SKYJACKER TJ2030X 2.5 Inch 3 Inch Suspension Lift Installation Guide

SKYJACKER TJ2030X 2.5 Inch 3 Inch Suspension Lift

Product Information

The product being referred to in the user manual is a suspension lift kit for 1997-2006 Jeep TJ & LJ Wrangler models. The kit includes various components such as dual rate coils, shocks with boots, cam bolts, track bar bracket, and hardware.

 Installation Instructions

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Required Tools List

• SAE Hex Key & SAE Sockets \ Wrenches
  (5/32″ Hex Key Socket & 3/4″)

• Metric Hex Key & Metric Sockets \ Wrenches
  (13mm, 15mm, 17mm, & 18mm)

• Star-Shaped T55 Torn Head Bit

• Sawzall, Dremel Tool or Similar Cutting Tool

• Pitman Arm Puller Tool

• Channel Lock Pliers
  

• Power Drill
  

• Hammer
  

• Safety Glasses
  

• Floor Jack
  

• Paint Marker
  

• Torque Wrench
  

• Drill Bit (1/2″)
  

• Center Punch
  

• Wheel Chock
  

• Jack Stands
  

• Measuring Tape
  

Before beginning installation, read these instructions & enclosed driver’s WARNING NOTICE thoroughly & completely. Also affix WARNING decal in passenger compartment in clear view of all occupants. Please refer to Parts List to insure that all parts & hardware are received prior to disassembly of vehicle. If any parts are found to be missing, contact SKYJACKER® Customer Service at 318-388-0816 to obtain needed items. If you have any questions or reservations about installing this product, contact SKYJACKER® Technical Assistance at 318-388-0816.

Make sure you park vehicle on a level concrete or asphalt surface. Many times a vehicle is not level (side-to-side) from factory, but is usually not noticed until a lift kit has been installed which makes difference more visible. Using a measuring tape, measure front & rear (both sides) from ground up to center of fender opening above axle. Record this information below for future reference.

Important Notes

• The Drag Link Must Be Adjusted to Center the Steering Wheel Before the Vehicle Is Driven. Failure to Do So Will Cause Computer Errors, Odd Handling Characteristics, & Poor Performance.
• If Larger Tires (10% More Than the OEM Diameter) Are Installed, Speedometer Recalibration Will Be Necessary. Contact Your Local JEEP Dealer or an Authorized Skyjacker® Dealer for Details.
• After Installation, a Qualified Alignment Facility Is Required to Align the Vehicle to the OEM Specifications.

Component Box Breakdown

Item #

| Description|

Qty

---|---|---
A2016 (FRONT)| ADX 2.0 REMOTE RESERVOIR| 2
A2018 (REAR)| ADX 2.0 REMOTE RESERVOIR| 2
Item #| Description|

Qty

---|---|---
TJ25FS-DR| DUAL RATE COIL, FRONT| 2
TJ25RS-DR| DUAL RATE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
Item #| Description|

Qty

---|---|---
TJ25FS-DR| DUAL RATE COIL, FRONT| 2
TJ25RS-DR| DUAL RATE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
B8516 (FRONT)| BLACK MAX SHOCK W/BLK BOOT| 2
B8518 (REAR)| BLACK MAX SHOCK W/BLK BOOT| 2
Item #| Description|

Qty

---|---|---
TJ25FS-DR| DUAL RATE COIL, FRONT| 2
TJ25RS-DR| DUAL RATE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
H7016 (FRONT)| HYDRO SHOCK W/RED BOOT| 2
H7018 (REAR)| HYDRO SHOCK W/RED BOOT| 2

Item #

| Description|

Qty

---|---|---
TJ25FS-DR| DUAL RATE COIL, FRONT| 2
TJ25RS-DR| DUAL RATE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
M9516 (FRONT)| M95 MONOTUBE SHOCK| 2
M9518 (REAR)| M95 MONOTUBE SHOCK| 2

Item #

| Description|

Qty

---|---|---
TJ25FS-DR| DUAL RATE COIL, FRONT| 2
TJ25RS-DR| DUAL RATE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
N8016 (FRONT)| NITRO SHOCK W/RED BOOT| 2
N8018 (REAR)| NITRO SHOCK W/RED BOOT| 2

