Installation Instructions

Installation Instructions
7” Premium Long Arm Lift Kit
Installation Instructions:
Jeep ZJ Grand Cherokee 1993-1998
Box 1 (24x12x12)
 ZJ 7” Front springs (1 pair)
 Front shocks DT 8421 (2)
 Rear shocks DT 8403 (2)
Box 2 (24x12x12)
 Instructions
 Invoice
 Iron Rock Off Road logo decal (2)
 Ironrockoffroad.com decal (1)
 ZJ 7” Rear springs (1 pair)
 XJ/ZJ double shear track bar bracket (1)
 Rear sway bar link set #007 (1 set)
 JKS Front sway bar quick disconnects #2001 (1)
 ZJ Brake Line set (1)
 3” front bump stop spacer/rear coil spring retainer (4)
Hardware kit 13 ( rear track bar)
 Track bar bushing half (4)
 Track bar bushing sleeve 12mm I.D. (2)
 M12 x 70mm class 10.9 hex bolt (2)
 M12 class 10.9 hex nut (1)
Hardware kit 20 (front track bar)
 Track bar bushing half (4)
 7/16” I.D. track bar bushing sleeve (1)
 7/16 x 2 1/2”lg gr8 hex bolt (1)
 7/16 gr8 hex nut (1)
 12mm track bar bushing sleeve (1)
 7/16 flat washers (2)
 12mm x 80 hex bolt, class 10.9 (1)
 12mm hex nut, class 10.9 (1)
 7/8-14 jam nut (1)
Hardware kit 29 (track bar jam nut)
 7/8-14 jam nut (1)
Hardware kit 33 (shock relocation kit)
 Front BPE shock relocation bracket (2)
 3/8 x 1-1/4 gr8 hex bolt (4)
 3/8 gr8 hex nut (4)
 M10 x 60 cl10.9 hex bolt (2)
 M10 hex nut (2)
 10mm shock sleeve (2)
Hardware kit 34 (front long arm subframe)
 1/2 x 1-1/2 gr8 hex bolt (5)
 1/2 x 6-1/2 gr8 hex bolt (1)
 7/16 x 1-1/4 gr8 hex bolt (8)
 M10 x 100mm hex bolt (2)
 1/2 gr8 hex nut (6)
 7/16 gr8 hex nut (8)
 1/2 gr8 lock washer (6)
 1/2 USS washer (6)
 3/8 USS washer (8)
Hardware kit 35 (rear long arm subframe)
 7/16 x 1-1/4 gr8 hex bolts (12)
 3/8 x 4 carriage bolt (2)
 3/8 USS washer (14)
 3/8 hex nut (2)
 2 hole nut plate (2.75” center to center) (6)
 M10 x 90 cl10.9 hex bolt (2)
 M10 cl10.9 hex nut (1)
 ZJ rear coil spring retainer washer (2)
Iron Rock Off Road, Inc.
952-210-7185
Website: www.ironrockoffroad.com
E-mail: [email protected]

ZJ Rear coil spring retainer carriage bolt insert (2)
Box 3 (24x12x12)
 ZJ Front long arm subframe center section (2 hole or 4 hole specific to customer vehicle) (1)
 ZJ Front long arm subframe left outer (1)
 ZJ Front long arm subframe right outer (1)
 ZJ 1-3/4” Drop Pitman Arm (XJ5ARM)
Box 4 (42x15x6.5)
 ZJ Rear long arm subframe (1)
 XJ/ZJ double shear adjustable track bar (1)
 ZJ adjustable rear track bar (1)
Box 5 (42x15x6.5)
 ZJ Iron Y LCA (~36-1/2” center to center)
 Bushing installed
 Super flex joint assembled, adjusted, and set screw installed
 Caster adjuster assembled including 5/16 x 1 gr5 carriage bolts (4), gr8 nuts (4), and ¼” USS washers (4)
 M10 x 90 cl10.9 hex bolt, 3/8” USS washers (2), and m10 cl10.9 nylock nut
 ZJ Passenger side LCA (~36-1/2” center to center)
 Bushing installed
 Super flex joint assembled, adjusted, and set screw installed
Box 6 (36x12x12)
 Rear LCA left (~32” center to center)
 Bushing installed
 Super flex joint assembled, adjusted, and set screw installed
 Rear LCA right (~32” center to center)
 Bushing installed
 Super flex joint assembled, adjusted, and set screw installed
 Rear UCA left (~30-1/4” center to center)
 Rear UCA right (~30-1/4” center to center)
Installation Instructions:
Safety Warning: ***Important! Read before installation.***
Installing a suspension lift kit raises the center of gravity of the vehicle. This increases the possibility of a rollover accident. Avoid sudden maneuvers at
high speed and avoid all situations where a side rollover may occur. In addition larger tires decrease braking performance, please drive accordingly.
