SKYJACKER 1984-2001 Jeep Cherokee 8 Inch Rock Ready 2 Suspension Lifts Installation Guide

SKYJACKER 1984-2001 Jeep Cherokee 8 Inch Rock Ready 2 Suspension Lifts Installation Guide

Required Tools List:

• SAE Hex Key & SAE Sockets \ Wrenches
• Metric Sockets \ Wrenches
• Star-Shaped T40 & T55 Torx Head Bit
• Reciprocating Saw or Similar Cutting Tool
• Adjustable Locking Pliers
• Diagonal Cutting Pliers.
• Brake Line \ Flare Nut Wrenches
• Pipe Wrench
• Power Drill
• Center Punch
• Power Grinder
• Safety Glasses
• Floor Jack
• Wheel Chocks
• Paint Marker
• Pitman Arm Puller Tool
• Drill Bit 1/8″, 5/16″, 3/8″
• Hole Saw Bit 7/8″
• Torque Wrench
• Ball Peen Hammer
• 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.

Please Record the Important Measurement Information Below for Reference.
It is very helpful on determining an Accurate Achieved Lift Height Measurement.
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.

Driver Side Front: / Passenger Side Front: /
BEFORE / AFTER BEFORE / AFTER
Driver Side Rear: / Passenger Side Rear: /
BEFORE / AFTER BEFORE / AFTER

Important Notes:

• If Larger Tires (10% More Than 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 Vehicle to OEM Specifications.
• A Slip Yoke Eliminator Kit (Part # RR231) & Rear CV Drive Shaft Are Required for 6″ & 8″ Lifts.

Component Box Breakdown

Part # JC4258S

Part # JC4258SB

Part # JC4258SM
** Item #| Description| Qty**
---|---|---
FBL44-RBL44| BRAKE LINE SET, FRT & RR| 1
SBE320| SWAY BAR END LINK, SINGLE| 1
TBA10B| TRACK BAR ASSY. W/STABILIZER| 1
12X234X6U| 1/2 X 2-3/4 X 6 U-BOLT ROUND| 4
12X318X612U| 1/2 X 3-1/8 X 6-1/2 U-BOLT ROUND| 4
HB-12| HDWR BAG: 1/2 NUTS \ WASHERS| 1
M9525 (FRONT)| M95 MONOTUBE SHOCK| 2
M9528 (REAR)| M95 MONOTUBE SHOCK| 2

  Part # JC45X

  Part # JC68X
** Item #| Description| Qty**
---|---|---
A2049 (FRONT)| ADX 2.0 REMOTE RESERVOIR| 2
A2063 (REAR)| ADX 2.0 REMOTE RESERVOIR| 2

Part # JC6058S

Part # JC6058SB

Part # JC6058SM

Part # JC405XS2****

Part # JC605XS2

Part # JC805XS2

Part # JC408XS2

Part # JC608XS2

Part # JC808XS2

Part # JC48RRX / JC60RRX

Part # TBA10

Part # TBA10B

Part # TBA10M

Part # TBA60

Part # TBA60B

Part # TBA60M

Part # TBA80

Part # TBA80B

Part # TBA80M

Part # JC48RRX / JC60RRX

Front Coil Springs Breakdown

Part # JC45FDR|
---|---
Item #| Description| Qty
TJ45FDR| DUAL RATE LONG TRAVEL 4.5 PAIR| 1
Part # JC60FDR|
Item #| Description| Qty
TJ60FDR| DUAL RATE LONG TRAVEL 6 PAIR| 1
Part # JC80FDR|
Item #| Description| Qty
TJ80FDR| DUAL RATE LONG TRAVEL 8 PAIR| 1
| |

Rear Leaf Springs Breakdown

Part # JC25RSB|
---|---
Item #| Description| Qty
JC25RSB| SOFTRIDE LEAF SPRING, 2.5| 2
Part # JC55RSB|
Item #| Description| Qty
JC55RSB| SOFTRIDE LEAF SPRING, 5-5.5| 2
Part # JC75RSB|
Item #| Description| Qty
JC75RSB| SOFTRIDE LEAF SPRING, 7.5| 2

