SKYJACKER I-JK3540BP Jeep Wrangler JK 3.5 4 Suspension Lift Instruction Manual

**SKYJACKER I-JK3540BP Jeep Wrangler JK 3.5 4 Suspension Lift Instruction Manual

**

Installation Instructions

Required Tools List:

• SAE Hex Key & SAE Sockets \ Wrenches
  (5/16″, 5/32″ & 7/32″ Hex Key Socket & 7/16″, 1/2″, 5/8″, 9/16″, 3/4″, 13/16″, 7/8″ & 1-1/8″)

• Metric Hex Key & Metric Sockets \ Wrenches
  (10mm, 14mm, 15mm, 16mm, 18mm, 19mm, 21mm & 24mm)

• Drill Bits (25/64″,

• Power Drill

• Hammer

• Sawzall, Dremel

• Safety Glasses

• Floor Jack

• Paint Marker

• Torque Wrench

• Center Punch

• Locking C-Clamp Pliers

• Tool or Similar Cutting Tool

• 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.

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

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:

Part # JK35BLT

Part # JK3570X

Part # JK35BPBLT

Part # JK35BPHLT

Part # JK35BPMLT

Part # JK35BPNLT

Part # JK350BPBSR

Part # JK350BPHSR

Part # JK350BPMSR

Part # JK350BPNSR

Part # H-BOX JK40BP

Part # JK40BLT

Part # JK4070X

Part # JK40BPBLT

Part # JK40BPHLT

Part # JK40BPMLT

Part # JK40BPNLT

Part # JK40BPBSR

Part # JK40BPHSR

Part # JK40BPNSR

Part # JK400BPMSR

Hardware Box Breakdown:

Part # H-BOX JK40BP

Part # JKFTBA717

Part # JKBRC15

Part # SBE502

Hardware Bag Breakdown:

Part # HB-JKBRC15

Part # HB-SBE502

Part # HB-JK4BL

Part # HB-JK40BP

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

ATTENTION: Parts Shown in Red are for Picture Clarification Only. Skyjacker Coil Springs & Metal Brackets Are Powder Coated Black.

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 the front tires \ wheels using a 19mm socket.

4. Remove OEM front sway bar end link at lower axle mount using a 18mm socket \ wrench.
   Remove upper mount to sway bar using a 19mm socket \ wrench. (See Photo # 1)
   
   Note: OEM rear sway bar end link will be re-used on front sway bar. (See Rear Step # 4)

5. Disconnect OEM front track bar from lower passenger side axle mount using a 21mm socket \ wrench.
   (See Photo # 2)

6. Disconnect OEM front track bar from upper driver side frame mount using a 21mm socket \ wrench. (See Photo # 3) Remove track bar & retain hardware.

7. Note: If installing a Skyjacker OEM Replacement Steering Stabilizer, remove OEM steering stabilizer using a 18mm socket \ wrench. (See Photo # 4)

8. Remove OEM front shock. Disconnect at lower axle mount using a 18mm socket \ wrench & at upper frame mount a 14mm socket \ wrench. (See Photo # 5)

9. Tech Note: On some models, it will be necessary to remove OEM brake line bracket to allow coils to be removed.
   Disconnect OEM front brake line bracket using a 10mm socket \ wrench.
   Note: 2007-10 Models: Disconnect from frame rail mount. 2011-18 Models: Disconnect from axle mount below coil spring.

10. On RUBICON Models: Disconnect OEM front axle locker sensor & some of the line clips. (See Photo # 6)

Tech Note: Red safety lock clip must be slid rearward to unlock. Press & hold rearward tang down, grab connector & pull away while from plug-in.

11. Tech Note: On some models, it will be necessary to disconnect OEM front drive shaft to ensure the drive shaft does not bind when installing taller springs. Mark the location of OEM front drive shaft \ flange at axle & disconnect using a 15mm socket \ wrench. (See Photo # 7)

12. While checking for appropriate slack in ABS lines, brake lines, differential vent hose & etc, lower the front differential & remove OEM front coil springs.
    Photo # 6 Photo # 7
    Photo # 5
    Photo # 3 Photo # 4
    I-JK3540BP REV5 06/22 Page 6 of 14

13. Place Skyjacker # ABSS2535 Front Bump Stop Spacer on top center of OEM lower coil spring mount pad. Measure, mark & center punch OEM lower coil spring mount pad. (See Photo # 8) Drill center mark using a 25/64″ drill bit. (See Photo # 9)

