3.5”— 4.5” Dualsport suspension

3.5”— 4.5” Dualsport suspension
AEV30213AA
Last Updated: 07/26/12
INS TALLATION GUIDE
3.5”— 4.5” Dualsport
suspension
PLEASE READ BEFORE YOU START
TO GUARANTEE A QUALITY INSTALLATION, WE RECOMMEND READING THESE INSTRUCTIONS
THOROUGHLY BEFORE BEGINNING ANY WORK. THESE INSTRUCTIONS ASSUME A CERTAIN
AMOUNT OF MECHANICAL ABILITY AND ARE NOT WRITTEN NOR INTENDED FOR SOMEONE NOT
FAMILIAR WITH AUTO REPAIR.
INCLUDED PARTS
QTY
REQUIRED TOOLS
Springs
4
Basic Standard and Metric hand tools
Shocks
4
3/8-in Drill Bit
Bump Stop Spacer Kit
1
Rear Track Bar (LHD system only)
1
Rear Track Bar Tower
1
Brake Line Drop Bracket Set
1
Front Stabilizer End Link
Relocation Brackets (ST)
2
Rear Sway Bar End Links
2
High Steer Kit (SC or RS)
1
Drop Bracket Kit
1
1
REAR SUSPENSION
1.
A. Raise Jeep and support the frame using jack stands or a hoist, such that the rear axle can be lowered
enough to remove the springs. Support the axle by placing floor jack under the center of the axle.
Remove the wheels.
B. Loosen but DO NOT remove all 8 control arm bolts.
C. Remove the track bar. (NOTE: Right hand drive vehicles will reuse the factory track bar)
C.
A.
A.
B.
A.
B.
2
2.
A. Remove the bolts that hold the brake lines to the frame.
B. Remove the shocks.
C. Remove the swaybar end links and save. You will reuse the hardware for the rear and the end links will
be installed on the front of the vehicle. Note the orientation of the end links, the new end links will be
installed in the same way.
A.
B.
C.
B.
3
3.
Carefully lower the axle using the floor jack enough to remove the springs. DO NOT overextend the wheel
speed sensor or locker wiring.
Remove the factory springs.
4.
Install the track bar tower as shown. Tighten the U-bolt to NO MORE than 40 ft lbs. NOTE: The trackbar
bolts will be reinstalled in the opposite direction from factory (A.) Use the lower mounting hole for 3.5”
suspensions (shown) and the upper for 4.5” suspensions.
Install AEV springs making sure to properly index them on the axle spring seat (B.)
A.
2 Washers
B.
REAR OF JEEP
4
5.
Install new Bump Stop Spacers on axle as shown using the supplied hardware. DO NOT
reverse the orientation from what is shown (screws should be inboard.)
6.
Install new shocks at upper mount. Raise axle slowly and guide springs into position.
Install AEV swaybar end links and tighten.* Re-install lower shock nut and bolt and tighten* (refer
to step 2B.) Install brake line drop brackets as shown below and tighten.* Reinstall wheels and
tighten lug nuts, working in a star pattern.*
*Refer to Appendix for proper torque specs
5
FRONT SUSPENSION
7.
A. Raise Jeep and support the frame using jack stands or a hoist, such that the front axle can be lowered enough to remove the springs. Support the axle by placing floor jack under the center of the axle.
Remove the wheels.
A.
A.
A.
B. Loosen but DO NOT remove all 8 control arm bolts.
C. Disconnect the drive shaft. Make sure to mark both sides of the connection so you can properly align
it when you reconnect it. Tie loose end of the drive shaft up so it will not hang down. Failure to follow
this step may result in damage to your drive shaft.
D. Loosen but DO NOT remove the frame-side track bar bolt. Remove and save the axle-side track bar bolt
and flag nut.
C.
D.
6
8.
Note: On Rubicon models, remove the “fir tree” zip ties holding the speed sensor wiring to the frame and
upper control arm.