Component Breakdown

Part # FBL44

Part # RBL44

Part # SBE320

Part # SBE326

Part # SBE328

Part # SBE638-6XJ

Part # SH130

Hardware Bag Breakdown

Part # HB-12

Part # HB-JC48RRX

Part # HB-JC60RBS

Part # HB-TBA60

Part # HB-SBENB02

Part # HB-XJ20

Pre-Installation Tips: ‘SET’ Length of Rock Ready® Flex Link Arm Assemblies

Note: Skyjacker Lower Flex Link
Arm Are Side Specific: # JLL46FD-SX-L Driver & # JLL46FP-SX-L Passenger. Skyjacker Lower Flex Link Arm with # RE114-916R Right Hand 1-1/4″ Rod End & # 114RFTJN Jam Nut. (See Photo # 3)

On rod end, rotate jam nut against steel tubing. Hold rod end in place with a pipe wrench & a 1-13/16″ wrench on jam nut to completely tighten. (See Photo # 1 & # 2) I-JCRRX REV6 10/22

Measure length of Skyjacker Flex Link Arm assembly from centerline of rod end to centerline of bushing. ( See Photo # 3 & # 4) Note: Be sure to keep ends square with each other.

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. Raise front of vehicle, support frame rails using jack stands at indicated lift points in OEM service manual.
3. Remove front tires \ wheels.
4. Place a floor jack underneath front axle for support. Put a slight load on axle \ jack to prevent axle from moving. Remove OEM front shocks. Tech Note: Access upper shock retaining nut through engine compartment using a 15mm socket \ wrench. It also may be necessary to temporarily remove OEM washer fluid reservoir to access driver side. Disconnect OEM front shock lower mount using a 15mm socket \ wrench. Retain factory lower mounting hardware for re-use.
5. Remove OEM track bar. Disconnect track bar from passenger side lower axle mount. (See Photo # 5)
   
   Note: It may be necessary to pry track bar loose from axle mount. Disconnect track bar from driver side upper frame mount. **(See Photo # 6)

**

6. Remove OEM steering stabilizer. Disconnect stabilizer from OEM drag link at stud mount using a 11/16″ using a socket \ wrench. Remove stud mount from drag link. Disconnect stabilizer from axle mount using a 18mm socket \ wrench.

7. Disconnect OEM drag link assembly from OEM pitman arm. Take caution not to tear drag link grease boot. Tech Note: Replace OEM drag link if any excessive wear, defects or if you can twist OEM stud in its socket easily.

8. Mark position of OEM pitman arm on steering gear box. Remove OEM nut & washer from steering gear box using a 33mm socket \ wrench. Use a pitman arm puller tool to detach pitman arm. (See Photo # 7) Align & install Skyjacker # JA500 Pitman Arm on OEM steering gear shaft. Install with OEM washer & nut. Tighten using 33mm socket \ wrench. (See Photo # 8 Torque 185 ft-lbs.

9. Disconnect OEM sway bar end links from front axle mounts. Note: Some early models use a T55 Torx Bit & 19mm socket \ wrench for lower mount. (Later models used a bolt with a serrated neck that is pressed into OEM bracket, so it will not rotate.) Use a 15mm socket \ wrench for upper nut. (See Photo # 9)

10. Disconnect electrical \ vacuum four-wheel drive wiring plugs at passenger side of axle.

11. Unclip all ABS line rubber grommets from OEM brake line rubber keepers. Remove two (2) OEM brake caliper mounting bolts using a 12mm socket \ wrench. Remove brake caliper from OEM knuckle. (See Photo # 10)

Note: Do not disconnect OEM brake line from caliper. Tech Note: Hang brake caliper on frame out of way using a hook or bungee. Do Not hang by rubber brake line.

12. Support front axle with a floor jack. While checking for appropriate slack in ABS lines, differential vent hose & etc, lower front differential until OEM front coil springs become loose.
    Remove OEM bottom bolt & clip from driver side OEM coil spring using a 13mm socket \ wrench. (See Photo # 11)
    Remove OEM coil springs. Tech Note: If front axle cannot be lowered enough to allow coi spring to be installed, carefully rotate pinion up to provide more clearance.

13. Remove OEM upper control arms using a 15mm socket \ wrench.

14. 8″ Lift Only: Remove OEM upper bump stop. Tech Note: Use adjustable locking pliers working OEM bump stop back & forth to remove. Install Skyjacker # BP59XJS Bump Stops into OEM bump stop cups. Tech Note: A silicon spray or lubricant will help installation.