We recommend a tire and wheel combination that makes the vehicle's track width wider (wheels with less backspacing). This will lower the center of
gravity and add stability. We also recommend that this system be installed by a qualified professional. Knowledge of suspension component function is
necessary for safe installation and post installation inspections. Be sure to re-torque all suspension components after the first 100 miles of use, and
frequently inspect all safety critical suspension components.
Before you begin:
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Read all safety warnings.
Read and understand installation instructions.
Check all steering and suspension components for wear and replace as needed.
Contact Iron Rock Off Road with any questions before, during, or after installation.
You will need a hand drill and good quality 7/16” drill bit.
You will need undercoating and anti-seize compound.
You will need a good quality pitman arm puller.
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Ensure that all parts are present and in good condition per attached shipping checklist!
Prepare the parts for installation:
1.
2.
3.
Locate the front track bar and hardware kit 20. Remove threaded end and install jam nut. Adjust length to 34” center to center as a starting point.
(This may need to be readjusted after a short test drive). Lubricate poly bushings and inner sleeves with multi-purpose grease and install into track
bar. 12mm I.D. inner sleeve at threaded end, 7/16 I.D. inner sleeve other end. Leave remaining hardware in the bag for future use.
Locate the rear track bar, hardware kit 13, and hardware kit 29. Remove threaded end and install jam nut. Adjust length to 32-3/4” center to center
as a starting point. This may need to be readjusted after a short test drive. Lubricate poly bushings and inner sleeves and install into track bar.
Leave remaining hardware in the bag for future use.
Lubricate and install hourglass shock bushings into shocks (if needed). Lubricate and install 12mm I.D. x 1.5” long inner sleeve into rear shocks at
body end (bottom). Lubricate and install 10mm I.D. x 1.5” long inner sleeve into front shocks at body end (bottom). Install shock relocation
brackets to bottom side of front shocks using M10 x 60mm bolts and nuts.
Subframe Installation:
4.
5.
6.
7.
Lift front of vehicle and support with tall jack stands under the axle.
Lift rear of vehicle and support with tall jack stands under the axle.
Ensure the vehicle is safely supported.
Optional welding instructions: Some hardcore off roaders will wish to weld the subframes in place. This is optional and not required even in
abusive off road situations. Welding should only be performed by a qualified professional welder. If you wish to weld the subframe in place, follow
the same installation procedure as the bolt in with the following changes: Clean the unibody down to bare metal around the outside edge of the
subframe. Do not undercoat in areas that will be welded. Clean the outside edge of the subframe down to bare metal where it meets the unibody.
After bolting in both subframes, stitch weld the subframe to the unibody using 1” of weld and 1.5” gap between welds around the outside edges and
front and rear edges (no welds on the inside edges). The unibody is thin .075” thick sheet metal so direct most of the heat toward the 1/4” thick
subframe. Allow time between welds and take all necessary precautions to avoid burning through or overheating the unibody. Beware of any
nearby flammable materials such as fuel lines, brake lines, wiring, etc… After the welds have cooled, clean any exposed metal, apply primer, and
apply undercoating.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Locate the rear subframe and hardware kit 35. Hold the rear subframe up the the unibody using a floor jack. Place the subframe just in front of the
factory rear lower control arms mounts as far back as possible. Control arm openings face rear, Iron Rock Off Road text faces forward.
Center the subframe left to right.
Using the subframe as a guide, drill the 12 mounting holes. Peck drill and use plenty of oil.
Lower the subframe, remove burrs from inside of the holes, clean surface for undercoating.