Item #| Description|

Qty

---|---|---
CAM500| CAM BOLTS, UPPER REAR| 1
TJRTB-B| TRACK BAR BRACKET, REAR| 1
HB-TJ25| HDWR BAG: 1997-2006 TJ 2.5| 1
I-TJ2530| INST SHEET: TJ2530| 1
Item #| Description|

Qty

---|---|---
TJ30FS| SOFTRIDE COIL, FRONT| 2
TJ30RS| SOFTRIDE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
Item #| Description|

Qty

---|---|---
TJ30FS| SOFTRIDE COIL, FRONT| 2
TJ30RS| SOFTRIDE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
B8516 (FRONT)| BLACK MAX SHOCK W/BLK BOOT| 2
B8518 (REAR)| BLACK MAX SHOCK W/BLK BOOT| 2
Item #| Description|

Qty

---|---|---
TJ30FS| SOFTRIDE COIL, FRONT| 2
TJ30RS| SOFTRIDE COIL, REAR| 2
TJ250| COMP BOX: 1997-2006 TJ 2.5| 1
H7016 (FRONT)| HYDRO SHOCK W/RED BOOT| 2
H7018 (REAR)| HYDRO SHOCK W/RED BOOT| 2

Hardware Bag Breakdown

Item #| Description|

Qty

---|---|---
10MMX70MMB| 10MM X 70MM METRIC BOLT| 4
12X70MMB| 12MM X 70MM METRIC BOLT| 1
12MMN| 12MM METRIC NUT| 1
12X112FTB| 1/2 X 1-1/2 FINE THREAD BOLT| 1
12FTN| 1/2 FINE THREAD LOCK NUT| 1
12SAEW| 1/2 SAE WASHER| 3
BPS20-B| BUMP STOP SPACER| 4
SSTJRTB| CRUSH SLEEVE| 1

Front Installation

Note: Save all factory components & hardware for reuse, unless noted.

1. With vehicle on flat level ground, set emergency brake & chock rear tires \ wheels.

2. From inside the engine compartment, disconnect both OEM front shock upper stud mounts using a 15mm socket \ wrench.

3. Raise front of vehicle, support frame rails using jack stands at indicated lift points in OEM service manual.

4. Remove the front tires \ wheels using a 3/4″ or 18mm socket.

5. Place a floor jack underneath front axle for support. Disconnect OEM front shock lower mount using a 13mm socket \ wrench. Retain factory lower mounting hardware for re-use.

6. Note: If installing a Skyjacker OEM Replacement Steering Stabilizer, remove OEM steering stabilizer using a 15mm socket \ wrench.

7. Disconnect OEM front track bar from lower passenger side axle mount using a 15mm socket \ wrench or a T55 Torx head bit. (See Photo # 1)

8. Disconnect OEM drag link assembly from OEM pitman arm. Use a pitman arm puller tool to detach drag link from pitman arm. Take caution not to tear the draglink grease boot.

9. Disconnect OEM sway bar end links from axle brackets using a 18mm socket \ wrench & a T55 Torx head bit. (See Photo # 2)

10. Support front axle with a floor jack. While checking for appropriate slack in ABS lines, brake lines, differential vent hose & etc, lower the front differential until the OEM front coil springs become loose.
    Remove OEM bottom bolt & clip from driver side OEM coil spring using a 13mm socket \ wrench. (See Photo # 3)
    Remove OEM coil spring. Tech Note: If front axle cannot be lowered enough to allow coil spring to be installed, carefully rotate the pinion up to provide more clearance.
    Remove OEM upper bump stop. Tech Note: Use channel lock pliers working OEM bump stop back & forth to remove.

11. Remove the OEM 10mm bolt from inside the OEM bump stop cup using a 15mm socket \ wrench.
    Install Skyjacker # BPS20-B Bump Stop Spacer into OEM bump stop cup with supplied 10mm x 70mm Bolt using a 17mm socket. Re-install OEM bump stop into OEM bump stop cup. (See Photo # Tech Note: A silicon spray or lubricant will help installation.

