frame so that the axles will be able to
drop down far enough to remove and
replace the coil springs. When placing
supports under the frame, take into
consideration the new brackets will be
in a different location than the factory
brackets and you may need to temporarily change the location of your
frame supports because the area you
will be working with in the rear is a
large section of the frame.
2. Remove the tires.
3. Remove front transmission skid plate
for driveline clearance.
4. Remove the front sway bar links.
5. Remove the clips that secure the ABS
wiring harness to the brake line and
disconnect the wire connecter behind
the spring tower. Secure the lines temporarily to the axle in a position that
will be safe for them through the rest
of the install.
6.Remove the front brake calipers and
hang them off the frame.
7.Remove the front lower control arms.
8.Remove the front upper control arms.
On the passenger side it will be necessary to cut the bolt for the upper arm
on the frame side. This will allow you
to get the bolt out without removing
the exhaust.
9.Support the axle and remove the front
shocks.
10.Lower the front axle to make more
room for working on removing the
front upper and lower control arm
mounts.
11.Use a plasma cutter, oxy/acetylene
torch or zip cutoff wheel to remove
just the front bracket. Be very careful
to avoid undercutting into the frame.
Use the following photos to determine
where to cut.
12.Remove both front upper and lower
brackets and grind the remaining weld
smooth with the frame in preparation
for installing the new combination
front bracket.
13.The new front bracket mounts to the
cross member bolts, and the transmission skid plate hole is used to help
locate the bracket (some models may
not have threads in this frame hole
because not all models come with
16.After the welds have cooled, clean the
frame and brackets. Paint over welds
and any other raw metal areas left
from grinding and sanding.
17.Install the front lower arms with the
rubber bushing at the frame end and
the angled modular urethane joint at
the axle end. The arm is bent for tire
clearance so make sure the bend goes
in toward the center of the jeep. Position grease zerks for access and where
they will be most protected from rocks
or other damage. Set front lower arm
length to 34 3/16”.
Revised 03 September 2008
18.The front upper arms require lifting the
engine about one inch to get the provided 9/16”x3” bolt in on the frame
side. The engine mounts are slotted,
making it so that you can loosen the
two main bolts and lift the engine
about an inch. Use the bottom of the
two holes for most applications. Position grease zerks for access and where
they will be most protected from rocks
or other damage. Set front upper arm
length to 28 1/16”.
19.Remove the factory trackbar bolt on
the frame side using a 21mm wrench,
to hold the nut on the backside, a
21mm socket, and an impact gun.
With the impact gun and socket
remove the axle side. There should be
a nut on the backside with a small tab
that will hold it so you do not need
a wrench on it. Once bolts are out,
remove the track bar.
20.Remove the two lower bolts for the
steering box with a 18mm socket and
impact gun.
21.Slide the new track bar bracket over
the factory bracket. Use the steering
box bolts to hold the bracket; start
the threads, but do not tighten them.
Install the 1/2” button head bolt
from the inside of the factory bracket
through the TeraFlex track bar bracket
so the head of the bolt is on the
inside.
22.Place the brace with the fixed end in
the factory trackbar bracket and the
bend upward. Use the 9/16” bolt to
hold it in place. Do not tighten at this
point.
23.Hold the bracket for the brace up
against the frame on the passenger
side directly across from the factory
trackbar bracket. Then hold the brace
up in place to make sure you have
lined it up in the proper location.
When the desired location is established mark the frame in the area you
plan to weld.
24.Remove the brace and bracket for
welding prep. Clean the frame and
bracket make sure you clean all surfaces that you will be welding. Clean
surfaces are critical for a good weld.
25.Reinstall the bracket and the brace.
Adjust the brace so it fits with bolts in
each end.
Make sure the bracket fits the frame and
is in the proper location. Tack two or
three places to keep the bracket from
pulling during final welding. Remove
the brace and then final weld the rest
of the bracket. A professional certified
welder is always a good way to go if
you have any doubts about your welding ability.
26.Clean all welded surfaces with a wire
brush or something similar that will
remove the dust in all the small
grooves of the weld. Remove any paint
that has been damaged from the heat
created during the welding process.
27.Prime and paint all welded or raw
areas.
