RUSTY S OFF ROAD PRODUCTS RK-405A-XJ XJ Cherokee 4.5 Inch Advanced Kit Instruction Manual

RK-405A-XJ XJ Cherokee 4.5 Inch Advanced Kit

7161 Steele Station Road
Rainbow City, AL 35906
1-256-442-0607
www.rustysoffroad.com

Rusty’s XJ Cherokee 4.5” Advanced Kit
RK-405A-XJ
INSTALLATION INSTRUCTIONS
Last Revised: 1.10.18

Introduction:

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. 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.

Warning:

• Seat belts and shoulder harnesses should be worn at all times.
• It is the owners’ responsibility to inspect all Rusty’s products for proper torque specs to prevent loosening of components.
• 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 tires so the vehicle cannot roll in either direction.
5. 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 sup-

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

Parts List:

Part #

|

DESCRIPTION:

|

Quantity

---|---|---

RC-CS405-XJ

|

Rusty’s 4.5” Front Coil Springs (Pair)

|

1

RC-CA111-UV

|

Rusty’s Fixed Front Lower Control Arms (16.25”)(XJ,TJ) (Pair)

|

1

RC-CA121-UV

|

Rusty’s Fixed Front Upper Control Arms (XJ,TJ,ZJ) (Pair)

|

1

RC-TB122-UV

|

Rusty’s Track Bar – Adjustable Front (TJ,XJ,ZJ)

|

1

RC-SB500-UV

|

Rusty’s Forged Adjustable Sway Bar Quick-Disconnects (Pair)

|

1

RC-LS450-XJ

|

Rusty’s XJ 4.5″ Rear Leaf Spring (Pair)

|

1

RC-SHIMS-6

|

Rusty’s Billet Steel 6 Degree Shims (Pair) (Contents Below)

|

1

CB0504

|

5/16″-24 x 4″ Length Centering Pin

|

2

CB0504

|

5/16″-24 Grade 8 Nut

|

2

RX-36

|

Rusty’s RX100 Performance Shock: RX-36 (Contents Below)

|

2

|

(Bushing Packs: PO1318 & PO1314)

|

RX-13

|

Rusty’s RX100 Performance Shock: RX-13 (Contents Below)

|

2

|

(Bushing Packs: PO1313 & PO1532)

|

RC-TCD1-XJ

|

Rusty’s Transfer Case Drop Kit (Contents Below)

|

1

RC-TCD1-XJ-SP

|

Rusty’s Transfer Case Drop Spacer (XJ,MJ)

|

2

09889080

|

M10 x 1.50mm x 50mm Length Hex Head Cap Screw

|

4

67493080

|

M10 x 20mm O.D. Flat Washer

|

4

RB-SBL10-UV

|

Rusty’s Stainless Steel Brake Hoses Set (Contains Front & Rear Lines)

|

1

RC-UB-2

OR

RC-UB-3

|

Rusty’s Dana 35/44 Grade 8 U-Bolt

OR

Rusty’s Chrysler 8.25 Grade 8 U-Bolt

|

4

OR

4

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

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

Front Installation Instructions

1. Raise vehicle and place jack stands under the frame. Chock the rear tires to prevent any accidental movement. Note: Save all factory components and hardware for reuse, unless noted.
2. Remove the tires and wheels.
3. Remove the stock shock absorbers using a 15mm wrench. The stock bolts and nuts on the bottom of the  shock will be reused. (Note: In order to access to the upper shock studs will be obtained through the en gine compartment. It also may be necessary to temporarily remove the washer fluid reservoir to access  the driver side upper shock mount nut.) 
4. Remove the sway bar links on both sides using a T-55 Torx bit /19mm wrench and a 15mm for the upper  nut.
5. Support the front axle with the floor jack.
6. Remove the track bar from the axle housing on passenger side using a 15mm wrench. Retain factory bolt  and flag nut for re-use.
7. Remove the factory coil spring retainer clips with a 13mm wrench. Retain the hardware for re-use.
8. Slowly lower the jack used to support the front axle until the coil springs can be removed. If using a coil  spring compressor use caution! (Note: Use caution to not overextended the brake lines, if needed you  can remove the brake calipers from the rotors to allow the axle to be lowered further. If you remove the  brake calipers do not let allow them to hang from the brake lines as this may cause damage to the lines  or fittings. We suggest using a bungee cord or similar device to hold the caliper up out of the way tempo rally.)
9. With the front axle supported use a 21mm wrench to remove the mounting hardware for the factory  front lower control arms at the lower control arm axle and frame mounts. Retain factory hardware, as it  will be reused.
10. With the front axle lowered, install the supplied front coil springs. (Note: Make sure to seat the coil  spring wrap into the lower spring cup. 
11. Reinstall the factory coil spring retainers with a 13mm wrench.
12. Install the supplied 16-1/4”fixed lower control arms with the short side bend at the axle end to clearance  the lower axle control arm mount as illustrated below using the factory hardware. (Note: If you upgraded  to the optional Rusty’s adjustable lower control arms adjust them to 16-1/4” center hole to center hole,  and install the fixed end of the control arm at the axle mount and the adjustable end is positioned at the  frame mount.)