14. Place Skyjacker Front Bump Stop Spacer inside Skyjacker Front Coil Spring. (# JL12FS-DR 2 Door / # JL34FS-DR 4 Door) Install front coil spring with bump stop inside. 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.
    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. Insert supplied 3/8″ x 4″ Button Head Bolt into bump stop. Align bolt into hole of OEM lower coil spring mount pad. Reach under spring mount pad & above axle tube to install supplied 3/8″ SAE Washer & 3/8″ Nylon Insert Lock Nut onto bolt. Tighten bump stop into place using a 7/32″ hex key socket \ wrench & 9/16″ socket \ wrench. (See Photo # 10) Torque 25 ft.-lbs.

15. Raise front axle in order to load Skyjacker front coil springs.

16. Align marks on OEM front drive shaft \ flange & connect drive shaft with OEM hardware using a 15mm socket \ wrench. (See Photo # 6) Torque 81 ft.-lbs.

17. If installing replacement Skyjacker Steering Stabilizer, install now per separate instructions.
    NOTE: Kit With HYDRO, NITRO, Black MAX, or M95 Monotube: Proceed to Step

18. Kit With ADX 2.0 Remote Reservoir: Proceed to Step 19.

19. Install Skyjacker front shock at upper shock tower mount with supplied stud bushings, cup washers & nut using a 14mm socket \ wrench.
    Connect Skyjacker shock at lower axle mount with OEM hardware using a 18mm 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. (See Photo # 11)

20. 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). (See Photo # 12 & # 13)

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 14mm 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.

20. Connect OEM front brake line bracket with OEM hardware using a 10mm socket \ wrench.

21. On RUBICON Models: Connect front axle locker sensor. Note: Pull out on connector to verify that it is securely plugged in properly. (See Photo # 5)

22. Install the front tires \ wheels using a 19mm socket & lower the vehicle to the ground.

23. Make sure that tires \ wheels are pointed straight ahead. Install fixed end of Skyjacker # JKFTBA717 Front Adjustable Track Bar to frame with OEM hardware using a 21mm socket \ wrench. (See Photo # 14) Secure, but Do Not Completely Tighten at this time.

24. Install rod end assembly into front axle mount with OEM hardware using a 21mm socket \ wrench. (See Photo # 15) Secure, but Do Not Completely Tighten at this time. Tech Note: It may be necessary to turn steering wheel to align track rod end with mount.

25. Check front of vehicle to make sure body is centered over front tires \ wheels. Using a measuring tape, measure from inside of tire to frame on driver side, then measure passenger side. Compare two measurements; the aim is to make both sides equal. Note: If driver side measurement is greater than passenger side, track bar needs to be lengthened. If passenger side measurement is greater than driver side, track bar needs to be shortened. Remove adjustable rod end of track bar, loosen jam nut using a 1-1/8″ wrench & turn rod end to adjust in or out. Once body is properly aligned over front tires \ wheels, tighten OEM hardware using a21mm socket \ wrench. Fully tighten all OEM hardware at upper frame mount & axle mount. Fully tighten jam nut of Skyjacker adjustable front track bar using a 1-1/8″ wrench. Tighten supplied jam nut of Skyjacker Adjustable Front Track Bar using a 1-1/8″ wrench.

26. Connect OEM front sway bar end link at lower axle mount with OEM hardware using a 18mm socket \ wrench. (See Photo # 1)

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 using a 19mm socket.

3. Remove OEM rear shock. Disconnect at lower axle mount using a 18mm socket \ wrench & at upper frame mount a 16mm socket \ wrench. (See Photo # 16)

4. Disconnect OEM rear sway bar end link at axle mount using a 18mm socket \
   wrench. (See Photo # 17)

Remove upper mount to sway bar using a 19mm socket \ wrench. Relocate OEM rear sway bar end links to the front sway bar with front OEM hardware saved from Front Step # 4. Note: Replacement Double Disconnect Front Sway Bar End Links are Available Separately (Part # SBE126).

5. Disconnect OEM brake line bracket from frame mount using a 10mm socket \ wrench. (See Photo # 18)

6. Disconnect OEM rear track bar at axle mount using a 21mm socket \ wrench. (See Photo # 19)

7. Lower the rear differential. Remove OEM rear coil spring & upper coil spring isolator.

8. Install Skyjacker # JK24RTB-B Rear Lower Track Bar Bracket over OEM rear lower track bar bracket at axle. (See Photo # 20)

With Skyjacker bracket seated flush, clamp Skyjacker bracket & OEM bracket together in using locking C-clamp pliers. From the top side, use the Skyjacker bracket hole as a guide & mark / center punch the OEM bracket. (See Photo # 21) Remove Skyjacker bracket & drill axle mount using a 15/32″ drill bit.

