tj/lj 3.5” duroflex suspension read instructions in full ... · product: tj/lj 3.5” duroflex...

PRODUCT: TJ/LJ 3.5” Duroflex Suspension

The MetalCloak experience includes the ease of installation of our products. We design for most contingencies, but installation may be different based on different Jeep condition, configuration and/or year.

We are continually trying to improve our products and instructions – please help us by providing feedback and pictures if you find any part of the instructions that do not match your particular Jeep or are not easily understandable.

If you have any difficulties at all, please give us a call. Thank you and enjoy your MetalCloak Products!

IMPORTANT NOTE: We use Stainless Steel Hardware where possible. Therefore, a tube of Silver Anti-seize is provided and should be used on all bolts—only a small amount is needed.

WARRANTY INFORMATION: This article is sold without warranty expressed or implied. No warranty or representation is made as to this products ability to protect the user from injury or death. The user assumes that risk. The effectiveness, warranty and longevity of this equipment are directly related to the manner in which it is INSTALLED, USED and/or MAINTAINED. THE USER ASSUMES ALL RISK. By purchasing this product and opening the packaging, purchasers expressly acknowledge, understand and agree that they take, select and purchase these MetalCloak products from Armored Works, LLC, its affiliates and distributors and agents as is and with all faults. The entire risk as to the quality and performance of these MetalCloak products is with the purchaser. Working on your vehicle can be a dangerous activity. If you are unsure of what you are doing, please leave mechanical or safety critical work to a skilled mechanic. We take no responsibility for the incorrect use and/or installation of MetalCloak products.

READ INSTRUCTIONS IN FULL BEFORE INSTALLATION. QUESTIONS? CALL 916-631-8071 M-F 7:00 AM – 5:00 PM PST

REV: B | 02-11-2016 | II-7153

Section 1: Tools & Notes on Installation

Electric Drill

Tools Required: This list is the recommended tools for ease of installation. Other versions of the same tool can be used. For example, Allen Wrenches instead of Allen Drive Sockets.

27/64” Drill Bit5/16” Drill Bit

Socket & Ratchet Wrench

1/2” -13 Tap

14MM Socket 15MM Socket 16MM Socket 17MM Socket18MM Socket 19MM Socket22MM Socket 15/16” Socket

1/2” Socket 3/4” Socket

II-7153 | Rev B | 02/11/2016 | Copyright 2011 Armored Works, LLC of 26

5/16” Hex Key Socket

T55 Torx Socket

Tape Measure

Grinder Welder

Mallet

1/2” Box Wrench3/8” Box Wrench

Section 1: Tools & Notes on Installation

HOW TO USE THIS GUIDE: The installation guide contains ALL steps for installation. Please read and follow the instructions in order of each page top to bottom, and left to right.Jeep Model: Instructions may apply to multiple Jeep models, but are labeled separately where appropriate (i.e. TJ vs. LJ).Options: Because of the number of component options we offer, these instructions may contain steps that will not match your particular configuration. You can skip these steps.Images: Pictures are provided and parts are labeled throughout the instructions. Each text box contains guidance based on the pictures next to it. The text will refer to alphabetical labels (A, B, etc.) found in the images.Installation Notes: Terms may be used in the body of the instructions that you may not be familiar with, if you have any questions feel free to contact us at the number below, or email [email protected]: Any questions or comments about the instructions? Call us at 916-631-8071 M-F 7:00 AM – 5:00 PM PST.


Section 2: Product Components


Section 3: Installation Instructions

IMPORTANT NOTE: To install lift components you will need to fully ‘droop’ your suspension in the front and rear (not at the sametime). We strongly recommend that the vehicle be placed on an automotive lift and that all appropriate safety precautions be taken tosecure the vehicle while it is off the ground. Always use the necessary axle stands (or equivalent) to support the axle when thesuspension components are disconnected for safety, and to ensure the integrity of your suspension system during the installationprocess.

