RUSTY S OFF ROAD PRODUCTS RK-300AL-MJ 3 Inch Add-A-Leaf Kit Installation Guide

RUSTY S OFF ROAD PRODUCTS RK-300AL-MJ 3 Inch Add-A-Leaf Kit

Product Information

• Product Specifications:
  • Brand: Rusty’s Off-Road Products
  • Model: MJ Comanche 3 Add-A-Leaf Kit RK-300AL-MJ
  • Address: 7161 Steele Station Road Rainbow City, AL 35906
  • Contact: 1-256-442-0607
  • Website: www.rustysoffroad.com.

Product Usage Instructions

• Before Starting Installation:
  • Carefully read all warnings and instructions completely before beginning.
  • Verify all parts have been received in this kit by checking the parts list provided.
  • Only install this kit on the specified vehicle.
  • Park the vehicle on a clean, dry, flat, level surface and block the tyres to prevent rolling.
  • Secure the vehicle on jack stands or a vehicle lift before working around or under it.
• Front Installation Instructions:
  • Raise the vehicle and place the jack stand under the frame. Check the rear tyres to prevent movement.
  • Remove the tyres and wheels.
  • Remove the factory shocks and sway bar links, keeping the hardware for reuse.
  • Support the front axle with a floor jack.
  • Remove the bolt at the axle end of the track bar.
  • Remove the front lower control arm bolts on both sides.
  • Remove the bolt holding the spring keeper clip on each side.

FAQs

• Q: How can I contact Rusty’s Off-Road Products for questions or suggestions?
  • A: You can contact their Tech Department at 1-256-442-0607.

Introduction

• Rusty recommends that this installation be performed by a certified automotive technician or a person with professional mechanical knowledge.
• Installing this kit without this expertise may jeopardize the handling and safety of the vehicle.
• Read instructions several times before starting. Be sure you have all the needed parts and know where they are installed.
• Read each step completely as you go. Exhaust modifications may be necessary.
• Before drilling or cutting, check behind the surface being worked on for any wires, lines, or hoses that could be damaged.
• After any drilling or cutting, remove burrs and grind smooth any surfaces.
• An inclinometer or similar tool may be needed to measure driveshaft angles before and after the installation.

Warning:

• It is the owners’ responsibility to inspect all Rusty’s products for proper torque specs to prevent the loosening of components.
• Seat belts and shoulder harnesses should be worn at all times.
• Re-check all bolts and nuts after the first 100 miles and after any off-road usage during the first 300 miles.
• Although all of our products are made from the highest quality materials possible, they are not a substitute for Safe and Careful driving. In other words, have good safe on-road/off-road sense.
• Know the terrain, the speed limitations, and any obstacles that may lie ahead.
• Please remember to preserve our right to enjoy public land through the proper use of off-road vehicles.

Before Starting Installation

1. Carefully Read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by checking the parts list on page#2 of this document.
3. Only install this kit on the vehicle for which it is specified.
4. Park the vehicle on a clean, dry, flat, level surface and block the tyres so the vehicle cannot roll in either direction.
5. Be certain the vehicle is safely secured on jack stands or a vehicle lift before working around or under a vehicle. Never rely on a jack alone to support a vehicle’s weight; use appropriately rated stands to sup

Parts List

Note: Please be sure that you have all the provided parts listed below before continuing with the installation.

Front Installation Instructions

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

1. Raise the vehicle and place the jack stand under the frame. Check the rear tyres to prevent any accidental movement.

2. Remove the tyres and wheels.

3. Remove the factory shocks at the top inside of the fender well and at the bottom, don’t discard hardware. The hardware will be reused.

4. Unbolt the sway bar links on both sides, don’t discard the hardware. The hardware will be reused.

5. Support the front axle with the floor jack.

6. Remove the bolt at the axle end of the track bar.

7. Remove the front lower control arm bolts on both driver’s and passenger’s sides. If replacing the control arms remove the rear bolt and remove the arm.