Lower Control Arm Measurement: 16-1/4” Center to Center Length

13. Remove the driver side upper control arm by removing the factory hardware at the upper control arm  axle and frame mounting points. Retain factory hardware, as it will be reused. (Note: This is a great time  to inspect and replace the axle housing upper control arm bushings if needed, however, removal is not  needed for installation of this suspension kit.)
14. Install one of the supplied fixed upper control arms using the factory hardware. The axle side mounting  point of the supplied fixed upper control arms will have two offset mounting holes. Measure from the  center of the hole in the fixed bushing end to both mounting holes in order to determine which  mounting point is correct for your lift height. For the installation of this kit, you will use the shorter dis tance of 15-1/4” center hole to center hole. Refer to the image below for correct installation orientation.  (Note: Install the fixed upper control arm so that the extra mounting hole is positioned above the hole  used to mount the control arm to the axle mount.) Axle Side Frame Side Upper Control Arm Measurement: 15-1/4” Center to Center Length
15. Repeat steps 13-14 on the passenger side of the vehicle.
16. The caster adjustment bolts on the lower control arm frame mounts can be adjust if needed to add more  castor. However the final alignment should be preformed by a professional alignment shop.
17. Install the track bar in the factory location axle mount using factory hardware. Do not attach the frame  end of the new track rod at this time. Installation is to be completed once the vehicle is lowered to the  ground using the instructions provided with the adjustable front track bar.
18. Install the supplied 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.)
19. Install the lower end of the shock to the axle using the factory hardware. (Torque to 20 ft. lbs.)
20. Install the supplied Rusty’s Forged Adjustable Sway Bar Quick-Disconnects and install using the supplied  instructions.
21. Reinstall the wiper reservoir if removed.
22. Install the front wheels and tires. Jack up the vehicle, remove jack stands and lower the vehicle to the  ground.
23. At this time refer to the supplied instructions with the Rusty’s front adjustable track bar and complete  the adjustment and installation of the track bar. 
24. Front installation is completed!

Rear Installation Instructions

25. Remove the factory shocks, keeping the hardware and discarding the old shocks.

26. Raise rear of the vehicle and place jack stands under frame. Chock the front tires to prevent any accidental  movement.

27. Remove the tires and wheels.

28. 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.

29. Support the rear axle with a floor jack.

30. Unbolt the U-bolts and carefully lower the axle by lowering the floor jack slowly. Retain the U-bolt plates  for reuse. (Note: Use caution not to over extend the rear brake line.)

31. Unbolt the leaf springs at the front frame mounting points and remove the lower rear shackle bolts using a  21mm wrench. (Note: Inspect the hardware once removed and replace if needed.)

32. Remove the factory spring packs and discard.

33. Grind or cut off the excess length of rear bumper bolt that is located directly behind the shackle at the  frame mounting point in order to allow more clearance when the shackle pivots towards the rear of the  vehicle. Refer to the image below.

Grind or cut off the excess length   of this bolt.

34. Install the new spring packs with the factory hardware removed in step 27; it’s a good idea to grease the  threads on the spring bolts, mount the frame end first and then the shackle. Jack up axle into position, be  sure to align center pins. (Note: Do not torque hardware until instructed.)

35. Slowly raise the axle up into position and be sure the center pins align with the holes in the axle pads on  each side.

36. 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.)

37. 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 orientation of the rear shocks.

CORRECT:

Mount RX-100 series shocks with the body down and   shaft pointing up.

38. Reinstall the tires and wheels and lower vehicle.

INCORRECT:

DO NOT MOUNT RX-100 Series  Shocks with the Shaft pointing  towards the ground. This will  cause poor handling and ride  quality.

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

40. 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.)

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

42. Install the Rusty’s Rear Stainless Steel Brake Hose using the supplied instructions. 43. Install the supplied Rusty’s Transfer Case Drop Kit using the supplied instructions. 44. Installation Completed!

Alignment Recommended Specifications 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 tire wear or just a bad handling  vehicle.

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

Tighten hardware to torque specifications called for the components below with the vehicle resting at ride  height to prevent preloading any of the joints or bushings.

• Control Arms
• Leaf Springs
• Shackles
• Track Bars

It is the owners’ responsibility to inspect all Rusty’s products for proper torque specs to prevent 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 obsta cles that may lie ahead. Please remember to preserve our right to enjoy public land through the proper use of

Rusty’s Extended Stainless Steel Front and Rear Brake Hoses  RB-SBL10-UV

INSTALLATION INSTRUCTIONS

Parts List:

RB-SBL10F-UV Parts List:

Part #

|

DESCRIPTION:

|

Quantity

RB-SBL10F-UV

|

Rusty’s Front Extended Stainless Steel Brake Hose

|

2

RB-SBL10-CW

|

3/8” Copper Crush Washer

|

4

RB-SBL10-MB

|

Brake Hose Frame Mounting Bracket

|

2

RB-SBL10-RC

|

Brake Hose Mounting Bracket Retaining Clip

|

2

67378927

|

5/16″ -18 x .625″ Length Hex Head Thread Cutting Screw

|

2

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

RB-SBL10F-UV Installation Instructions

1. The installation of these brake lines can be installed with the vehicle on the ground. You need to park the  vehicle on level ground and set the parking brake/chock the tires to prevent any movement.  Note: Save all factory components and hardware for reuse, unless noted.