While undercoating is still wet, install the subframe and hold in position using a floor jack.
Insert one nut plate into the uni-frame and put it in position above the rearmost holes. Use a piece of bailing wire and a small screwdriver to help
line it up and get it into position. This can be frustrating so be patient and take your time – the rest of the nut plates are easier.
Add a washer and thread each bolt into the nut plate. Repeat for remaining mounting holes.
Torque all 12 bolts to 65 foot pounds.
Locate the front subframe (3 pieces) and hardware kit 34. Loosely assemble the 3 pieces together and tighten bolts finger tight. Use the upper
holes that give 1” transfer case drop. Assemble all bolts with the nuts on the outside. The 6 1/2” long bolt goes on the passenger side upper hole
with the nut toward the rear (opposite the “Iron Rock Off Road” text).
Slightly lift transfer case and support with jack stand.
Remove factory crossmember.
Apply anti-seize compound to all bolts. If you wish to weld the subframe in place (optional, not required), clean the unibody down to bare metal
around the outside edge of the subframe, do not undercoat in areas that will be welded.
Apply undercoating to mating surface of uni-frame and install new subframe using existing bolts.
Drill the four 7/16” mounting holes per side.
Install 7/16 x 1-1/4 bolts, washers, and nuts with washers and nuts on top.
Torque all 8 bolts to 65 foot pounds.
Torque factory 10mm bolts to 50 foot pounds.
Torque all seven 1/2" subframe to subframe bolts to 90 foot pounds.
Front suspension:
26. Lift front of vehicle and support with tall jack stands under the unibody frame.
Tip: break lug nuts loose before lifting vehicle if necessary.
27. Ensure that vehicle is safely supported.
28. Remove front tires.
29. Support front axle with a floor jack (do not lift vehicle).
30. Remove front shocks.
31. Remove front sway bar links.
32. Remove front track bar and the bracket that attaches track bar to unibody. No need to separate the track bar from the bracket.
33. Remove front upper and lower control arms.
34. Allow axle to droop as much as possible.
35. Remove front coil spring clamps and coil springs.
36. Remove bump stop and bump stop cups.
37. Locate front coil spring retainers (2” O.D. x 3” long plastic spacers). Apply anti-seize compound to provided M10 x 100mm bolts and install coil
spring retainers between bump stop cup and unibody.
38. Install coil springs. Ensure coil spring is aligned to spring bucket on axle. Longer springs go in front.
39. Locate front track bar, track bar mounting bracket, and hardware kit 20.
40. Install the track bar bracket onto the unibody and torque bolts to 92 ft. lbs.
41. Install the track bar and torque bolt at axle to 74 ft. lbs., and bolt at bracket to 80 ft. lbs.
42. Locate JKS front sway bar quick disconnect kit. Install per JKS instructions. Adjust sway bar link length to maximum length recommended by JKS.
43. Remove brake hoses and replace with supplied hoses. Rotate the hoses away from other items to ensure no rubbing or chaffing.
44. Locate front shocks, and remainder of hardware kit 33.
45. Install front shocks using provided bolts. Tighten upper stud mount nuts just enough to slightly compress the bushings. *Note: Overcompressing
these bushings will result in damage to the bushings and premature bushing failure.
46. Torque shock relocation bracket bolts to 45 foot pounds and M10 shock bolt to 60 foot pounds.
47. Install passenger side front Lower control arm using factory bolts.
48. Install driver’s side Iron Y arm. Start with the lower axle side bolt, then upper axle side bolt, then unibody side bolt.
49. Remove drag link (goes from pitman arm to passenger side steering knuckle). Add a bend, just above where the tie rod connects. Bend roughly 5
degrees outward, or just enough to clear the sway bar mount while turning with the suspension fully drooped.
50. Remove drag link from pitman arm (the arm that connects the steering gearbox to the drag link) then remove pitman arm from steering gearbox
using a pitman arm puller (the arm that connects the steering gearbox to the drag link). Install provided pitman arm. Apply red locktite to threads
and torque pitman arm nut to 185 foot pounds.
51. Remove drag link (goes from pitman arm to passenger side steering knuckle). Add a bend, just above where the tie rod connects. Bend roughly 5
degrees outward, or just enough to clear the sway bar mount while turning with the suspension fully drooped.