15. Drill a 3/8″ hole in center indent of OEM lower coil springs mount pads. (See Photo # 12) Install Skyjacker # ABSS2535 Bump Stop Spacers. Insert supplied 3/8″ X 4-1/2″ Fine Thread Bolt with 3/8″ SAE Washer into each bump stop. Align bolt into drilled hole of spring mount pad. Reach under spring mount pad & above axle tube to install supplied 3/8″ Nylon Insert Lock Nut onto bolt. Tighten bump stop into place using a 9/16″ socket \ wrench. Torque 25 ft.-lbs.

16. With front differential supported, remove OEM lower control arms using a 21mm socket \ wrench. Lower axle down.
    Remove OEM lower control arm mounting brackets. First, draw a line along outer face of OEM bracket along body. (See Photo # 13)
    Connect drawn line to all sides of OEM bracket in order to have a single cutting reference line.
    Cut along drawn line using a reciprocating saw or similar tool. (See Photo #

CAUTION: Be careful not to cut into body of vehicle. Using care, grind off any excess material smooth. File smooth any burrs or sharp edges, then paint or undercoat all exposed metal surface areas. (See Photo # 15)

17. Support OEM transmission crossmember with transmission \ floor jack. Remove transmission crossmember using a 15mm socket \ wrench.
    Remove OEM studs that secured crossmember to body mount using stud extractor or jam nut method. Use supplied 10mm x 1.5 Standard Nuts for jam nut method.
    Tighten both nuts onto stud. (See Photo # 16) Lock nuts together by tightening in opposite directions using a 15mm socket \ wrench. Extract by turning top nut counter clockwise.

Lower crossmember slightly (1-1/2″).

18. Note: Skyjacker Outer Lower Link Brackets Are Side Specific: # JLL46LB-D1 Driver & # JLL46LB-P1 Passenger. Locate Skyjacker bracket for appropriate side of vehicle. Align two (2) rearward slotted holes of Skyjacker Outer Lower Link Bracket with OEM crossmember two (2) body mount holes. Attach with supplied 10mm x 30mm Bolts with 3/8″SAE Washers using a 15mm socket \ wrench. (See Photo # 17)

19. Using Skyjacker bracket holes as a guide, mark, center punch & drill three (3) mounting holes using a 5/16″ drill bit. (See Photo # 18) Note: Prior to drilling, check behind surface area being worked on for any wires, brake lines, fuel lines, hoses, etc that could be damaged. Attach with supplied 3/8″ x 1″ Thread Cutting Bolts using a 9/16″ socket \ wrench.

20. Using Skyjacker bracket hole as a guide, mark, center punch & drill forward hole using a 7/8″ hole saw bit. CAUTION: ONLY drill through outer portion of body. Do Not drill completely through to inside of body. (See Photo # 19) WARNING: Prior to drilling, check behind surface area for brake lines, fuel lines, hoses, etc that could be damaged.

21. Place supplied 5/8″ Flat Washer & 3.938″ Long Inner Sleeve (Part # CS3938) onto 5/8″ x 6-1/2″ Bolt. Insert bolt \ washer \ sleeve through bracket & 7/8″ drilled body mounting hole. Place supplied 1″ Long Outer Sleeve (Part # CS1000) over exposed 5/8″ x 6-1/2″ Bolt & Sleeve at inner body mounting hole. Note: It may be necessary to slightly bend brake \ fuel hard lines along body for proper clearance. (See Photo # 20)

22. Note: Skyjacker Inner Lower Link Brackets Are Side Specific: # JLL46LB-D2 Driver & # JLL46LB-P2 Passenger. Locate Skyjacker bracket for appropriate side of vehicle. Align Skyjacker Inner Lower Link Bracket with Skyjacker Outer Bracket & OEM crossmember. (See Photo # 21) Attach onto 5/8″ x 6-1/2″ Bolt with supplied 5/8″ Washer & 5/8″ Nylon Insert Lock Nut using a 15/16″ socket \ wrench. Attach to OEM crossmember with supplied 3/8″ x 1″ Bolt with 3/8″ SAE Washer on bottom & 3/8″ Washer with 3/8″ Nylon Insert Lock Nut on top using a 9/16″ socket \ wrench. Secure, but Do Not Completely Tighten.

