PRODUCT: XJ Duroflex Short Arm Suspension READ ...

PRODUCT: XJ Duroflex Short Arm 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: C | 04-17-2018 | II-7181

II-7181 | Rev C | 04/17/2018 | Copyright 2011 Armored Works, LLC of 21

IMPORTANT NOTE: Early and late model Jeeps have different size bolts and the tools needed may be different than listed. The toolsMetalCloak list and used for installation is for the 2001 XJ Cherokee.

Section 1: Tools & Notes on Installation

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 thecoils. As such, the process of powder coating the coils will void any warranty stated or implied in relation to the coils.


Section 1: Tools & Notes on Installation

Socket & Ratchet Wrench

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. Be sure to use metric on metric and SAE on SAE.

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 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.

Set of SAE & Metric Sockets & Wrenches

Metal Head Hammer

10” Socket Extension3/8” Flare Nut Wrench (10mm will

work) for Brake Lines

Metric Hex Drive Socketsand/or Hex (Allen) Wrenches

Electric Drill 1/4”, 1/2”, 7/16”, L, 5/8”,

9/16”,15/32” 27/64” Drill Bits


Section 2: Product Components


Section 3: FRONT SUSPENSION Installation Instructions

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

IMPORTANT NOTE: To prevent tires from rubbing the shocks at full turn and flex, a clearance of 11-3/4” between inner wall of the tire and the outside of the unit body is recommended. Wheel backspacing, wheel spacers, axle width and tire width can effect this value. We recommend a wheel backspacing of less than or equal to 4.0” for most common vehicle builds.

IMPORTANT NOTE: 1984-1986 vehicles may require modifications to the front drive shaft for proper installation. These vehicles use a double offset joint, while later vehicles use a double cardan (spicer) style CV joint. The spicer CV joint may be retro fitted to the earlier vehicles by changing the transfer case output yoke for the later model. Lift heights this tall may also require modifications to the rear drive shaft (see troubleshooting). Installation time should be approx. 6 hours.

Important Note: This installation may be done on the ground and should be done one side at a time to closer match the caster that has already been set. If you are using a lift you must remove the lower side of the track bar off of the front axle to keep the track bar from pulling the axle off center before raising the Jeep.

Step 1: Remove Stock Components

of 21II-7181 | Rev C | 04/17/2018 | Copyright 2011 Armored Works, LLC

HOW TO USE THIS GUIDE: The installation guide should be used as a reference 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.


A. Open hood to allow more light while working.

B. Remove upper front shock bolts using 15mm wrench.

C. Raise vehicle and support with stands.

D. Remove wheels.

Step 1: Before Getting Started


Note: Access to the upper shock studs will be obtained through the engine compartment. It also may be necessary to temporarily remove the washer fluid reservoir to access the driver side upper shock mount nut.

A

B

CD


E. Remove lower shock bolts and remove front shocks using 15mm wrench.

F. Remove front sway bar end links. Using a 19mm wrench and a 15mm wrench for the upper nut.

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

H. Disconnect steering linkage at axle end.

I. Remove front spring retainers (at bottom) and springs using a 17/64 wrench.

Step 2: Remove Front Stock Components


Note: Be careful not to overextend the brake lines. The caliper can be removed from the rotor to allow the axle to lower. Do not let the brake caliper hang from the brake line.

EF G

H

I

I1


J. Support the front axle with jack stands.

K. Remove brake hose mounting screw from inner fender well and straighten z shaped bend on lower brake hose.

L. Install stainless brake lines, simply remove and replace your factory lines with the supplied lines. Mark new location of the brake line bracket and drill hole. Reinstall brake line bracket to inner fender well.

M. Install front brake line retainer clips.

N. Remove the factory lower control arms. Using a 21mm wrench.

Step 2: Remove Front Stock Components


J

K1

K2L

N


Step 3: Install Duroflex Bushing


Important Note: MetalCloak Control Arm Lengths are estimated based on a 3.5” Lift. It is recommended that you consult a alignment and suspension specialist for precise tuning and adjustment.

O. Measure and install the MetalCloak Duroflex lower control arms (re-use factory bolts; do not fully tighten until vehicle is back on to the ground). The offset tube is to be located as low as possible at the axle end.

