BARNES 4WD B4WK12903 XJ Rear Coil Spring Swap Axle Truss Kit Owner’s Manual

: September 23, 2024
: BARNES 4WD

Table of Contents

BARNES 4WD B4WK12903 XJ Rear Coil Spring Swap Axle Truss Kit
Product Usage Instructions
Possible Kit Combinations
Contents of each box
FAQ
Read User Manual Online (PDF format)
Download This Manual (PDF format)

BARNES 4WD B4WK12903 XJ Rear Coil Spring Swap Axle Truss Kit

Product Specifications

Manufacturer : Unknown
Model : XJ Rear Coil Spring Conversion Axle Truss
Compatibility : Various makes and models

Product Usage Instructions

Kit Combinations
Use the information below to determine the kit combination you have received based on your vehicle make and model.

Contents of Each Box
The following is a breakdown of the contents for each kit part number:

B4WK12903: XJ Rear Coil Spring Conversion 8.25 Axle Truss Kit
B4WK12904: XJ Rear Coil Spring Conversion Dana 35 Axle Truss Kit
B4WK12905: XJ Rear Coil Spring Conversion Dana 44 Axle Truss Kit

Installation Notes
Follow these steps for the successful installation of the product:

Identify the kit combination based on your vehicle.
Check the contents of each box against the provided list.
Ensure all parts are accounted for and undamaged.
Refer to the installation manual for detailed instructions.
Install each component as per the provided guidelines.
Verify proper installation and functionality.

Thank you for purchasing this product!

Installation Notes:

This product is designed to fit Jeep Cherokees 2 door or 4 door 1984-2001 XJ.
This kit requires welding, automotive mechanical knowledge, and general fabrication skills, it should only be installed by qualified individuals.
This kit will give you a minimum of 4” of lift with factory height 1998-2004 Jeep Grand Cherokee WJ rear coil springs.
This kit is designed to use 1997-2006 Jeep Wrangler TJ rear lift shocks matching your lift height.
The components of this kit will need to be painted or powder coated during installation.
This kit provides provisions for a factory sway bar from a 1997-2006 Jeep Wrangler TJ.

Tools required:

Various Hand Tools
Jack
Jack Stands
Welding machine with the capability to weld at least ¼” thick steel
Grinder
Tape Measure
Angle Finder
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 vehicle. Each box should have a barcode with the kit part number listed on it.

Qty| Kit Part Number| Kit Description
1| B4WK12903| XJ Rear Coil Spring Conversion 8.25 Axle Truss Kit
1| B4WK12904| XJ Rear Coil Spring Conversion Dana 35 Axle Truss Kit
1| B4WK12905| XJ Rear Coil Spring Conversion Dana 44 Axle Truss Kit

Contents of each box

Bill Of Materials for B4WK12903

QTY| Part Number| Etch Number| Description
1| B4W250A46| A46 B| Chrysler 8.25 Rear Axle Truss
1| B4W250A43| A43 B| XJ Rear Coil Spring Axle Bracket Driver
1| B4W250A42| A42 B| XJ Rear Coil Spring Axle Bracket Passenger
2| B4W188A34| A34| XJ Rear Coil Spring Axle Bracket Driver Gusset
2| B4W188A33| A33| XJ Rear Coil Spring Axle Bracket Passenger Gusset
1| B4W250A66| A66 B| XJ Rear Coil Swap 8.25 Link Bracket Driver
1| B4W250A68| A68 B| XJ Rear Coil Swap 8.25 Shock Bracket Driver
1| B4W250A67| A67 B| XJ Rear Coil Swap 8.25 Shock Bracket Passenger
1| B4W250A65| A65 B| XJ Rear Coil Swap 8.25 Link Bracket Passenger
2| B4W188A35| A35 B| XJ Rear Axle Coil Spring Swap Sway Bar Bracket
1| B4W250621| 621 B| TJ 4 Link RAUCAM
1| B4W250644| 644 B| TJ 4 Link RAUCAM Right
4| B4W188971| 971 B| TJ Rear Coil Spring Center Half
2| B4W188972| 972| TJ Rear Coil Spring Center
2| B4W250352| 352 B| TJ 8.8 Kit Coil Spring Retainer V2.0
6| 37C100HCS8Y| NA| 3/8″-16X1″ Hex Head Grade 8
6| 37CNNE0Y/GC| NA| 3/8-16 Nylock Yellow
6| 37NWSAFY| NA| 3/8 SAE Washer Yellow Zinc
Bill Of Materials for B4WK12903