8. On each side, remove the bolt that holds the spring keeper clip, it’s located on the lower coil spring mount.

9. Remove the factory coil springs from the vehicle. Lower the jack used to support the axle if needed to remove the coil springs. (Note: If using a coil spring compressor, take special care.)

10. Set the new coil springs into place and reinstall the factory coil spring retainer clips you removed in step 7. (Torque to 10 ft. lbs.)

11. Raise the front lower control arm up into position and install bolts before unloading the coils. (Torque to 85 ft. lbs.)

12. Position the new coils into place. Install the factory spring keeper clip. (Torque to 10 ft. lbs.)

13. Install the new Rusty’s front shocks into their upper mounting position with the supplied hardware. (Torque to 17 ft. lbs.) (Note: It is a good idea to take a wire brush and clean any excess paint from the threads on the stud to prevent the nut from tightening properly.)

14. Install the lower end of the shock to the axle using the factory hardware. (Torque to 20 ft. lbs.)

15. Reinstall the factory sway bar links at this time using factory hardware. (Note: If you purchased Rusty’s Forged Adjustable Sway Bar Quick-Disconnects install them at this time using the supplied instructions.)

16. Install tyres and wheels.

17. Jack up the vehicle and remove the jack stands to lower the vehicle back to the ground.

18. Unlock the steering wheel and have an assistant rotate the steering wheel to line the track bar back to its axle side mounting point.

19. Reinstall the factory bolt removed in step 6. (Torque to 35 ft. lbs.)
    Rear Installation Instructions

20. Raise the vehicle and place the jack stand under the frame. Check the rear tyres to prevent any accidental movement.

21. Remove the tyres and wheels.

22. Remove the factory shocks, keep the hardware and discard the old shocks.

23. Remove the clip that fastens the rear brake line to the factory bracket. Pull the brake line towards the axle until it drops out of the factory bracket.

24. Attach the rear brake line extension bracket using the smaller hole location to the factory brake line location with the supplied hardware. (Note: Make sure that the side of the bracket with the larger hole location points towards the ground.

25. Attach the bracket line to the installed rear brake line extension bracket in the reverse method of how you removed it from the factory mounting point and secure it with the factory clip

26. Install the supplied add-a-leafs by referencing the supplied instructions on page #6 to complete their installation.

27. Position the supplied U-bolts and factory spring plates into position. Install a flat washer followed by the nut then tighten the hardware. (Torque to 75 ft. lbs.)

28. Install the bushings and sleeves in the new Rusty’s shocks. Install them on the vehicle with the factory hardware. (Torque upper bolts to 18 ft. lbs. and lower bolts to 40 ft. lbs.) (Note: Please note the oriental

29. Reinstall the tires and wheels and lower the vehicle.

30. Remove the jack stands and lower the vehicle to the ground.

31. Tighten the leaf spring and shackle hardware to the torque specifications. (Torque the frame bolts to 100 ft. lbs and shackle bolts to 25 ft. lbs.)

32. Tighten the lug nuts to the factory torque specifications.

33. Installation Completed!

Final Notes:

At this point, there should be no parts left but installing the stickers. The vehicle will need to have an alignment as soon as possible, if you don’t you may get the “death wobble”, poor tyre wear or just a bad handling vehicle.
Alignment Recommended Specifications

• Toe: Should be set at 0 to 1/32” Toe Out
• Castor: 7.5 Degrees Positive
• Camber: 0

WARNING

• It is the owners’ responsibility to inspect all of Rusty’s products for proper torque specs to prevent the loosening of components.
• Seat belts and shoulder harnesses should be worn at all times.
• Re-check all bolts and nuts after the first 300 miles and after any off-road usage during the first 300 miles.
• Although all of our products are made from the highest quality materials possible, they are not a substitute for Safe and Careful driving.
• In other words, have good safe on-road/off-road sense.
• Know the terrain, the speed limitations, and any obstacles that may lie ahead.
• Please remember to preserve our right to enjoy public land through the proper use of off-road vehicles.
• Thank you for choosing Rusty’s Off-Road Products

INSTALLATION INSTRUCTIONS

Parts List:
Note: Please be sure that you have all the provided parts listed below before continuing with the installation.