12. Install Skyjacker front coil springs. Insert coil spring into upper tower first. Be sure that the coil & OEM spring isolator are indexed to seat properly, then raise axle enough to hold coil spring in place. Re-install OEM bottom clip & bolt to driver side OEM coil spring using a 13mm socket\ wrench. Torque 20 ft.-lbs.

13. 13. Install Skyjacker front coil springs. Insert coil spring into upper tower first. Be sure that the coil & OEM spring isolator are indexed to seat properly, then raise axle enough to hold coil springin place. Re-install OEM bottom clip & bolt to driver side OEM coil spring using a 13mm socket wrench. Torque 20 ft.-lbs.
    NOTE: Kit With HYDRO, NITRO, Black MAX, or M95 Monotube: Proceed to Step Kit With ADX 2.0 Remote Reservoir: Proceed to Step 15.

14. Install Skyjacker front shock at upper shock tower mount with supplied stud bushings, cup washers & nut using a 15mm socket \  wrench. (See Photo # 5)

Connect Skyjacker shock at lower axle mount with OEM hardware using a 13mm socket \ wrench. Secure, but Do Not Completely Tighten. To set bushings properly for ride height, these will be tightened once vehicle is on ground with full vehicle weight on tires \
wheels.

15. Install Skyjacker ADX front shock. Tech Note: ADX Remote Reservoir are to be mounted with the remote reservoir toward rear for proper clearance (opposite side of coil spring mount).opposite side of coil spring mount). (See Photo # 6 & # 7)

Loosely assemble two (2) supplied reservoir clamps with two (2) supplied hex head bolts using a 5/32″ Hex Key socket. Position clamp into place around shock & reservoir cylinder. Secure, but Do Not Completely Tighten. Install Skyjacker ADX front shock at upper shock tower mount with supplied stud bushings, cup washers & nut using a 15mm socket \ wrench  Connect Skyjacker shock at lower axle mount with OEM hardware using a 18mm socket \ wrench. Secure, but Do Not Completely Tighten at this time. These will be tightened once vehicle is on ground with full vehicle weight on tires \ wheels.

16. Connect OEM drag link to OEM pitman arm using OEM hardware. Torque 60 ft.-lbs.
    Note : Always tighten, never loosen castellated nut to align cotter pin hole.

17.  Connect OEM sway bar end links to axle brackets with OEM hardware using a 18mm socket \ wrench & a T55 Torx head bit.

18.  If installing replacement Skyjacker Steering Stabilizer, install now per separate instructions.

19.  Install the front tires \ wheels using a 3/4″ or 18mm socket & lower the vehicle to the ground.

20. Connect OEM front track bar to lower passenger side axle mount using a using a 15mm socket\ wrench or a T55 Torx head bit. (See Photo # 1) Tech Note: It may be necessary to raise \ lower axle to align track bar bolt.

Rear Installation

Note: Save all factory components & hardware for reuse, unless noted.

1. Chock front tires \ wheels. Raise rear of vehicle & support frame rails using jack stands at indicated lift points in OEM service manual.

2. Remove the rear tires \ wheels using a 3/4″ or 18mm socket.

3. Remove OEM rear shocks. Disconnect upper mount bar pin using a 13mm socket \ wrench. Disconnect lower axle mount using a 18mm & a 15mm socket \ wrench.

4.  Disconnect OEM rear track bar at axle mount using a using a T55 Torx bit.

5. Disconnect OEM rear sway bar end links using a 18mm & a 15mm socket \ wrench.

6. Support rear axle with a floor jack. While checking for appropriate slack in ABS lines, brake lines, differential vent hose & etc, lower the rear axle until the OEM front coil springs become loose. Remove OEM coil spring.

7. Remove OEM upper bump stop. Tech Note: Use channel lock pliers working OEM bump stop back & forth to remove.

8. Remove OEM 10mm bolt from inside OEM bump stop cup using a 15mm socket \ wrench. Install Skyjacker # BPS20-B Bump Stop Spacer to OEM bump stop  cup with supplied 10mm x 70mm Bolt using a 17mm socket \ wrench. Install OEM bump stop into OEM bump stop cup. (See Photo # 8)