23. Using Skyjacker Outer bracket hole as a guide, mark, center punch & drill lower rear mounting hole using a 5/16″ drill bit. (See Photo # 22) Attach with supplied 3/8″ x 1″ Thread Cutting Bolts using a 9/16″ socket \ wrench.

Tech Note: If desired, you can utilize front slotted mounting hole of Skyjacker Outer bracket as an additional mount. Tap OEM mounting hole with a 7/16″ Coarse Thread Tap & install a 7/16″ x 1″ Coarse Thread Bolt & SAE Washer. (This hardware is not supplied).

24. Install Skyjacker front coil springs. Insert coil spring into upper tower first. Be sure that coil & OEM spring isolator are indexed to seat properly, then raise axle enough to hold coil spring in place. (See Photo # 23) Re-install OEM bottom clip & bolt to driver side OEM coil spring using a 13mm socket \ wrench. Torque 20 ft.-lbs. (See Photo # 11)

25. Note: Skyjacker Lower Link Flex Arms Are Side Specific: # JLL46FD-SX-L Driver & # JLL46FP-SX-L Passenger.
    Note: Bend down with upper link mounting tabs leaning inward toward middle of vehicle. Locate Skyjacker bracket for appropriate side of vehicle. Install Skyjacker Lower Link Flex Arms with rod end into Skyjacker body bracket with bushing end at OEM axle mount. Attach with OEM hardware using a 21mm socket \ wrench. (See Photos # 24)
    
    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.

26. Note: Skyjacker Upper Link Flex Arms Are Not Side Specific: # JULF24-L. Install Skyjacker Upper Link rod end into Skyjacker Lower Link mounting tabs. Attach with supplied 9/16″ x 3″ Bolt with 9/16″ SAE Washer on top & 9/16″ Washer with 9/16″ Nylon Insert Lock Nut on bottom using a 13/16″ socket \ wrench. (See Photo # 25) Attach Skyjacker Upper Link forked clevis end at OEM axle mount with OEM hardware using a 15mm socket \ wrench. Secure both mounts, 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.

27. . Locate Skyjacker Adjustable Track Bar. Locate # HB-TBA60 Hardware Bag. Coat two (2) # 2888 Poly Bushing halves & one (1) # ES24 1.38 Long Steel Sleeve with a water resistant grease. Press bushings & sleeve into upper track bar mount. Insert bushing end of Skyjacker track bar into OEM Steering Stabilizer location on passenger side axle (Not OEM track bar location). (See Photo # 26) Attach Skyjacker # 7146-B Steering Stabilizer Mounting Bracket with tab over OEM sway bar end link stud with OEM nut. (See Photo # 26) Attach Skyjacker track bar to mounting bracket with supplied 1/2″ x 2-1/2″ Flat Socket Head Bolt & 1/2″ Stover Nut using a 5/32″ Hex Key Socket & 3/4″ socket \ wrench. (See Photo # 26)

Note: In extreme situations (depending on pinion angle & caster settings), OEM drag link may contact Skyjacker Steering Stabilizer Mounting Bracket when turning. This bracket can be ground slightly for clearance if needed.

28. From # HB-TBA60 Hardware Bag, install Skyjacker Track Bar rod end by following hardware pictured. (See Photos # 27 & # 28) Keep rod end square (parallel) with frame mount. Note: Be sure No More than 1/2″ of threads are extended from track bar including jam nut measurement.

On rod end, rotate jam nut against steeltubing. Hold rod end in place with a pipe wrench & use another pipe wrench or 1-1/8″ wrench on jam nut to completely tighten. Tech Note: Jam nut must be tightened against steel tubing before installation.

29. Connect OEM drag link to Skyjacker pitman arm with OEM hardware. Locate Skyjacker # 140629 EB6 Stud & # P837 Tapered Stud Hardware.