(See Photo # 22)

9. Insert supplied 7/16″ x 1″ Fine Thread Bolt down through bracket \ axle mount. Attach with 7/16″ SAE Washer & 7/16″ Nylon Insert Lock Nut using a 5/8″ socket \ wrench. (See Photo # 23) Torque 60 ft.-lbs.

10. With bracket \ axle mount tightly in place, use the OEM bracket hole as a guide & mark / center punch the Skyjacker bracket. Drill mount hole using a 17/32″ drill bit. (See Photo # 24) Insert supplied 1/2″ x 1-1/4″ Fine Thread Bolt with 1/2″ SAE Washer outside & 1/2″ Nylon Insert Lock Nut inside using a 3/4″ socket \ wrench.

Secure, but Do Not Completely Tighten. Insert supplied 9/16″ x 3-1/2″ Fine Thread Bolt with 9/16 SAE Washer from rear-to-front through bottom hole of bracket \ axle mount. Place #CS1625 Crush Sleeve inside OEM mount & insert bolt through bracket \ axle mount. Attach with 9/16″ SAE Washer & 9/16″ Nylon Insert Lock Nut using a 13/16″ & 7/8″ socket \ wrench. (See Photo # 25) Tighten All Mounting Hardware.

11. Install Skyjacker # JK40RBS-S Rear Bump Stop Spacer to OEM axle bump stop pads with supplied 5/16″ x 1″ Fine Thread Bolt with a 5/16″ SAE Washer & a 5/16″ SAE Washer with 5/16″ Nylon Insert Lock Nut using 1/2″ wrenches. (See Photo # 26)

Note: Install Skyjacker bump stop spacer with angle cut forward toward front of vehicle.

12. Install Skyjacker rear coil spring (# JL25RS-DR 2 Door / JL40RS-DR 4 Door).
    Be sure coil spring is seated properly at lower axle mount by rotating the coil until the pigtailhits the spring stop. Note: Be sure OEM upper coil spring isolator is properly aligned with coil & upper coil spring mount. (See Photo # 27) Raise rear axle to load Skyjacker rear coil springs.

13. Remove the three (3) OEM upper left differential cover bolts. (See Photo # 28)

14. Attach Skyjacker # JKBRC15-B Track Bar Brace to rear differential. Place tapered end of Skyjacker brace in between coil spring mount & track bar mount bracket. Connect Skyjacker brace to differential cover \ housing. Note: Insert supplied 5/16″ x 1″ Coarse Thread Bolt with 5/16″ Lock Washer through brace. Place 5/16″ Extra Thick Flat Washer between brace & differential cover. (See Photo # 29) Secure using a 1/2″ socket \ wrench, but Do Not Completely Tighten.

15. Connect OEM rear track bar to Skyjacker brace & bracket. Run supplied 9/16″ x 3″ Fine Thread Bolt with 9/16 SAE Washer from front-to-rear through lower hole of brace, bracket & OEM track bar. (See Photo # 30)

Attach with 9/16″ SAE Washer & 9/16″ Nylon Insert Lock Nut using a 13/16″ & 7/8″ socket \ wrench. 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.

16. Install Skyjacker # JKBE4D Rear Brake Line Bracket to frame with OEM hardware using a 10mm socket \ wrench. (See Photo # 31

Connect OEM rear brake line bracket to Skyjacker bracket using supplied 1/4″ x 1″ Fine Thread Bolt with 1/4″ SAE Washer outside & 1/4″ SAE Washer with 1/4″ Nylon Insert Lock Nut on inside with a 7/16″ socket \ wrench. Slightly bend \ straighten OEM rear hard brake line. Note: Be very careful not to damage OEM rear hard brake lines.

17. Coat with a water resistant grease & press # ES22 1.25 Long Steel Sleeves into upper & lower mounts of Skyjacker # SBE502-L Rear Sway Bar End Links. Install upper end link mount with supplied 1/2″ x 2-1/2 Button Head Bolt with a 1/2″ USS Washer from outside of vehicle inward through sway bar with a 1/2″ SAE Washer & 1/2″ Nylon Insert Lock Nut on inside using a 5/16″ hex key socket & a 18mm socket \ wrench.
    (See Photo # 32) Attach lower end link with OEM hardware with large washer to bushing side of end link using a 18mm socket \ wrench.