28.Tighten the bolts that go in the steering box and the 1/2” button head
bolt.
29.Install the brace and tighten the blots
and jam nut. Use a 1 1/4” wrench for
the jam nut.
30.Install the monster track bar with fac-
tory hardware.
31.Adjust the track bar so the axle is centered under the vehicle. From center
to center of the joint should be close
to 32 3/4”(with a 6” lift). Tighten the
bolts on the adjuster sleeve.
Install front bump stop extensions
32.Remove the factory upper bump stop
from the cup on the bottom of the
coil tower.
33.Remove the front upper spring isolator.
34.Install the new front spring spacer.
35.Reinstall the factory spring isolator
below the new TeraFlex spring spacer.
36.Install the new upper bump stop
extension by putting some grease on
the upper part of the spacer and popping it into the bump stop cup.
37.Insert the factory bump stop into the
bottom of the new bump stop extension.
38.Install the front lower bump stops by
locating the center of the spring pad
on the axle and drilling a 5/16 hole,
then use a self tap bolt or a hand tap
to create 3/8 coarse threads in the
pad. Install the lower bump stops on
each side with the 3/8 self tap bolts
in the hardware kit.
39.Install the new front springs. Using a
coil spring compressor can make this
easier.
40.Install the new front shocks.
41. Install the front sway bar quick disconnect links.
Revised 03 September 2008
Rubicon models will need the
factory swaybar holes drilled to
1/2" to fit the new TeraFlex
Swaybar Links.
45.Reinstall the breather hose if it was
disconnected during disassembly.
NOTE: On JK models with the factory
disconnect front sway bar it is not necessary to install the QD brackets and pins on
the front bodymounts. All other models
install the brackets and pins where the
sway bar links will be parked when disconnected, as shown in the photo.
42. The six-inch kit requires re-routing
the front ABS lines. Route the line
inside the frame rail and reconnect the
line to the wheel speed sensor then
zip tie or secure the line so it will be
out of harms way. Make sure the line
will not be pinched or smashed by any
moving parts. Also make sure there is
enough length for droop. Then repeat
on the other side.
43.Remove the
front factory
brake lines
and replace
them with
the new
longer steel
braided lines.
24 inch goes
in the front.
44.Remove the factory draglink at the
steering knuckle. Loosen the adjuster
sleeve and remove the long side of the
drag link. The threads will be left hand
so you will need to turn it opposite
of way you might be used to. Install
the new heavy flip drag link into the
adjuster sleeve and set the length to
41 ¼”. The flip drag link is installed
from the top down on the knuckle. To
convert the taper, a sleeve is provided.
To install the sleeve you must drill out
the knuckle to a 13/16” hole. Drilling
the knuckle straight is very important.
After you have drilled the hole, install
the sleeve, you may need to tap it
into place, from the top down. Install
the new heavy flip drag link. Use the
provided washer and tighten the nut
over the washer.
REAR INSTALLATION:
46.Now moving on to the rear, start by
removing the tires if you haven’t done
so already.
47.Remove the clips connecting the ABS
lines to the upper arm mount on the
axle side and the clips on the frame
side directly above the arm.
48.Remove the bolt that holds the brake
line to the frame. This will allow the
axle to droop far enough to get your
six-inch springs in.
49.Remove the rear upper and lower
control arms.
50.Remove rear springs
51.Support the rear axle and remove the
rear shocks.
52.Remove the lower arm mounts from
the frame. Be careful not to cut into
the frame. First cut the passenger
lower arm mount into sections. We
recommend using a cut off wheel or
zip wheel for this bracket because it
will be easier to be precise in your
cuts. Cut the bends of the bracket
so the bracket will come off in three
pieces. The middle piece should come
off easily after these cuts have been
made. Cut along the weld on the
outside of the frame and remove the
outer piece. Then begin cutting the
inside bracket staying as close to the
frame as possible.
Be Very Careful Not
To Damage The Fuel
Tank!
On the rear most part of the bracket,
the gas tank may be touching, so
cut as much as you are comfortable
with, then break the rest off so you
don’t nick the tank. The upper on the
passenger side is less critical, but
if you use a torch or plasma cutter
remember all the slag that goes over
the frame could land on the gas tank.