Install Skyjacker # 140629 EB6 Stud into upper mounting hole on Skyjacker Track Bar Bracket. Attach with stud hardware. (See Photo # 29)

Install Skyjacker # P837 Tapered Stud into OEM drag link. Attach with stud hardware. (See Photo # 30)
Coat two (2) # Hourglass 5/8 Bushings with a water resistant grease. Press bushings into Skyjacker Steering Stabilizer eyes. Attach to Skyjacker bracket stud mount & OEM drag link

NOTE: Brake line installation should be done by a professional mechanic. After installation of Skyjacker Brake Lines, vehicle’s brake system will need to be bleed & purged of any air in lines before vehicle can be driven. It is suggested to familiarize yourself with brake bleeding process before beginning installation of Skyjacker brake lines. A brake bleeding tool is useful, but bleeding brake system should be done by two (2) professional mechanics.

30.  Attach brake caliper to OEM knuckle using a 12mm socket \ wrench. (See Photo # 10) Disconnect OEM brake line banjo fitting bolt from brake caliper using a 14mm socket \ wrench. (See Photo # 31)

Discard OEM crush washer from each side of banjo fitting. (See Photo # 32) Retain OEM banjo bolt.

31. Disconnect OEM hard brake line from brake line using a 3/8″ brake line \ flare nut wrench. (See Photo # 33) Remove OEM brake line bracket from frame using a T40 Torx bit. (See Photo # 33)

32. Install Skyjacker # BE15 Brake Line Bracket to frame with OEM hardware using a T40 Torx bit. (See Photo # 34) Attach Skyjacker # FBL44S Brake Line banjo fitting to OEM caliper with OEM banjo bolt & supplied 3/8″ Copper Crush Washers. Install with one (1) supplied 3/8″ Copper Crush Washer on each side of Skyjacker banjo fitting using a 14mm flare nut wrench. Note: Install with brake line bend at same angle as OEM. Torque 26 ft-lbs. Route Skyjacker brake line around suspension components same as OEM up to frame mount. Insert brake line fitting up through Skyjacker bracket at frame mount. Carefully thread OEM male brake hard line nut into female fitting on Skyjacker brake line. Note: Take care to not cross thread fittings. Tighten using a 3/8″ flare nut wrench on OEM brake line & a 5/8″ flare nut wrench on Skyjacker brake line. (See Photo # 34)

33. Install supplied Skyjacker #HC1 Brake Line Clip between OEM frame mount & top of Skyjacker brake line. Line up clip& tap it into position to secure it in place. (See Photo # 34)

34. Attach OEM ABS line at rubber grommets to Skyjacker brake lines with supplied plastic ties. Trim with Diagonal Cutting Pliers. (See Photo # 35)

NOTE: Kit With HYDRO, NITRO, Black MAX, or M95 Monotube: Proceed to Step 35. Kit With ADX 2.0 Remote Reservoir: Proceed to Step 36.

35. Install Skyjacker 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 15mm 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.

36. Install Skyjacker ADX front shock. Tech Note: ADX Remote Reservoir are to be mounted with remote reservoir toward rear for proper clearance (opposite side of coil spring mount). 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 15mm 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.

37. Locate Skyjacker Front Sway Bar End Links. # SBE320 (4.5″), # SBE326 (6″) & # SBE328 (8″) Coat # ES25 1.50 Long Steel Sleeves with a water resistant grease & press into upper & lower end links mounts.
    Note: Sway Bar End Links are to be installed with offset inward as shown. (See Photo # 36) Install Skyjacker # SBB2 Sway Bar End Link U-Bracket to bottom of OEM sway bar.

Connect with 10mm x 35mm Bolt up through u-bracket & sway bar with 3/8″ SAE Washer & 10mm Nut on top. Tighten using a 17mm socket \ wrench. Install upper end link mount into Skyjacker U-Bracket. Connect with supplied 1/2″ x 2-1/2 Bolt from frame side out to provide adequate clearance Attach 1/2″ Center Lock Nut toward outside of vehicle using a 3/4″ socket \ wrench. (See Photo # 37)

Driver side, attach lower end link to OEM axle mount with OEM hardware using a 18mm socket \ wrench & a T55 Torx head bit. (See Photo # 37) Secure, but Do Not Completely Tighten at this time.
Passenger side, attach lower end link with OEM hardware using a 18mm socket \ wrench & a T55 Torx head bit in between OEM mount & Steering Stabilizer Mounting Bracket . (See Photo # 38) Secure, but Do Not Completely Tighten at this time.

