124304 - BDS Suspension
#124304
Installation Instructions
Transfer Case Drop Kit
Jeep Wrangler TJ
Read and understand all instructions and warnings prior
to installation of system and operation of vehicle.
SAFETY WARNING
BDS Suspension Co. 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 BDS Suspension 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. BDS
Suspension Co. 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.
rev. 1/10/2007
4. Post suspension system vehicles may experience
drive line 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 BDS Suspension components.
Always wear safety glasses when using power
tools.
6. If installation is to be performed without a
hoist, BDS Suspension Co. recommends rear
alterations first.
7. Due to payload options and initial ride height
variances, the amount of lift is a base figure. Final
ride height dimensions 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.
102 S. Michigan Avenue • Coldwater, MI 49036
517-279-2135 • www.bds-suspension.com
Page PARTS LIST
Part #Description
Automatic Transmission Linkage Adapter
01420 Linkage Adapter Bracket
1/4” x 3/4” bolts
1/4” SAE washer
1/4” Prevailing Torque Nut
Transfer Case Drop Kit
YJTC1 Transfer Case Drop Sleeve
YJTC2 Transfer Case Drop Conical Washer
1/2-13 x 3” Transfer Case Bolts
Qty
1
2
2
2
6
6
6
INSTALLATION INSTRUCTIONS
Linkage Adapter Installation
1.
2.
Remove the two bolts mounting the shift linkage pivot
bushing from the pivot bracket on the underside of the
driver’s side floorboard.
Remove the pivot bracket from the floorboard. Pull up
the floor covering (carpet, rubber mat, etc.) in front of the
driver’s seat to access the four bracket mounting bolts.
Remove the bolts and remove the pivot bracket and
bushing from the vehicle.
3.
Mount the pivot bushing relocation bracket to the OE
bracket as shown in figure 1.
4.
Mount the pivot bushing to the relocation bracket as
shown in figure 1. Torque all mounting hardware to
proper specifications.
5.
Install the modified bracket assembly in 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.
FIG. 1
Page Transfer Case Drop Kit
6.
Support the transfer case skid pan with a floor jack.
7. Remove the three bolts on the passenger side holding the crossmember to the frame. Install the spacers
between the crossmember and the frame. Be sure the
cupped end is in contact with the crossmember.
8.
Attach the crossmember using the conical washer and
the 1/3 x 3” bolt supplied. Tighten bolts.
9.
Repeat the above steps for the driver side of the vehicle.
Note: Some models may experience interference
between the transfer case and the skid pan. It will be
necessary to trim the pan to eliminate contact. See
figure 2.
FIG. 2
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