After removing all the rear control arm
brackets clean off the leftover welds
or material from the frame.
53.Install the passenger side rear bracket
first. This bracket uses one of the
gas tank skid plate bolts. Loosen the
gas tank skid plate bolts and lower
the skid plate just enough to get the
bracket between the frame and the
skid plate. Line up the bolt hole and
mark the frame and the bracket for
welding preparation. Then remove the
bracket and clean the paint from all
marked areas. Reinstall the bracket,
tack into place, and then fully weld.
On the driver side hold the bracket
into place. There is no hole to match
up the to on the frame so the exact
location should be determined by
measuring the other side and matching
the driver side to it. Mark the bracket
and the frame for welding preparation.
Remove the bracket and clean off the
paint from the bracket and the frame
Revised 03 September 2008
in all marked areas. Reinstall the
bracket and tack into place. Check the
passenger side to make sure you are in
the right place and fully weld.
54.Clean all welds and any raw metal
areas. Then prime and paint them.
55.Install rear upper arms with factory
hardware on the axle side and the
provided 9/16”x 3” bolt on the frame
side. Make sure the bend goes in away
from the tire. The fixed end goes to
the frame and the adjustable end goes
to the axle. Set the rear upper arm
length to 20 9/16”.
56.Install the rear lower arms with the
rubber end at the frame side and the
flex joint at the axle and the bend is
supposed to go up and in towards the
center of the vehicle. Place grease
zerks so they are accessible and out
of harms way. Do not fully tighten
the rubber end at this time. Set rear
lowers to 36 1/8”.
57.Remove the rear track bar.
58.Install new rear trackbar bracket.
The rear lower control arm bolt and
the new U-Bolt brace the rear trackbar bracket. Remove the rear lower
control arm bolt. Place the bracket
into position and reinstall the bolt.
Use the provided bolt 3 ½” x9/16” in
the bracket going through the factory
bracket also use the provided sleeve in
the factory bracket to keep the bracket
from crushing.
59.Install the U-bolt.
60.Install the new adjustable trackbar
using the factory fasteners. Set trackbar to 40 ½”.
61.Install your new rear spring spacer/
guides. They pop into the hole in the
middle of the spring bucket. It helps
to put some grease on the part and
the frame. Then pop your factory isolator onto the spring guide.
62.Install your new six-inch springs.
63.Install lower spring retainer. The lower
spring retainer has a special tool that
comes with it. This tool will make it
easier to get the nut up under the
lower spring mount. Place the nut in
the tool and then work it up under
the front side of the mount so you can
see the threads of the nut through the
hole in the mount. Place the spring
retainer plate on the mount and put
the bolt and lock washer through
the plate into the nut and tighten it
down.
64.Install new sway bar links. Mount
the sway bar links so they are on the
inside of the sway bar and on the
inside of the axle mount. This will
give you the best tire clearance.
65.Install new shocks.
66.Remove the factory rubber brake lines
and replace them with your new steel
braided brake lines. Anchor the new
rear brake hoses with the angle brackets and clips provided in the hardware
kit.
67.Remove the rear factory bump stop
cushion from the cup in the frame.
The TeraFlex upper bump stop extension goes into the factory location.
Pop it into place then pop the factory
cushion in the TeraFlex extension.
68.Install the rear lower bump stop extension. Use the 5/16” X 1 ¼” bolts to
fasten them into place. Make sure
they are in the right way. The rear bolt
head should be visible if you where
looking strait down on it and the front
should be covered by the over hanging
edge.
69.Bleed the brakes being careful to keep
fluid in the master cylinder at all
times. Reinstall the axle breather hose
if it was removed during disassembly.
70.Reinstall tires and wheels.
71.Set on the ground and torque all the
control arm bolts, trackbar bolts,
steering and lug nuts. Lock-Tight is
highly recommended for all fasteners.
72.Secure the brake hoses and ABS wiring
so they will not be damaged during
vehicle operation.
73.Have the vehicle alignment checked
and adjusted by a shop that is familiar
with proper alignment settings on a
lifted vehicle.
NOTE: Caster should be set at 5 degrees.
The passenger side may need to be turned
1/4 to 1/2 a degree more to avoid pulling
to the right while driving.