38. Connect electrical \ vacuum four-wheel drive wiring plugs at passenger side of axle. Connect all things disconnected to lower front axle (ABS lines, differential vent hose & etc.)
39. Install front tires \ wheels. Lower vehicle to ground. Torque lugs to OEM service manual specifications.

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 rear tires \ wheels.

3. Support rear axle with a hydraulic jack. Allow ample room to lower rear axle.

4. Remove OEM rear shocks. Disconnect shock lower mount using a 3/4″ socket \ wrench. Retain factory lower mounting hardware for re-use. Use a 13mm socket \ wrench for upper mount.

5. Prepare Skyjacker # XJ55RS-B Shackles. Install supplied drive-in Zerk Grease Fitting Alemite into each end of Skyjacker Shackle. Use a 1/4″ socket over Zerk fittings & tap with a hammer until fitting is completely set into place. (See Photo # 39) Coat # SP2400 Bushings & # SSXJ Steel Sleeve with a water resistant grease & press into upper shackle mount. (See Photo # 40)

6. Locate OEM rear bumper bolt that is protruding into leaf spring shackle pocket. (OEM bolt will make contact with larger Skyjacker shackle through suspension travel.) One side at a time, remove each OEM bumper bolt & replace with supplied 10mm x 20mm bolt using a 15mm socket \ wrench. (See Photo # 41)

7. Remove OEM u-bolts. Discard u-bolts & hardware. Retain lower OEM u-bolt plate.

8. While checking for appropriate slack in ABS lines, brake lines, differential vent hose, & etc, lower rear axle to gain access to OEM rear leaf springs.
   Note: Perform Steps 9-12 on One Side at a Time. Complete Steps on One Side, THEN Go to Opposite Side & Repeat Same Steps.

9. Remove OEM rear leaf spring using a 21mm socket \ wrench. (Note direction of OEM hardware.) Loosen front spring eye bolt. Loosen rear spring eye bolt. Loosen rear shackle eye bolt. (See Photo # 42)

10. Disconnect spring eye bolts & remove leaf spring with rear shackle attached. Tech Note: A helping hand is recommended to keep leaf spring assembly from falling. Remove OEM shackle. Attach Skyjacker Shackle to rear eye of Skyjacker Replacement Rear Leaf Springs with OEM hardware using a 21mm socket \ wrench. Secure, but Do Not Completely Tighten. Tech Note: Shackle Zerk grease fitting goes toward rear.

11. Install Skyjacker Leaf Spring \ Shackle Assembly to OEM frame mount with OEM hardware. (See Photo # 43)

Note: Long end of Skyjacker leaf spring & thick end of bottom degree shim goes to rear. (See Photo # 44) Secure OEM hardware, but Do Not Completely Tighten leaf spring hardware at this time. To set bushings properly for ride height, these will be tightened once vehicle is on ground with full vehicle weight on tires \ wheels.

12. 12. Clean spring pads of all debris. Raise axle to mate leaf spring to axle. Note: Be sure that leaf spring center bolt head seats properly into axle pad. Tech Note: Two (2) different U-bolt sizes are included. Use appropriate U-bolt for your axle housing size. Install supplied Skyjacker 1/2” U-Bolts under axle up into OEM u-bolt plate. (Comanche pickups install over axle down).
    Install supplied 1/2″ Nylon Insert Nuts using a 3/4″ socket \ wrench. (See Photo # 44) Torque u-bolts evenly using an ‘X’ crisscross tightening sequence. Torque to 90 ft-lbs.
    Note: Perform Steps 9-12 on Opposite Side at a Time, Then Proceed to Step 13.

13. 6″ & 8″ Lifts: Replace rear sway bar links. Locate Skyjacker Rear Sway Bar End Links. # SBE638-L (6″ & 8″) Coat 5/8 Hourglass Bushing with a water resistant grease & press into upper & lower end links mounts. Coat # ES24 1.38 Long Steel Sleeves with a water resistant grease & press into one (1) end links mount.
    Remove OEM sway bar end link upper & lower mount using a 18mm socket \ wrench. Remove OEM sway bar upper bushing from sway bar. Measure a 1/4” from each end of OEM sway bar. Mark hole to be drilled. Mark with a center punch. Using your punched marks as a guide, drill out mark using a 1/8” drill bit. Tech Note: You may want to first drill out holes with a smaller drill bit to be more precise. Install non-sleeved end of Skyjacker end link onto sway bar with supplied 5/8” SAE Washer outside & Clevis Pin Clip. Install sleeved end of Skyjacker end link into OEM lower sway bar mount with supplied 1/2” x 2” Clevis Pin.
    Note: Install Clevis Pin from outside-to-inside. Attach with supplied 1/2” SAE Washers & Clevis Pin Clip. (See Photo # 45)