IMPORTANT NOTE: With this kit, you will need a slip yoke eliminator.


Step 1: Remove Stock Components

A. Disconnect front sway bar links.

B. Watch the brake lines as the axle drops! Unbolt the bracket from the frame in case the lines are stretched while working.

C. Remove the front track bar.

D. Remove stock springs, and any spacers that have been used if vehicle has been previously lifted.

Important Note: MetalCloak does not recommend powder coating your True Dual Rate Coils. The baking process in powder coatingcan, in some cases, cause the metallurgical properties of the coils to be changed, resulting in the loss of the lift properties of the coils.As such, the process of powder coating the coils will void any warranty stated or implied in relation to the coils.

Step 2: Swap Control Arms

A. Remove stock arms one at a time and replace with Duroflex arms. Start with the bottom arms, and re-use the stock hardware. The weld-on joint is offset to provide greater clearance between the arm and the stock bracket at the axle; orient the joint “up” so the arm hangs low. You can fully tighten all hardware as you reinstall the lower arms.

B. Repeat the process for the upper control arms. M12 hardware is provided to replace the stock hardware at the frame end of the Duroflex Control Arms. After removing the stock arm, drill open the original hole in the frame bracket using either a 12mm or 7/16” drill. When installing the arms put the M12 hardware in place and re-use the stock hardware on the axle end. You can fully tighten the M12 hardware at the frame, but leave the hardware loose at the axle so you can make any needed adjustments to the caster angle once the Jeep is on the ground.




Step 3: Remove Springs

A. Droop your suspension and remove your springs to gain access to the spring perch. This process may include disconnecting shocks, sway-bar links, track-bar, and/or steering drag link.

Step 4: Drill Spring Cup

B. Center a Bump Stop Disk on the top of the spring perch and mark the center of the hole.

C. Drill and tap this location with a 1/2”-13 tap. You can simply drill a 27/64” clearance hole, but the inside of the bump perch is very difficult to access on the driver side, and basically impossible on the passenger side.

A

B



Step 5: Install Bump Stop

D. Select the appropriate Screw length so that the threads stick out of the bottom Disks approximately 3/4”. Assemble your bump stops by feeding the 1/2” Countersunk Screw through the Cover Plate, and then threading through the Bump Stop Disks. The center hole in the Disk is intentionally small to create the most rigid assembly possible after installation.

E. IMPORTANT! Place the assembled Bump Stop inside the spring before re-installing. Re-install the spring and place the end of the 1/2” Screw in the drilled hole.

F. Tighten until everything is tight; the hardware will not bottom out, but instead will begin to compress the Disks.

D

E



Step 6: Install Front Coils

A. If the axle does not “droop” enough to allow the coil to be put in place a coil compressor can be used to compress the coil to allow fitment.

B. Install Front Dual Rate Coils with the tightly wound coils oriented upward.

C. Slip the bottom of the coil onto the coil base on the axle.

A

B

C


Step 7: Remove Stock Front Track Bar

A. Disconnect front track bar at axle end on the passenger side using a 15mm socket.

B. Disconnect front track bar on the driver side using a 17mm socket. Tap on the track bar with hammer or rubber mallet to release from the tapered thread.


BA


Step 8: Install Front Tack Bar

C. Use a 14mm drill bit and re-drill front track bar bolt hole on the passenger side.

D. Use a 5/8” drill bit and re-drill front track bar on driver side.

E. Install new track on driver side using a 15/16” socket. Do not tighten track bar bolt fully.

F. Install Passenger side of track bar. Do not tighten track bar bolt as it may need to come off to re-center axle when vehicle is lowered.

G. Lower vehicle and re-center axle if necessary.

H. Tighten all hardware.


Torque Specifications:

Track Bar Lower Bolt – 120-130Track Bar Upper Bolt - 150

C

D

E

F

Note: MetalCloak increased the driver and passenger side track bar frame holes to a larger diameter for additional strength.