52. Torque all lower control arm bolts to 120 foot pounds. Set the caster adjuster for maximum caster as a starting point. Torque the upper control arm
nut to 60 foot pounds. Torque the 5/16” locking nuts to 15 foot pounds.
53. Ensure drag link bolts and any other steering bolts are tightened and cotter pins are installed.
54. Any remaining loose bolts will be tightened after rear suspension is installed.
Rear Suspension:
55. Lift rear of vehicle and support with tall jack stands under the unibody frame.
Tip: break lug nuts loose before lifting vehicle if necessary.
56. Ensure that the vehicle is safely supported.
57. Remove rear tires.
58. Support rear axle with floor jack (do not lift vehicle).
59. Remove rear shocks.
60. Remove rear sway bar links.
61. Remove rear track bar (most ZJ’s require a T55 torx socket for the track bar bolts).
62. Remove upper and lower control arms.
63. Allow axle to droop as much as possible.
64. Remove coil spring clamps.
65. Remove coil springs.
66. Locate rear coil spring retainers (3” long black plastic cylinders) and hardware kit 35.
67. Place carriage bolt inserts (small not round washer with square hole) onto 3/8 x 4” carriage bolts.
68. Insert this assembly into coil spring post on unibody.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
Place a coil spring retainer over carriage bolt.
Place the large coil spring retainer washer, a 3/8” USS (standard) washer, and a 3/8 hex nut onto the carriage bolt and tighten nut.
Install the provided new springs
Install lower control arms. Superflex joint at axle side, bend faces up and in toward center of Jeep. Use front hole in subframe.
Install upper control arms. Bend faces down and in toward center of Jeep. Use provided M10 x 90mm bolts and nuts. The rearmost hole in the
subframe is hole 1. Install in hole 4 as a starting point.
Locate rear track bar and hardware kit 13.
Using provided new bolts and nut, install the track bar with the threaded end at the axle.
Torque track bar bolts to 78 foot pounds.
Lubricate upper shock bushings and upper shock mounting studs on the vehicle with multi-purpose grease.
Install rear shocks with shock shafts facing up. Torque upper nuts to 46 foot pounds, and lower nuts to 80 ft. lbs.
Remove brake hose and replace with provided brake hose.
Raise vehicle and relocate the jack stands under the front and rear axles so that the vehicle’s weight is on the suspension system.
Ensure that the vehicle is safely supported.
Install rear sway bar links with nuts facing down. Tighten nut until snug but do not compress the bushings, the spacer sleeve in the center of the
link should still be able to be rotated by hand after tightening.
Install front and rear coil spring clamps.
Torque front and rear upper control arm nuts to 60 foot pounds.
Torque front and rear lower control arm nuts to 120 foot pounds.
Tighten any jam nuts very tight (track bars, control arms if adjustable, etc…).
Torque any remaining loose bolts to spec.
Bleed the brakes. See factory service manual for brake bleeding procedure.
Install tires.
Remove vehicle from jack stands.
Torque wheel lug nuts to spec. (usually 85-115 foot-pounds, verify using factory service manual)
Adjustments and Safety Inspection:
92. Check all components for clearance for suspension to fully cycle up and down and wheels to turn lock to lock. Pay special attention to brake line
length and location of all brake lines, axle vent hoses, and ABS wires. Reposition as needed.
93. Check front and rear driveshafts for proper running length. Slight adjustments can be made by adjusting caster angle, otherwise different length
control arms, or custom driveshafts may be required.
94. Go for a short test drive.
95. Check if front tires are centered side to side under vehicle. Adjust the length of the front track bar as needed.
96. A professional front end alignment is required after installation. Your toe-in will be affected and may cause unpredictable steering and accelerated
tire wear.
Recommended caster setting: +3.0 to +6.0 (+3.5 degrees is recommended unless a different setting is required for proper driveshaft running
length)
Recommended toe in setting: 0 to .1 degrees
* Re-torque all fasteners, including lug nuts, after 100 miles, and frequently inspect all safety critical suspension components.
ZJ 7 inch premium long arm kit install.doc
Rev. 2.1
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