18. (See Photo # 33) Secure, but Do Not Completely Tighten at this time.

NOTE: Kit With HYDRO, NITRO, Black MAX, or M95 Monotube: Proceed to Step 18. Kit With ADX 2.0 Remote Reservoir: Proceed to Step 19.

19. Install Skyjacker rear shock. Connect upper shock mount with OEM hardware using a 16mm socket \ wrench. Connect lower shock mount with OEM hardware using a 18mm socket \ wrench. (See Photo # 28) Secure, but Do Not Completely Tighten at this time. Tech Note: Black MAX & M95 Monotube are to be mounted with cylinder body up for proper installation of pre-installed upper mount bushings.

20. Tech Note: ADX Remote Reservoir shocks are to be mounted with cylinder body up. Remote reservoir is to be mounted toward rear of vehicle & rotated inward for proper clearance. (See Photo # 29)
    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 shock mount with OEM hardware using a 16mm socket \ wrench. Connect lower shock mount with OEM hardware using a 18mm socket \ wrench. Secure, but Do Not Completely Tighten at this time.

21. Install the rear tires \ wheels using a 19mm socket \ wrench & lower the vehicle to the ground.

Final Clearance Check & Torque Steps

Note: 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. Skyjacker track bar at axle using a 21mm socket \ wrench. Torque 125 ft-lbs. Front shock absorber upper mount using a 14mm socket \ wrench. Torque 32 ft-lbs. Front shock absorber lower mount using a 18mm socket \ wrench. Torque 74 ft-lbs. ADX Reservoir clamp. Double check position & clearance. Tighten with 5/32″ Hex Key socket. Sway bar end link upper bolt using a 19mm socket \ wrench. Torque 69 ft-lbs. Sway bar end link lower bolt using a 18mm socket \ wrench. Torque 59 ft-lbs.
4. Rear Tighten & Torque Sequence. Skyjacker track bar bracket bolts. 1/2″ Bolt Torque 90 ft-lbs. 9/16″ Bolt Torque 130 ft-lbs. Track bar at Skyjacker bracket using a 13/16″ & 7/8″ socket \ wrench. Torque 130 ft-lbs. Skyjacker track bar brace at differential cover using a 1/2″ socket \ wrench. Torque 45 ft-lbs. Rear shock absorber upper mount using a 16mm socket \ wrench. Torque 45 ft-lbs. Rear shock absorber lower mount using a 18mm socket \ wrench. Torque 74 ft-lbs. ADX Reservoir clamp. Double check position & clearance. Tighten with 5/32″ Hex Key socket. Sway bar end link upper bolt using a 19mm socket \ wrench. Torque 69 ft-lbs. Sway bar end link lower bolt using a 18mm socket \ wrench. Torque 59 ft-lbs.

Front Lower & Rear Upper Cam Bolt Installation

1. Use Skyjacker # CAM700 Eccentric Cam Bolts for Front Lower Control Arms for OEM axle mount brackets. Perform Steps on One Side at a Time. Disconnect front OEM lower control arm from OEM front axle mount using a 21mm socket \ wrench & a 24mm socket \ wrench.

2. 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 OEM control arm bracket mounts. (See Photo # 36 & # 37)

3. Connect OEM front lower control arm to modified OEM front axle mount using Skyjacker eccentric cam bolt, eccentric washer, nut, a 21mm socket \ wrench & a 24mm socket \ wrench. (See Photo # 38)

Note: These new eccentric cam bolts can be rotated forward or backward for proper driveline phasing, caster adjustment & to adjust axle pinion angle to eliminate driveline vibrations.

4. Use Skyjacker # CAM700 Eccentric Cam Bolts for Rear Upper Control Arms for 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 21mm socket \ wrench. Using same process as front mount brackets, repeat notching of slotted holes in steps on rear upper OEM axle mount brackets.
   Connect OEM rear upper control arm to modified OEM rear axle mount using Skyjacker eccentric cam bolt, eccentric washer, nut & a 21mm socket \ wrench. (See Photo # 39)

5. With vehicle on ground & weight of vehicle on tires \ wheels, tighten front & rear eccentric cam bolts using a 21mm socket \ wrench & 24mm socket \ wrench.

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.

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

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