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

1. Park the vehicle on a level surface. Set the parking brake and choke the front wheels. Raise the rear of the vehicle and support the frame with jackstands.
2. Remove the rear wheels.
3. Support the rear axle with a floor jack to relieve the tension on the leaf springs. (Note: On MJ Comanche models the springs are under the axle, so with the frame fitting on jack stands.)
4. Remove the factory shocks at the top inside the fender well and at the bottom, do not discard. Disconnect the axle vent hose from the axle housing. The hardware will be reused.
5. Unbolt the U-bolts and carefully lower the axle by lowering the floor jack slowly. (Raise the axle if in-stalling on a MJ Comanche or Spring Under Axle Configuration) Retain the U-bolt plates for reuse. (Note: Use caution, not to overextend the rear brake line.)
6. Position a C-clamp near the spring centring pin and tighten it to hold the spring pack together. Remove or cut off the spring centring pin if it is seized. Carefully loosen the c-clamp to relieve the pressure in the spring pack in a controlled manner.
7. Using a chisel, cutoff wheel, saw, or similar tool, remove the leaf spring retaining straps that align the leaves in the spring pack. They are located on both the front and rear portion of the springs.
8. Lower the spring leaves below the the main leaf of the leaf spring assembly as shown in the image below.
   • Note: Save all factory components and hardware for reuse, unless noted.
9. Position the supplied Rusty’s add-a-leaf in the spring pack. It should be placed directly under the main leaf, or under the next longest leaf in the spring pack. All of the shorter leafs should be placed under the add-a-leaf in order of descending length. The long side of the new leaf will go towards the rear of the vehicle.
10. Align the centring pin holes in each leaf and use a C-clamp to clamp the pack together.
    • ( Note: Do not use the centring pin to compress the leaf pack.) Position the pin so that the head is pointed downward and install the supplied new centering pin in the aligned holes. Lube the threads and slowly tighten the nut; do not over-tighten the pin as it will strip easily.
11. Slowly raise the axle up into position and be sure the centre pins align with the holes in the axle pads on each side. (Lower the axle if installing on a MJ Comanche or Spring Under Axle Configuration)
12. Position the U-bolts and factory spring plates into position. Install a flat washer followed by the nut then tighten the hardware. (Torque to 75 ft. lbs.)
13. Remove the C-clamps from the leaf spring at this time.
14. Reconnect the axle vent hose and shock absorbers
    • ( Note: If you are installing new shocks supplied with your suspension system you will them install now.)
    • Note: Save all factory components and hardware for reuse, unless noted.
15. Install the rear wheels and lower the vehicle to the ground.
    • ( Note: Do not release the parking brake or remove the wheelchairs.)
16. Install the supplied new leaf spring retaining straps on the front or rear portion of the leaf springs near where the original ones were located as shown in the image below. Apply light pressure to the clamps when installing. (Note: When bending the do not bend them sharply.) (Note: The leaf spring clamps are designed for lateral shifting of the spring leaves. They are not intended to hold the springs tight against one another.)
17. Installation is now complete!

WARNING

• It is the owners’ responsibility to inspect all of Rusty’s products for proper torque specs to prevent the loosening of components.
• Seat belts and shoulder harnesses should be worn at all times.
• Re-check all bolts and nuts after the first 300 miles and after any off-road usage during the first 300 miles.
• Although all of our products are made from the highest quality materials possible, they are not a substitute for Safe and Careful driving.
• In other words, have good safe on-road/off-road sense.
• Know the terrain, the speed limitations, and any obstacles that may lie ahead.
• Please remember to preserve our right to enjoy public land through the proper use of off-road vehicles. Thank you for choosing Rusty’s Off-Road Products.

CONTACT

• For Questions or Suggestions, contact our Tech Department (256-442-0607)
• Rusty’s Off-Road Products
• 7161 Steele Station Road
• Rainbow City, AL 35906
• 1-256-442-0607
• www.rustysoffroad.com.

References

• Rusty's Off-Road – Rusty's Off-Road Products

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