9. Install Skyjacker # TJRTB-B Rear Lower Track Bar Bracket over OEM rear lower track bar bracket at axle.
   With Skyjacker bracket seated flush, insert supplied 12mm x 70mm Bolt with 1/2″ SAE Washer from rear-to-front through bottom hole of bracket \ axle mount. Place # SSTJRTB Crush Sleeve inside OEM mount & insert bolt through bracket \ axle mount. Attach with 12mm Nylon Insert Lock Nut using a 18mm socket \ wrench. (See Photo # 9) Tighten. With bracket \ axle mount tightly in place, use the Skyjacker bracket hole as a guide & mark /center punch the OEM bracket. (See Photo # 10)
   Remove Skyjacker bracket & supplied hardware. Drill axle mount using a 1/2″ drill bit. Re-install Skyjacker bracket. Insert supplied 1/2″ x 1-1/2″ Fine Thread Bolt with 1/2″ SAE Washer through bracket \ axle mount at drilled hole. Attach with 1/2″ SAE Washer & 1/2″ Nylon Insert Lock Nut using a 3/4″ socket \ wrench. (See Photo # 11) Torque 60 ft.-lbs. Re-install supplied hardware for bracket \ axle mount as stated before & tighten all mounting hardware. 1/2″ Bolt Torque 65 ft-lbs. 12mm Bolt Torque 75 ft-lbs.
   

10. Install Skyjacker rear coil spring. Be sure coil spring is seated properly at lower axle mount by rotating the coil until the pigtail hits the spring stop. Note: Be sure OEM upper coil spring isolator is properly aligned with coil & upper coil spring mount. Photo # 12
    Raise rear axle to load Skyjacker rear coil springs.

11. Connect OEM rear track bar to Skyjacker rear track bar bracket with OEM hardware from rear-to-front using a using a T55 Torx bit. (See Photo # 12) Secure, but Do Not Completely Tighten at this time. Tech Note : It may be necessary to raise \ lower axle to align track bar bolt. A rachet strap can be helpful to align track bar / bracket together.

12. Connect OEM sway bar end links to rear axle with OEM hardware using a 13mm socket \ wrench.

13.  Install Skyjacker rear shock. Connect upper bar pin mount with OEM hardware using a 15mm socket \ wrench. Connect lower axle mount with OEM hardware using a 18mm socket \ wrench. Secure, but Do Not Completely Tighten at this time. (See Photo # 13)

14. Assemble Skyjacker ADX rear shock. Loosely assemble two (2) supplied reservoir clamps with two (2) supplied hex head bolts using a 5/32″ Hex Key socket. Position clamp into place around shock & reservoir cylinder. Secure, but Do Not Completely Tighten at this time.
    Install Skyjacker ADX rear shock. Connect upper bar pin mount with OEM hardware using a 15mm socket \ wrench. Connect lower axle mount with OEM hardware using a 18mm & a 15mm socket \ wrench. Secure, but Do Not Completely Tighten at this time. Tech Note: Remote reservoir is to be mounted toward rear of vehicle & rotated for proper clearance.

15. Install the rear tires \ wheels using a 3/4″ or 18mm socket & lower the vehicle to the ground.

Final Clearance Check & Torque Steps:

Notes: Check Front Center Axle Disconnect (CAD) connection & on RUBICON Models: Check Front & Rear locker connections.
The Drag Link Must Be Adjusted to Center the Steering Wheel Before the Vehicle Is Driven. Failure to Do So Will Cause Computer Errors, Odd Handling Characteristics, & Poor Performance.

1. Start vehicle. Make sure there are no dash lights pertaining to suspension.

2. Jounce vehicle a couple of times. This will help suspension settle to new ride height. Cycle steering lock-to-lock & check all components for proper operation & clearances. Pay special attention to clearance between tires \ wheels, ADX Shocks & Reservoirs, control arms, brake hoses, ABS wiring, etc.

3.  Front Tighten & Torque Sequence.
   Track bar at axle mount using a 15mm socket \ wrench or a T55 Torx head bit.
   997-2002 Models Torque 55 ft-lbs.
   2003-2006 Models Torque 40 ft-lbs.
   Front shock absorber upper mount using a 15mm socket \ wrench. Torque 17 ft- lbs.
   Front shock absorber lower mount using a 13mm socket \ wrench. Torque 250 in- lbs.
   ADX Reservoir clamp. Double check position & clearance. Tighten with 5/32″ Hex Key socket. Sway bar end link upper nut using a 15mm socket \ wrench. Torque 45 ft-lbs.
   Sway bar end link lower bolt using a 18mm socket \ wrench & T55 Torx bit. Torque 75 ft-lbs.