A. Remove and save all anti-sway bar link hardware. Note orientation, new links will be installed in the
same way
B. Remove shocks and save all shock mounting hardware.
C. Lower axle and remove springs. DO NOT remove factory isolator.
D. For 2011 and newer models, remove and discard factory bracket from the brake line.
A.
A.
D.
7
9.
A. Drill a 3/8 inch hole in the center of the axle
bump stop pad.
A.
B. Place bump stop spacer inside springs.
C. Install AEV springs, keeping factory isolator in
place. Make sure to properly index the springs
on the lower spring seat.
B.
D. Install and tighten supplied bump stop spacer
hardware.
bump stop pad
bump stop spacer
10.
A. Install Shock Doubler brackets on both sides
as shown using supplied hardware.
A.
B. Install AEV Shocks. If you are installing Remote
Reservoir Shocks install the reservoir bracket
and use the supplied hose clamps to secure
the reservoir portion of the shock into it.
B.
B.
NOTE: If you purchased a SC or RS suspension install High Steer Kit now (refer to instructions contained in kit P/N: IJKS1002-E) then continue with step 12. For ST suspensions continue to step 11.
8
11.
A. Install new sway bar end link brackets and tighten to 80 ft lbs. (ST only)
B. Install sway bar end links (reusing the factory end links from the rear.)
C. For 2007—2010 model year JK’s install the front brake line drop brackets tightening to 8 ft lbs.
(2011 or newer refer to step 12)
A–B.
C.
12.
For 2011 and newer models, use supplied zip ties
to secure the brake line to the shock as shown.
Reinstall wheels and tighten lug nuts, working
in a “star pattern.” Place Jeep on level ground.
Reconnect the drive shaft making sure to properly
align your marks.
13.
Install JK Geometry Correction Front Control Arm Drop Brackets (instructions included with kit.)
14.
Tighten all fasteners listed below to factory specifications.*
TIP: It is good practice to mark each major bolted suspension connection such as these with a paint pen.
Draw a line that runs from bolt head or nut to the adjacent bracket material. This will allow a visual inspection to easily catch bolts that work loose. After approximately 100 miles, you should perform a complete
visual inspection an re-torque any suspect bolts as well as your wheel lug nuts.
*Refer to Appendix for proper torque specs
9
appendix
jk Factory Torque Specifications
*nominal torque shown in ft. lbs.
Front Suspension & Steering
Powertrain Mounts
UCA bushings
M12
75
LCA bushings
M14
Track bar bushing frame
M14
Track bar bushing axle
M14
125
Stabilizer end link top
M12
65
Stabilizer end link bottom
M12
75
upper M12 bayonet
20
lower M12
56
Shock Absorber
M10 bracket to block
45
125
M12 bracket to block
90
125
M12 Isolator to frame
85
diesel
bracket to engine
85
diesel
M12 Hydro mt to bracket
65
diesel
M12 Hydro mt to frame
65
Steering gear
87
P/S pump to engine
21
High pressure hose pump
22
Hoses to steering gear
21
Intermediate shaft, all points
M10
Intermediate shaft toe plate
axle M12
50
7/8
195
Pitman to drag link nut
M14
78
Drag link to knuckle nut
M14
63
Tie rod to knuckle nut
M14
63
Tie rod clamp
M10
45
Drag link clamp
M10
26
UCA bushings
M14
125
LCA bushings
M14
125
Track bar bushing frame
M14
96
Track bar bushing axle
M14
111
Stabilizer bar sill bushing
M10
45
Stabilizer bar to link
M12
66
Stabilizer bar link to axle
M12
75
Rear Suspension
Shock Absorber
40
M10 mount to frame
40
(5” bolt circle/1.75” offset)
5 x 1/2” stud
105
50
cross-link M12
Pitman arm to gear
M10 trans to mount
Wheels
42
100 in. lbs.
Steering damper
Transmission Mount
upper M8
37
lower M12
56
M10 short bolts
45
M12 stud FESM
80
Cab Mounts
Driveline
T-case companion flange nut
Front driveshaft
Rear driveshaft
210
to front axle
80
to t-case
22
to rear axle
22
to t-case
22
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