BARNES4WD XJ Front 3 Link Long Arm Suspension Kit Installation Guide

XJ Front 3 Link Installation Instructions

Thank you for purchasing our XJ Front 3 Link!

Installation Notes:

• This product is designed to fit Jeep Cherokees 2 door or 4 doors 1984-2001 with an AW4 automatic transmission.
• The transfer case skid is designed to fit a NP231.
• This kit requires welding, automotive mechanical knowledge, and general fabrication skills, it should only be installed by qualified individuals.
• This kit requires a minimum of 4” of lift with 3” of bump stop extensions.
• If a front axle has been swapped using our swap kit the left upper control arm mount will need to be drilled out to accept a 9/16” bolt.
• The factory lower frame control arm mounts and the left side frame front upper control arm mount will need to be removed.
• The components of this kit will need to be painted or powder coated during installation.
• This kit includes stainless steel hardware on some components. We recommend using a quality anti-seize compound on any stainless hardware during installation.

Tools required:

• Drill
•  17/32” Drill Bit *if you do not have frame stiffeners installed
• 8.5mm Drill Bit
• R Drill Bit *only if you have frame stiffeners installed
• M10x1.5 Tap
• Various Hand Tools
• Jack
• Jack Stands
• Welding machine with the capability to weld at least ¼” thick steel
• Cutting torch, plasma cutter, or other appropriate cutting tool

Possible Kit Combinations

Use the charts below to determine which combination of boxes you will receive for your make and model of Jeep. Each box should have a barcode with the kit part number listed on it.

Contents of each box

Bill Of Materials for B4WK12787

QTY| Part Number| Etch Number| Description
1| B4W188980| 980 B| Xi Front 3 Link Driver Gusset
1| B4W250958| 958 B| Xi Front 3 Link Crossmember Frame Bracket Driver
1| B4W250961| 961 B| Xi Front 3 Link Kit Upper Bracket
1| B4W250960| 960 B| Xi Front 3 Link Lower Bracket Driver
1| B4W250956| 956 B| Xi Front 3 Link Crossmember Main
1| B4W250959| 959 B| Xi Front 3 Link Crossmember Frame Bracket
Passenger
1| B4W188981| 981 B| Xi Front 3 Link Passenger Gusset
1| B4W250971| 971 B| Xi Front 3 Link Lower Bracket Passenger
1| B4WK12786| 957| Xi Front 3 Link Crossmember Bottom Assembly
6| 37C125HC8Y| NA| 3/8″-16X1-1/4″ Hex Bolt Grade 8 Yellow
6| 37NWSAFY| NA| 3/8 SAE Washer Yellow Zinc
6| FPCALFST616150| NA| 3/8-16 Rivet Nut Insert .027-.150
6| 43CNNEOY/GC| NA| 7/16-14 NYLOCK
6| 43C125HCS8Y| NA| 7/16-14 x 1.25
12| 43NWSAFY| NA| 7/16 SAE Washer Yellow
6| .100C350BHFOY/6921| NA| M10-1.5 x 35mm Hex Flange Bolt Yellow Zinc
1| 43CNFH8Y| NA| 7/16-14 Nut
6| 37C125HTROZ| NA| 3/8″-16 x 1-1/4″ Hex Washer Thread Forming Screw
Bill Of Materials for B4WK12788

QTY| Part Number| Etch Number| Description
2| 56C400HCS8Y| NA| 9/16-12×4 GRADE 8 BOLT
2| 56CNNE0Y/GC| NA| 9/16-12 NYLOCK
2| DOM201536| NA| DOM 2″X1.5″X36″
2| JN125012LH| NA| LH 1-1/4″-12 Jam Nut
2| JN125012RH| NA| RH 1-1/4″-12 Jam Nut
2| 125HWRH| NA| Heavy Wall Tube Insert (1 1/4″-12) For 1 1/2″ I.D. Tubing
2| 125HWLH| NA| Heavy Wall Tube Insert (1 1/4″-12) For 1 1/2″ I.D. Tubing
4| HMS169ZP| NA| Hi Mis-Alignment Spacer Pair
2| XM16-CR| NA| Heat Treated Chromoly 1 1/4-12 X 1 RH Long Shank
2| XM16-CL| NA| Heat Treated Chromoly 1 1/4-12 X 1 LH Long Shank
Bill Of Materials for B4WK12789

QTY| Part Number| Etch Number| Description
1| 56C400HCS8Y| NA| 9/16-12×4 GRADE 8 BOLT
2| 56CNNE0Y/GC| NA| 9/16-12 NYLOCK
1| 56C325HCS8Y| NA| 9/16-12 X 3 1/4″ Grade 8 Bolt
1| B4WXJLAFUL| NA| XJ Front Long Arm Upper Link
1| TJFAUCAB9| NA| TJ Front Axle UCA Bushing 9/16″
1| B4W188660| 660 B| TJ Suspension Kit Front Upper Link Axle Bracket
1| JN125012RH| NA| RH 1-1/4″-12 Jam Nut
1| HMS169ZP| NA| Hi Mis-Alignment Spacer Pair
1| XM16-CR| NA| Heat Treated Chromoly 1 1/4-12 X 1 RH Long Shank
1| 1251215175RHMS| NA| Tube Insert 1.25-12RH 1.5ID 1.75OD
Bill Of Materials for B4WK12790