Step 9: Install Upper Sway Bar Links

B. The Upper components are installed outboard (to put the rod away from the frame).

C. Install the bracket to the sway bar by inserting the 9/16” Hex Bolt with washer, backed by the 9/16” Hex Locknut. Tighten the bracket by using an open-ended wrench to hold the Hex Bolt while using a socket and wrench to tighten the nut.

D. Attach the sway link to the bracket by inserting the 5/16” Button Cap Screw through the bracket and assembling the spacers with the biggest spacer positioned closer to the frame and the smaller spacer located farthest from the frame and the sway link positioned between them as shown. The Button Cap Screw is then backed by the 3/4” Hex Flange Nut

E. Tighten the assembly by using a 5/16” Allen wrench to hold the Button Cap Screw while using a 3/4” socket and wrench the tighten the Hex Flange Nut.

B

C

B

C

D



Step 9: Install Lower Sway Bar Links

F. The lower components are installed inboard.

G. Install the lower Quick Disconnect Pin in the stock location. Point the Pin toward the center of the vehicle. A hammer may be needed to tightly set it in.

H. Adjust the length of the adjustable links to set the sway bar at the desired length (usually leveled at a positive degree incline).

I. Back the Quick Disconnect Pin with the washer and the 3/4” Hex Flange Nut and tighten with socket and ratchet wrench.

J. Slide the lower sway bar link through the Quick Disconnect Pin Screw and insert the Hitch Pin.

G

F

H

J



Step 9: Install Lower Sway Bar Links

K. The links should be roughly vertical once installed.

L. The provided brackets can be installed on the frame as in the desired location by using a 9/32” drill bit to drill 2 holes. There is no exact location, but the goal is to keep the sway bar clear of the tires when stowed. Install the self-tapping screws through the frame by using an electric drill with a 1/2”socket.

K

L1

L2


Step 14: Remove Stock Rear Brake Lines

A. Remove brake hose mounting screw from inner fender well using 3/8” box wrench.

B. Disconnect bottom of brake line using 3/8” box wrench.


A

B


Step 15: Install Front Brake Lines

C. Install new brake line and bracket.

D. Carefully straighten bend from brake hardline.

E. Mark new bracket location and drill holes using a L drill bit or a 9/32” drill bit.

F. Re-attach brake line to inner fender well using a 1/2” box wrench.

G. Use hammer to Install brake line retainer clips.

H. Bleed brakes before driving.


CD

E

F

G


Step 16: Bleed Front Brake Lines

Important Note: Before driving bleed brake lines.




IMPORTANT NOTE: To install lift components you will need to fully ‘droop’ your suspension in the front and rear (not at the same time).We strongly recommend that the vehicle be placed on an automotive lift and that all appropriate safety precautions be taken to securethe vehicle while it is off the ground. Always use the necessary axle stands (or equivalent) to support the axle when the suspensioncomponents are disconnected for safety, and to ensure the integrity of your suspension system during the installation process.

IMPORTANT NOTE: With this kit, you will need a slip yoke eliminator.


Step 17: Remove Stock Components

A. Disconnect rear sway bar links.

B. Watch the brake lines as the axle drops! Unbolt the bracket from the frame in case the lines are stretched while working.

C. Remove the rear track bar.

D. Remove stock springs, and any spacers that have been used if vehicle has been previously lifted.


A. Mark the center of the stock bump stop; a puck and a punch work well for this process.

B. Drill and tap this location with a 1/2”-13 tap. You can simply drill a 27/64” clearance hole, but the inside of the bump perch is very difficult to access on the driver side, and basically impossible on the passenger side.

