INSTALLATION INSTRUCTIONS Brake Line Jeep TJ, YJ, & XJ 4WD120 & 121 Read and understand all instructions and warnings prior to installation of system and operation of vehicle. SAFETY WARNING 4WD Hardware 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. PRODUCT SAFETY WARNING Certain 4WD Hardware 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. 4WD Hardware 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. PRE-INSTALLATION 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. Post-suspension system vehicles may experience driveline vibrations. Angles may require tuning, slider on shaft may require replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced. 5. Secure and properly block vehicle prior to installation of 4WD Hardware components. Always wear safety glasses when using power tools. 6. If installation is to be performed without a hoist 4WD Hardware recommends rear alterations first. 7. Due to payload options and initial ride height variances of vehicles, the amount of lift is a base figure. Final ride height dimension may vary in accordance to original vehicle attitude. Always measure the attitude prior to beginning installation. 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. 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. 3. Perform head light check and adjustment. 4. Re-torque all fasteners after 500 miles. Always inspect fasteners and components during routine servicing. rev. 3/16/2006 Front Installation Instructions Rear Installation Instructions 1. 15. Block the front wheels. Safely raise the rear of the vehicle and support with jack stands for safety. 16. Remove driver’s side wheel to ease installation. 17. Remove retaining clip holding brake line to frame. (See Fig 3) 18. Disconnect rubber brake line from hard line at retaining clip location. 19. Disconnect brake line juncFIG. 3 tion block from driver’s and passenger’s side hard line (See Fig 4). 2. 3. 4. 5. 6. Park the vehicle on a clean, flat surface and block the rear wheels for safety. Safely raise the front of the vehicle and support with jack stands under the frame rails. Remove front wheels. Remove brake line retaining clips. (See Fig 1). Remove fasteners holding brake line anchors to frame on driver’s side, retain hardware. Disconnect rubber brake line from metal hard line (See Fig 1). FIG. 1 7. Disconnect brake line from caliper and discard hardware. Ensure old washer is removed from caliper and brake line mounting area. 8. Install new upper brake line bracket with OE bolt. 9. Mount hard line into new bracket before installing new flex line. 10. Install front brake line by attaching upper portion first. Torque to 25 ft-lbs. 11. Install lower portion with provided hardware. Note: One washer is required on EACH side of the fitting. Brake line must face up after installation. (See Fig 2). Torque bolt to 20 ft-lbs. FIG. 4 20. Unbolt brake line juncktion block from axle. 21. Install new brake line . Torque to 25 ft-lbs. (See Fig 5). FIG. 5 FIG. 2 12. Repeat for passenger’s side. 13. Reinstall front wheels and torque to specification (see owners manual). 14. Lower front of vehicle to ground. 22. Reinstall driver’s and passenger’s side hard line into new fitting. 23. Reattach axle breather 24. Install new retaining clip 25. Reinstall rear wheel 26. Lower vehicle to ground 27. With blocks still holding front wheels in place, bleed brakes starting with caliper furthest away from master cylinder. 28. Check brake fluid level after bleeding brakes.
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