QTY| Part Number| Etch Number| Description
1| B4W250963| 963 B| XJ 3 Link Tcase Skid Bracket
1| B4W250962| 962 CB| XJ 3 Link Tcase Skid
4| 37C100KFCS| NA| 3/8-16 x 1 Counter sunk SS bolt
3| 37C125HCS8Y| NA| 3/8″-16X1-1/4″ Hex Bolt Grade 8 Yellow
1| FPCALFST616150| NA| 3/8-16 Rivet Nut Insert .027-.150
5| 37NWSAFY| NA| 3/8 SAE Washer Yellow Zinc
2| 37CNNE0Y/GC| NA| 3/8-16 Nylock Yellow

Step 1:
Park vehicle on a level surface. Support the transmission and remove the factory crossmember.
Step 2:
Drill out the forward most hole in the unibody with an 8.5mm drill bit and tap to a M10X1.5 thread.

Step 3:
Remove crossmember studs from the unibody threading two nuts together onto the stud.
Tighten the nuts together and turn the top nut to remove the stud.

Step 4:
Assemble the crossmember as shown below making sure it is assembled in the correct orientation. Weld the bottom to the main crossmember.

Step 5:
Assemble the driver and passenger side control arm brackets as shown below. Once assembled in the correct orientation weld the assembly together.

Step 6:
Install the driver and passenger side bracket assembly, and gusset onto the vehicle as shown below. Mark the 3 holes in the gussets on each side of the unibody. Remove the bracket assembly. Drill a 7/32” hole if you do not have frame stiffeners and move to step 7. If you do have frame stiffeners drills a R size hole and move to step 8

Step 7:
Using one of the 3/8” bolts, two 3/8” washers, and the provided 7/16” nut, as shown below, install the six rivet nuts. Push the rivet nut into drilled in step 6. With a 11/16” wrench, hold the 7/16” nut and using a 9/16” wrench or socket, tighten the bolt until the rivet nut is fully installed. The bolt will become very tight and there should be no wiggle or twist to the rivet nut.

Step 8:
Reinstall the driver and passenger side bracket assembly and gusset to the unibody. Using 3/8” thread forming screws for frame stiffener installation and standard 3/8” hardware for nonstiffener installation. Leave hardware loose until crossmember has been installed.
Step 9:
Install the crossmember as shown below and tighten all the hardware.

Step 10:
With the Jeep sitting at ride height measure the bolt hole center distances from each bracket on the crossmember to the accompanying bracket on the axle and record these measurements in the table below. The measurements taken here will be used to build the new control arms.

Right Lower|
---|---
Left Lower|
Upper|

Step 11:
The provided front axle right side control arm bushing now needs to be installed in the front axle. Remove the front left upper control arm from the Jeep. Take a measurement from the side of the casting to the end of the bushing and record this measurement. The old bushing now needs to be removed. This can be accomplished with multiple methods, however using a pneumatic air hammer to drive the old bushing out is the most effective method. The new bushing will now need to be installed to the same dimension as recorded above. A ball joint press or other appropriate tool can be used to press the new bushing in.

Step 12:
Assemble the lowers, the provided tubing will need to be cut to length and the threaded inserts welded into each end. Referencing the images below for component placement, assemble each heim joint, tube insert and jam nut with 1” of thread showing between the end of the jam nut and the end of the threads on the heim. This will allow for some adjustment after installation if needed. Place the assembled components on a table or other flat surface and arrange them based on the bolt hole center measurements taken in step 10. Measure the distance between the tube inserts and cut the tubing to this length. Remove the heim joints from the threaded inserts, install the inserts in the tubing, and weld in place for each link.

Step 13:
Assemble the upper link as follows. The provided tubing will not need to be cut for the upper. Install the threaded insert and weld in place. Lay the tube flat on a level surface across the short bent and. Center B4W188660 on the tube, the top should measure 90° from the level surface. Weld the bracket together and to the tubing.

Step 14:
The unibody front left upper control arm mount and both the unibody lower control arm mounting brackets will need to be cut off from the unibody. This can be done all at the same time or one at a time. If only removing one link and unibody bracket at a time, the new link can be then installed in its place. This is a useful method if installing this kit without the use of a vehicle lift. Hardware has been provided for all the frame brackets and the uppers at the axle, the factory bolts for the lowers at the axle will be reused. The remaining upper control arm brackets on the unibody and axle brackets can be removed if desired or left in place. Tighten all 9/16” hardware to 110 Ft-lbs.

Congratulations! You have finished the installation of the Barnes4wd XJ Front 3 Link Kit.
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AJM 5/4/23

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