MAINTENANCE NOTE: grease all zerks every
3000 miles.
Shock Absorber Upper Nut
Shock Absorber Lower Nut
Suspension Arm Lower Axle Bracket Nut
Suspension Arm Lower Frame Bracket Nut
Suspension Arm Upper Axle Bracket Nut/Bolt
Suspension Arm Upper Frame Bracket Bolt
Sway Bar Retainer Bolts
Sway Bar Link Upper Nut
Sway Bar Link Lower Bolt
Track Bar Frame Bracket Nut
DESCRIPTION
Rear
N·m Ft. Lbs. In. Lbs.
Shock Absorber Upper
Bolts
50
37
—
Shock Absorber Lower
Nut
76
56
—
Suspension Arm Lower
Axle Bracket Nut
169
125
—
Suspension Arm Lower
Frame Bracket Bolt
169
125
—
Suspension Arm Upper
Axle Bracket Bolt
169
125
—
Suspension Arm Upper
Frame Bracket Bolt
169
125
—
Sway Bar Retainer
Bolts
61
45
—
Sway Bar Link
Nut/Bolt
102
75
—
Sway Bar to Link Nut
90
66
—
Track Bar Frame
Bracket Nut
169
125
—
Track Bar Axle
Bracket Bolt
169
125
—
Revised 03 September 2008
D
C
B
A
7
6
5
ITEM NO.
214
600448
990120
37
953000
PART NUMBER
Bolt 1/2-13X1.25 Bhcs Fs Rev 000240
Nut 1/2" x 13 UNC Stover Locknut Zinc Plated
DRAG LINK JK RAW JKDL RAW
Insert Sleeve Tapered for stock JK Drag Link
WASHER FLAT 1/2" ZINC PLATED
BRACKET DROP FOR JK FRONT TRACKBAR FRAME END
DESCRIPTION
1
1
1
1
3
1
QTY
4
1
2
3
4
240
1
8
8
9
5
BOLT 9/16-12X3.5 HEX ZINC
1
2
2
10
11
6
111
BRACKET JK TRACKBAR BRACE
Nut 9/16 - 12 UNC Nylock Zinc Plated
3
1
3
1
7
953400
278
WASHER 9/16" FLAT ZINC PLATED
BOLT 9/16" -18 UNC x 3" LONG HEX HEAD ZINC PLATED
1600440
8
9
318
62
Trackbar Drop Bracket KIT with Frame Brace and Flip Drag Link
10
11
4
1
5
Brace Bar Assembly for JK Front Trackbar Bracket
6
753509
7
12
8
6
12
3
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/32
ONE PLACE DECIMAL
0.03
TWO PLACE DECIMAL
0.015
THREE PLACE DECIMAL 0.005
ANGULAR:
MACH 1
BEND 2
PROPRIETARY AND CONFIDENTIAL
3
DRAWN
CHECKED
MATERIAL
WEIGHT
NAME
DATE
-
2
2
B.CALVIN 8 AUGUST 2008
-
MATERIAL
Kg
THE INFORMATION CONTAINED IN THIS HEAT TREATMENT
DRAWING IS THE SOLE PROPERTY OF
TERA MANUFACTURING. ANY
HEAT TREATMENT
REPRODUCTION IN PART OR AS A
WHOLE WITHOUT THE WRITTEN
FINISH
PERMISSION OF TERA
MANUFACTURING IS PROHIBITED.
FINISH
4
5
7
1
5251 COMMERCE DRIVE
MURRAY, UTAH 84107
TERA MANUFACTURING
1
SHEET 1 OF 1
REV
JK FRONT TRACKBAR DROP
KIT WITH FRAME BRACE
AND FLIP DRAG LINK
DO NOT SCALE
DRAWING
1600440
SIZE DWG. NO.
B
SCALE: 1:4
A
B
C
D
Revised 03 September 2008
PRODUCT
INFORMATION
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 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, steering, 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 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 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 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.
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,
FlexArms, 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.
TeraFlex, Inc. 5241 South Commerce Dr. Murray, Utah 84107
Phone/801.288.2585 Fax/801.713.2313 www.teraflex.biz
Revised 03 September 2008
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