RUSTY OFF ROAD RK-BL100-TJ 1” Body Lift Kit User Guide

: June 4, 2024
: RUSTY OFF ROAD

Table of Contents

Introduction:
Before Starting Installation:
Parts List:
Installation Instructions
Documents / Resources

Rusty’s TJ 1” Body Lift Kit
RK-BL100-TJ
INSTALLATION INSTRUCTIONS
Last Revised: 2/1/2017

Introduction:

Rusty’s 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 install. Read each step completely as you go. Exhaust modifications may be necessary. Prior to 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 loosen- ing 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 a 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:

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

Parts List:

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

Part #| DESCRIPTION:|

Quantity

---|---|---
RC-BLP| Rusty’s 1″ Body Lift Spacer| 11
RC-TL1| Rusty’s Transmission Linkage Adapter| 1
n/a| Ti Body Lift Radiator Support Spacers| 2
5728415| 1/2″-13 x 4-1/2″ Length Grade 8 Hex Head Cap Screw| 6
5724646| 1/2″ SAE Flat Washer| 6
67522524| 7/16″-14 x 3-1/2″ Length Grade 8 Hex Head Cap Screw| 5
5724638| 7/16″ SAE Flat Washer| 5
5726104| 5/16″-18 x 1 Length Grade 8 Hex Head Cap Screw| 2
5724612| 5/16″ SAE Flat Washer| 2
67488924| 5/16″ – 18 Grade 8 Hex Lock Nut| 2

Installation Instructions

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

Remove the top front splash pan by removing the two M10 bolts on the outside of each frame.
Remove the splash pan brace, by removing one bolt from each side on top of the frame rails.
Loosen, but do not remove, all 11 body mount bolts. One is located directly in front of the radiator, 6 are located under the doors and between the wheels, and 4 are located in the rear of the vehicle.
Position a floor jack under the driver’s side of the vehicle with a wooden block on it. Keep doors (if equipped) closed during rising to prevent body flex. Remove the bolts from the front mount, and all 5 mounts on the driver’s side. (Keep the stock bushing stacks intact on the vehicle when installing body blocks, unless installing polyurethane body mounts. Install the new body mounts now, then install the body block.)
Jack up the vehicle high enough (approximately 2 inches) to install spacer blocks between the frame and the body mounts. Be sure to check the engine compartment as you are lifting the vehicle for any lines, wires, hoses, or cables that way bind.
Install the blocks along the driver’s side. Do not install the block in front of the radiator yet. Fasten all bolts loosely, but do not tighten yet.
Installation Instructions (Continued)
Move the floor jack to the passenger side of the vehicle and repeat the installation of the blocks and bolts.
With the body still raised install the front block at this time.
On vehicles equipped with manual trans or automatic transcribe a vertical line along the straight part of the transmission linkage. Scribe a vertical line along the length of the linkage extension provided in the kit.
Cut the transmission linkage in half, through the scribed line.
Place the linkage extension between the two halves of the transmission linkage, line up all three lines, and weld them together. (RUSTY’S recommends that all welding be done by a certified welder)
Reinstall the lengthened transmission linkage to the stock mounting positions on the steering column and the transmission.
Replace the front splash pan and brace, it may be necessary to notch out approximately 1/2 inch. Tighten all bolts securely.
Reinstall the fan shroud, it may be necessary to trim the lower half of the shroud.
Check all brake lines to make sure they are not touching or chafing.
Check and reattach all other lines, wires, hoses, or cables that may have been loosened or moved for clearance during the raising of the vehicle.
Check the shift levers for clearance. On most vehicles, no modifications will be necessary, although in some cases you may need to put the transmission into 3rd gear and bend the lever slightly forward toward the dash.
Check the steering of the vehicle. Make sure the column rotates fully to the left and right, and that the steering does not bind.
Reinstall negative battery cable to the battery terminal. Check that all installation steps have been completed. Check all nuts and bolts for tightness.
Installation is complete!

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 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 a 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.

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