QTY| Part Number| Etch Number| Description
1| B4W250A46| A46 B| Chrysler 8.25 Rear Axle Truss
1| B4W250A43| A43 B| XJ Rear Coil Spring Axle Bracket Driver
1| B4W250A42| A42 B| XJ Rear Coil Spring Axle Bracket Passenger
2| B4W188A34| A34| XJ Rear Coil Spring Axle Bracket Driver Gusset
2| B4W188A33| A33| XJ Rear Coil Spring Axle Bracket Passenger Gusset
1| B4W250A66| A66 B| XJ Rear Coil Swap 8.25 Link Bracket Driver
1| B4W250A68| A68 B| XJ Rear Coil Swap 8.25 Shock Bracket Driver
1| B4W250A67| A67 B| XJ Rear Coil Swap 8.25 Shock Bracket Passenger
1| B4W250A65| A65 B| XJ Rear Coil Swap 8.25 Link Bracket Passenger
2| B4W188A35| A35 B| XJ Rear Axle Coil Spring Swap Sway Bar Bracket
1| B4W250621| 621 B| TJ 4 Link RAUCAM
1| B4W250644| 644 B| TJ 4 Link RAUCAM Right
4| B4W188971| 971 B| TJ Rear Coil Spring Center Half
2| B4W188972| 972| TJ Rear Coil Spring Center
2| B4W250352| 352 B| TJ 8.8 Kit Coil Spring Retainer V2.0
6| 37C100HCS8Y| NA| 3/8″-16X1″ Hex Head Grade 8
6| 37CNNE0Y/GC| NA| 3/8-16 Nylock Yellow
6| 37NWSAFY| NA| 3/8 SAE Washer Yellow Zinc
Bill Of Materials for B4WK12905

QTY| Part Number| Etch Number| Description
1| B4W250875| 874 B| TJ Dana 44 Rear 1 Piece Truss
1| B4W250A43| A43 B| XJ Rear Coil Spring Axle Bracket Driver
1| B4W250A42| A42 B| XJ Rear Coil Spring Axle Bracket Passenger
2| B4W188A34| A34| XJ Rear Coil Spring Axle Bracket Driver Gusset
2| B4W188A33| A33| XJ Rear Coil Spring Axle Bracket Passenger Gusset
1| B4W250482X| 482X B| TJ Rear Axle Shock Mount Stock Replacement Passenger
1| B4W250483X| 483X B| TJ Rear Axle Shock Mount Stock Replacement Driver
1| B4W250A87| A87 B| XJ Rear Coil Swap Dana 44 Dana 35 Link Bracket Passenger
1| B4W250A88| A88 B| XJ Rear Coil Swap Dana 44 Dana 35 Link Bracket Driver
2| B4W188A35| A35 B| XJ Rear Axle Coil Spring Swap Sway Bar Bracket
1| B4W250621| 621 B| TJ 4 Link RAUCAM
1| B4W250644| 644 B| TJ 4 Link RAUCAM Right
4| B4W188971| 971 B| TJ Rear Coil Spring Center Half
2| B4W188972| 972| TJ Rear Coil Spring Center
2| B4W250352| 352 B| TJ 8.8 Kit Coil Spring Retainer V2.0
6| 37C100HCS8Y| NA| 3/8″-16X1″ Hex Head Grade 8
6| 37CNNE0Y/GC| NA| 3/8-16 Nylock Yellow
6| 37NWSAFY| NA| 3/8 SAE Washer Yellow Zinc

You will need to establish the existing pinion angle of the axle in your vehicle. This number will be unique to your Jeep, depending on the amount of lift you have, type of rear driveshaft, and several other factors. This number usually ranges from 10-20 degrees. With the vehicle sitting level and at ride height measure the pinion angle of your existing axle with an angle finder. Place the angle finder on the front flat face of the pinion yoke, record this number.
Remove the axle from the jeep. With the proper cutting tool remove all the factory brackets from the axle and weld up any vent holes in the axle tube.
Place the axle at the same pinion angle as the axle in your Jeep. Three jack stands can be used, one under each axle tube and one under the pinion to set and hold the pinion angle.
Center the truss by measuring from the backing plates on the axle to the truss top. Use a level or angle finder on top of the truss to level the truss on the axle. Weld the axle into place.
Place the coil spring brackets on the axle with their gussets. The brackets should be parallel with the top of the truss as shown below. Weld the assembly into place.
The 3/8” nuts provided in the kit need to be welded to the coil spring caps. Center one nut on one coil spring cap and weld the nut to the cap, repeat this step for the other coil spring cap. Now the assembly is ready to be welded as shown below.
The sway bar brackets will also need nuts welded to the backside. Place one 3/8” nut over each hole on the backside of each bracket and weld in place.
Install and weld the upper control arm brackets into place on the top of the axle truss as shown below.
Install coil spring caps and nut assembly from step 6 in the holes on either side of the truss and tack weld in place.
Install the sway bar bracket assemblies from step 7. The brackets will tab into the truss as shown below.
Install the lower control arm brackets. Place the lower control arm brackets on the axle tube, the brackets should point in towards the pinion when on the correct side. Line the upper outside corner of the lower control arm bracket up with the corner of the leg on the truss top. Once lined up, the bracket is positioned correctly weld into place.
Install the shock brackets on the axle. The brackets should point away from the pinion when on the correct side. The bracket should touch the lower control arm bracket and should be 135° off the top of the truss.
Relocate an axle vent in the provided hole in the top of the truss.

Congratulations you have now completed the installation.

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FAQ

Q: Can this product be used on any vehicle?
A: No, this product is specifically designed for certain makes and models. Refer to the compatibility information provided.

Q: Are installation tools included in t he kit?
A: No, installation tools are not included. You will need basic tools for installation.