2. Turn the tires in order to gain better access to the calipers and the brake lines.

3. Inspect all of the brake components and repair or replace components as necessary.

4. Disconnect the factory soft line from the hardline connection at the frame rail. Retain the factory hard ware for reuse.

5. Remove the factory banjo bolt from the caliper, make sure to remove the factory crush washers as well.  Retain or replace the banjo bolt for installation of the new brake hoses.

6. Clean and inspect all of the mounting surfaces before continuing.

7. Mount the supplied brake hose mounting bracket to the frame rail in the factory mounting hole with the  original hardware. (Note: If needed use the supplied 5/16″ -18 x .625″ Length Hex Head Thread Cutting  Screws to mount brake hose mounting brackets to the frame rail if you need to relocate the lines for any  reason.)

8. Insert the supplied brake hose through the mounting bracket opening then insert the supplied retaining  clip to secure the line.

9. Attach the brake hose to the factory hard line by starting the threaded fitting on the factory hard line by  hand then tighten to factory specifications.

10. Attach the brake hose to the caliper using the factory banjo bolt and the supplied copper crush washers.  Position a crush washer on each side of the fitting at the bottom of the brake hose. Tighten to factory  specifications.

11. Position the brake line in order to make sure that it will not get caught or damaged by the suspension or  tire when in use.

12. Repeat steps 2-11 on the opposite side of the vehicle.

13. If only installing the front brake hoses at this time you may go ahead and bleed the brake lines using  standard brake system bleeding procedures. (Note: If installing the rear brake hose, you can wait to bleed  brake system until completing the installation.)

14. Front Installation Completed!

RB-SBL10R-UV Parts List:

Part #

|

DESCRIPTION:

|

Quantity

RB-SBL10R-UV

|

Rusty’s Rear Extended Stainless Steel Brake Hose

|

1

RB-SBL10-MB

|

Brake Hose Frame Mounting Bracket

|

1

RB-SBL10-RC

|

Brake Hose Mounting Bracket Retaining Clip

|

1

67378927

|

5/16″ -18 x .625″ Length Hex Head Thread Cutting Screw

|

1

RB-SBL10R-UV Installation Instructions

1. The installation of the rear brake line can be installed with the vehicle on the ground. You need to park  the vehicle on level ground and chock the tires to prevent any movement.  Note: Save all factory components and hardware for reuse, unless noted.

2. Inspect all of the brake components and repair or replace components as necessary.

3. Disconnect the factory soft line from the hardline connection at the frame rail. Retain the factory hard ware for reuse.

4. Remove the bolt that attaches the factory soft line to the frame rail. Retain the factory hardware for re use.

5. Disconnect the two hard lines at the brake line fitting on the rear axle.

6. Remove the fitting that the rear axle breather tube is attached to in order to remove the factory soft line.

7. Clean and inspect all of the mounting surfaces before continuing.

8. Mount the supplied brake hose mounting bracket to the frame rail in the factory mounting hole with the  original hardware. (Note: If needed use the supplied 5/16″ -18 x .625″ Length Hex Head Thread Cutting  Screws to mount brake hose mounting brackets to the frame rail if you need to relocate the lines for any  reason.)

9. Insert the supplied brake hose through the mounting bracket opening then insert the supplied retaining  clip to secure the line.

10. Attach the brake hose to the factory hard line at the frame by starting the threaded fitting on the factory  hard line by hand then tighten to factory specifications.

11. Attach the brake hose fitting to the axle tube using the fitting that the rear axle breather tube is attached  with.

12. Connect both of the factory hard lines on the axle tube to the threaded fittings on the rear brake hose  junction block by starting the threaded fittings on the factory hard lines by hand then tighten to factory specifications.

13. Connect both of the factory hard lines on the axle tube to the threaded fittings on the rear brake hose  junction block by starting the threaded fittings on the factory hard lines by hand then tighten to factory specifications.

14. If only installing the rear brake hose at this time you may go ahead and bleed the brake lines using stand ard brake system bleeding procedures.

15. Rear Installation Completed!

Important Safety Notes

It is the owners’ responsibility to inspect all Rusty’s products for proper torque specs to prevent 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 obsta cles that may lie ahead. Please remember to preserve our right to enjoy public land through the proper use of  CAUTION!!! Failure to properly bleed the brake system will cause your brakes not to work properly. Before  the vehicle is ready to drive you will need to refill the brake reservoir with brake fluid and bleed any air out of  the brake lines. If you have any reservations or not experienced in this procedure please do not attempt the  installation and seek professional assistance or help in order to ensure the effectiveness of your brake system.

For Questions or Suggestions, contact our Tech Department (256-442-0607)

References

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

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