14. 6″ & 8″ Lifts: Remove OEM bump stops from body using a 13mm socket \ wrench. Attach Skyjacker # JC60RBS-B Bump Stop Spacer to body with OEM hardware using a 13mm socket \ wrench. Torque 180 in-lbs. Attach OEM bump stop to Skyjacker Bump Stop Spacer with supplied 5/16″ x 1″ Bolt with 5/16″ SAE Washer bottom & 5/16″ SAE Washer with 5/16″ Nylon Insert Lock Nut top using a 1/2″ socket \ wrench. (See Photo # 46) Torque 180 in-lbs.

NOTE: Kit With HYDRO, NITRO, Black MAX, or M95 Monotube: Proceed to Step 15. Kit With ADX 2.0 Remote Reservoir: Proceed to Step 16.

15. Install Skyjacker rear shock. Connect upper shock mount with OEM hardware using a 13mm socket \ wrench. Connect lower shock mount with OEM hardware using a 3/4″ socket \ wrench.Secure, but Do Not Completely Tighten at this time.

16. Locate 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 body & reservoir cylinder. Secure, but Do Not Completely Tighten at this time.
    Install Skyjacker ADX rear shock. Connect upper shock mount with OEM hardware using a 13mm socket \ wrench. Connect lower shock mount with OEM hardware using a 3/4″ socket \ wrench. Secure, but Do Not Completely Tighten at this time.
    CAUTION: Make Sure ADX Shock Reservoir \ Reservoir Hose Does Not & Will Not Make Contact with Anything Throughout Full Travel Cycle of Suspension. (frame, frame brackets, springs, brake lines, exhaust, etc.) For proper clearance, it may be necessary to change location or orientation of reservoir on shock body. Use a 5/32″ Hex Key socket to loosen clamps to position reservoir cylinder as needed.

17. Locate OEM upper brake line mount on axle. Disconnect differential breather tube from brake line block. Disconnect OEM hard brake lines from each side of brake line block using a 3/8″ brake line \ flare nut wrench. Disconnect OEM top breather bolt from brake line block using a 9/16″ flare nut wrench. Install Skyjacker # RBL44 Brake Line. (See Photo # 47) Attach OEM hard brake lines to each side of Skyjacker brake line block using a 3/8″ brake line \ flare nut wrench. Attach Skyjacker brake line block with OEM top breather bolt to axle using a 9/16″ flare nut wrench. Connect differential breather tube to brake line block.

18. Locate OEM upper brake line mount on driver side body. Remove OEM spring clip from frame mount using pliers or screwdriver. Disconnect OEM hard brake line from OEM rubber line using a 3/8″ brake line \ flare nut wrench on metal line & 5/8″ flare nut wrench on rubber brake line. Route Skyjacker brake line around suspension components same as OEM up to frame mount. Insert Skyjacker brake line fitting up through OEM bracket at body mount. (See Photo # 48) Carefully thread OEM male brake hard line nut into female fitting on Skyjacker brake line.

Note: Take care to not cross thread fittings. Tighten using a 3/8″ flare nut wrench on OEM brake line & a 5/8″ flare nut wrench on Skyjacker brake line.

19. Bleed air from brake system as instructed by OEM service manual. Avoid getting brake fluid on painted surfaces. CAUTION: Do Not Drive Vehicle until you have made sure that all air is out of brake line system & you have a firm brake pedal. Check all brake line connections for leaks & tighten as necessary. Tech Note: A spray bottle of water works well to clean up residual brake fluid when installation is complete. REMEMBER: It is your responsibility to check brake lines for any leaks, abrasion, proper clearances. Check brake line fittings after first 100 miles & after every off-road activity.
20. Install rear tires \ wheels. Lower vehicle to ground. Torque lugs to OEM service manual specifications.