Step 18: Drill Spring Cup for Rear Bump Stops

BA



Step 19: Install Rear Bump Stop

C. Select the appropriate Screw length so that the threads stick out of the bottom Disks approximately 3/4”. Assemble your bump stops by feeding the 1/2” Countersunk Screw through the Cover Plate, and then threading through the Bump Stop Disks. The center hole in the Disk is intentionally small to create the most rigid assembly possible after installation.

D. IMPORTANT! Place the assembled Bump Stop inside the spring before re-installing. Re-install the spring and place the end of the 1/2” Screw in the drilled hole.

E. Tighten until everything is tight; the hardware will not bottom out, but instead will begin to compress the Disks.

F. Repeat all steps for other side, and then re-install all other suspension components.

C

D



Step 20: Rear Sway Bar Links

A. Use the two 18mm wrenches or socket to unbolt the lower bolt of the sway bar end link.

B. Use the 19mm wrench to hold ball socket side on upper attaching point (Inside the rubber cover).

C. Use the 18mm wrench for the back side of the sway bar to remove the nut.

D. Remove the factory sway bars.

E. Using the factory hardware install the bottom of the MetalCloak extended sway bar links.

F. Using the factory hardware install the top of the MetalCloak extended sway bar links.

G. Torque upper and lower bolts to 75lbs.

Note: Keep all factory hardware.

E

F


A. As with the front control arms, remove stock arms one at a time and replace with Duroflex arms. Start with the bottom arms, and re-use the stock hardware. The weld-on joint is offset to provide greater clearance between the arm and the stock bracket at the axle; orient the joint “up” so the arm hangs low. You can fully tighten all hardware as you reinstall the lower arms.

B. Repeat the process for the upper control arms. M12 hardware is provided to replace the stock hardware at both ends of the Duroflex Control Arms. After removing the stock arm, drill open the original hole in the frame bracket using either a 12mm or 15/32” drill. You can fully tighten the M12 hardware at the frame, but leave the hardware loose at the axle so you can make any needed adjustments to the pinion angle once the Jeep is on the ground.

Step 21: Replace Control Arms

IMPORTANT NOTE: If you chose the option of upgrading your hardware & joint to the larger bolt size (M12) drill out the frame size bracket to 15/32". Otherwise, use the stock sized hardware in the stock hole.



B

C

II-7153 | Rev B | 02/11/2016 | Copyright 2011 Armored Works, LLC


Step 22: Remove Stock Rear Track Bar

A. Raise the rear of the vehicle and support rear axle with jack stands.

B. Disconnect the axle side of the stock rear track bar with a T55 torx socket. Keep stock hardware.

C. Using a 15mm socket on the bolt and a 18mm socket on the nut disconnect the stock rear track bar from the frame bracket. Keep stock hardware.

D. Remove the rear track bar mount cover.

D



Step 23: Installing Rear Track Bar

E. Using a 5/16 drill bit drill out bottom hole in the stock track bar mount.

F. Place the MetalCloak rear track bar relocation bracket onto the stock track bar bracket and use a 5/16 drill bit to drill out the top hole.

G. Place the provided spacer Inside the stock track bar bracket.

H. Using the stock hardware tighten bolt using a T55 torx socket.

EF

G

H



Step 24: Installing Rear Track Bar

I. Install the bottom and top bolts into the drilled out holes and tighten using a 1/2” socket.

J. Using the provided hardware install the fixed end of the rear track bar into the upper part of the relocation bracket. Tighten bolt using a 22mm socket.

K. Remove stands and lower Jeep onto the ground.

L. Center vehicle over rear axle. Measuring carefully using like points on each side of the vehicle until centered.

I

J

K

L



Step 25: Center Rear Axle

M. Adjust the frame side of the rear track bar to fit into the factory track bar bracket.

N. Using a 15mm socket on the bolt and a 18mm socket on the nut install the adjustable end of the rear track bar using the stock hardware.

O. Tighten all hardware.

M

N

tj/lj 3.5” duroflex suspension read instructions in full ... · product: tj/lj 3.5” duroflex...

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