4. Rear Tighten & Torque Sequence.
   Skyjacker track bar bracket bolts. 1/2″ Bolt Torque 65 ft-lbs. 12mm Bolt Torque 75 ft-lbs. Track bar at Skyjacker bracket using a T55 Torx bit. Torque 74 ft-lbs.
   Rear shock absorber upper mount using a 13mm socket \ wrench. Torque 26 ft- lbs.
   Rear shock absorber lower mount using a 18mm & a 15mm socket \ wrench. Torque 74 ft-lbs. ADX Reservoir clamp. Double check position & clearance. Tighten with 5/32″ Hex Key socket. Sway bar end link mounts using a 18mm & a 15mm socket \ wrench. Torque 40 ft-lbs.

Rear Upper Cam Bolt Installation

Use Skyjacker # CAM500 Eccentric Cam Bolts for Rear Upper Control Arms at OEM axle mount brackets. Perform Steps on One Side at a Time.
Disconnect rear OEM upper control arm from OEM rear axle mount using a 15mm socket \ wrench.
Note: Only Disconnect One (1) Side at a Time.

The OEM control arm axle mount brackets have ‘knockout’ alignment inserts. Use inserts as a guide and cut a slotted rectangular hole. Using a Sawzall, Dremel or other small cutting device, cut out a notch on each side of rear upper OEM axle mount bracket. (See Photo # 14)

Connect OEM rear upper control arm to modified OEM rear axle mount using Skyjacker Eccentric Cam Bolt, Eccentric Washer & Nut using a 15mm & a 17mm socket \ wrench. (See Photo # 15)

With vehicle on ground & weight of vehicle on tires \ wheels, tighten front & rear eccentric cam bolts using a 15mm & a 17mm socket \ wrench. Note: These bolts can be rotated to adjust the axle pinion angle to eliminate any driveline vibration.

Final Notes

• After installation is complete, double check that all nuts & bolts are tight. Refer to the following chart for proper torque specifications. (Note: Do not re-tighten nuts & bolts where thread lock compound was used.)
• With vehicle placed on ground, cycle steering lock to lock & inspect steering, suspension, brake lines, front & rear drivelines, fuel lines & wiring harnesses for proper operation, tightness & adequate clearance.
• Have headlights readjusted to proper settings.
• Have a qualified alignment center align vehicle to OEM specifications.
• After first 100 miles, check all hardware for proper torque & periodically thereafter.

TORQUE SPECIFICATIONS

INCH SYSTEM

|

METRIC SYSTEM

Bolt Size| Grade 5| Grade 8| Bolt Size| Class 8.8| Class 10.9
5/16| 180 in-lbs| 240 in-lbs| 6MM| 102 in-lbs| 108 in-lbs
3/8| 30 ft-lbs| 35 ft-lbs| 8MM| 16 ft-lbs| 23 ft-lbs
7/16| 45 ft-lbs| 60 ft-lbs| 10MM| 32 ft-lbs| 45 ft-lbs
1/2| 65 ft-lbs| 90 ft-lbs| 12MM| 55 ft-lbs| 75 ft-lbs
9/16| 95 ft-lbs| 130 ft-lbs| 14MM| 85 ft-lbs| 120 ft-lbs
5/8| 135 ft-lbs| 175 ft-lbs| 16MM| 130 ft-lbs| 165 ft-lbs
3/4| 185 ft-lbs| 280 ft-lbs| 18MM| 170 ft-lbs| 240 ft-lbs
The Above Specifications Are Not to Be Used When the Bolt Is Being Installed With a Bushing.

Seat Belts Save Lives, Please Wear Your Seat Belt.

Documents / Resources

| SKYJACKER TJ2030X 2.5 Inch 3 Inch Suspension Lift [pdf] Installation Guide
TJ2030X 2.5 Inch 3 Inch Suspension Lift, TJ2030X, 2.5 Inch 3 Inch Suspension Lift, 3 Inch Suspension Lift, Suspension Lift, Lift
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