Final Clearance Check & Torque Steps

Notes: Check electrical \ vacuum four-wheel drive wiring plugs at passenger side of axle. Drag Link & Track Bar Must Be Adjusted to Center Steering Wheel Before Vehicle Is Driven. Failure to Do So Will Cause Computer Errors, Odd Handling Characteristics, & Poor Performance. Drag link at pitman arm mount. Torque 35 ft-lbs. Center Track Bar. Check vehicle to see if body is centered over the front tires \ wheels. Take a measurement from inside of tire to frame.

Repeat procedure on opposite side of vehicle. Compare two (2) measurements If not centered, disconnect track bar rod end from vehicle & adjust rod end in \ out as needed to correct center.

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

2. ounce 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.
   Skyjacker track bar at lower axle \ bracket mount using a 5/32″ Hex Key Socket & 3/4″ socket \ wrench. Torque 90 ft-lbs.
   Skyjacker track bar at upper frame mount using a 3/4″ socket \ wrench. Torque 90 ft-lbs.
   Front shock absorber upper mount using a 15mm socket \ wrench. Torque 25 ft- lbs.
   Front shock absorber lower mount using a 15mm socket \ wrench. Torque 32 ft- lbs.
   ADX Reservoir clamp. Double check position & clearance. Tighten with 5/32″ Hex Key socket.
   Sway bar end link upper bolt using a 3/4″ socket \ wrench. Torque 90 ft-lbs.
   Sway bar end link lower bolt using a 18mm socket \ wrench & T55 Torx bit. Torque 75 ft-lbs.
   Skyjacker lower link arm at axle mount using a 21mm socket \ wrench. Torque 130 ft-lbs.
   Skyjacker lower link arm at Skyjacker bracket using a 21mm socket \ wrench. Torque 130 ft-lbs.
   Skyjacker upper link arm at axle mount using a 15mm socket \ wrench. Torque 45 ft-lbs.
   Skyjacker upper link arm at lower link tabs using a 13/16″ socket \ wrench. Torque 130 ft-lbs.

4. Rear Tighten & Torque Sequence.
   Rear shock absorber upper mount using a 13mm socket \ wrench. Torque 25 ft- lbs. Rear shock absorber lower mount using a 3/4″ socket \ wrench. Torque 50 ft-lbs. ADX Reservoir clamp. Double check position & clearance. Tighten with 5/32″ Hex Key socket. Torque u-bolts evenly using an ‘X’ crisscross tightening sequence. Torque to 90 ft-lbs. Leaf Spring using a 21mm socket \ wrench. Spring eye & shackle eye bolts. Torque 65 ft-lbs.

Final Notes:

• After installation is complete, double check that all nuts & bolts are tight. Refer to 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.

Jesus Christ Died For You

John 3:16

For God so loved the world that He gave His only Son, so that everyone who believes in Him should not perish, but have everlasting life. Romans 3:23

For all have sinned; all fall short of God’s glorious standard. Ephesians 2:8

God saved you by his special favor when you believed. And you can’t take credit for this; it is a gift from God. Psalms 18:2

The Lord is my Rock, my fortress, and my savior; my God is my Rock, in whom I find protection. He is my shield, the strength of my

salvation, and my stronghold. Romans 10:9-10

That if you shall confess with thy mouth the Lord Jesus, and shall believe in your heart that God hath raised him from the dead, you shall be saved. For with the heart man believeth unto righteousness; and with the mouth confession is made unto salvation.

Pray This Simple Prayer:

God, I come to You admitting I have sinned against You and I need you to take control of my life. The Bible says anyone who calls on the name of the Lord will be saved. I am calling on You, Jesus. I ask that You come live in my heart and be the Lord over my life today. I do

believe You died on the cross for me and came back to life to give me life! Thank You, Lord Jesus for a new life in You!

Now, go and tell somebody about your new life in Jesus, get a Bible, begin to read it, and go to a Bible believing church.

If you would like someone to pray with you, call Kenneth Copeland Ministries anytime at 800-600-7395.

To listen to commercial free Christian radio on the web, go to www.887fm.org

Check out our favorite ministries at:

www.innministries.org
www.familychurch.org
www.kcm.org

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>