Note: Off-set of arm faces upward

Note: These are recommended starting lengths for the control arms only.

O


P. Drill a hole at the hole location with a 27/64” bit.

Q. Tap hole with a ½ - 13 tap for the coil bucket bump stop.

R. Secure the spring between the jounce tower and place an assembled MetalCloak bump stop inside the Dual Rate Coil.

S. Tighten MetalCloak bump stop.

T. Reattach the spring retainer clips.

Step 4: Remove Stock Components


Important Note: Do not over tighten the retainer bolt as it strips easily.

P

Q

T

R2

R1

S


Step 5: Install Duroflex Bushing


U. Remove Upper Front Control Arms.

V. Optional: If you upgrade to larger hardware and joint drill frame hole to 15/32”.

W. Install bushing end of upper front control arms.

X. Measure upper front control arms adjust to the correct length.

Y. Install lower end of upper front control arms.

Important Note: Do not drop hardware into the frame.

VW

UX

Y


Step 6: Reinstall Components


Z. Re-install shocks.

AA. Tighten Bottom shock bolts.

BB. Tighten Upper shock bolt.

AA

Z

Lower Shock Bolt Upper Shock Bolt

BB BB


Step 7: Install Sway Bar Quick Disconnects


CC. Remove factory sway bar stud.

DD. Install the lower Quick Disconnect Pin in the stock location. Point the Pin toward the center of the vehicle, backed by the provided ½”-13 hardware. A screwdriver through the hole on the end of the Pin is helpful while tightening the nut with a 3/4” wrench.

EE. Adjust the length of the adjustable links to set the sway bar at the desired length (usually level to the ground at ride height). With the lower rubber bushing installed on the Quick Disconnect Pin, tighten the jam nut.

CCDD1 DD2


Step 7: Install Sway Bar Quick Disconnects


FF. Install front sway bar end link mounts.

GG. Mark and drill holes for bracket. There is no exact location; the goal is simply to keep the sway bar clear of the tires when stowed. Mark the locations and drill with a 17/64” drill.

HH. Install new sway bar link mounts.

II. Install new sway bar links.

FF GG

HHII


Step 8: Install Front Track Bar


JJ. Re-drill front track bar axle bracket. Use a 5/8” drill bit for top track bar bracket and a 9/16” drill bit for the bottom.

KK. Reconnect track bar at new holes. Do not tighten track bar bolt as it may need to come off to re-center axle when vehicle is lowered.

LL. Tighten adjustment locking nuts on control arms.

MM. TORQUE ALL BOLTS.Track bar lower bolt – 120-130Track Bar Upper Bolt – 150Standard Control Arm Bolts – Factory specsUpgraded Upper Control Arm Bolts – 85 for M12 bolt

JJ1

JJ2

KK1

LL

KK2


Step 9: Finalize Installation


Note: Re-attach steering linkage at axle end. Once set, tighten all hardware. Again tighten all hardware. Finally, tighten the jam nuts on all control arms. When the jeep is back on the ground do not forget to center front axle and tighten the upper track bar bolt.


Step 1: Remove Rear Stock Components

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Section 4: REAR SUSPENSION Installation Instructions

II-7181 | Rev C | 04/17/2018 | Copyright 2011 Armored Works, LLC

Important Note: When lifting any vehicle, basic dynamics are changed. It is important for you to take your vehicle to a professional for alignment after installation. When doing so, make sure he is setting caster for lifted vehicle (not stock specs).

A. Support the rear axle.

B. Remove rear shocks.

C. Remove rear brake line.

D. Install extended rear brake lines.

E. Remove the factory U-bolts.

F. Remove rear leaf springs and rear shackle hardware.Note: If you have a rear sway bar we recommend you move it before installing. You will not reuse sway bar.

A

B

C D FE

Step 2: Shackle Bushings and Leaf Springs


L. Install leaf springs. Do not fully tighten springs eyebolts until the vehicle is back on the ground.

M. Install front end of leaf springs.

N. Install shackle end of leaf spring.

O. Install U-bolts and U-bolt spring plates.Torque for U-bolts is 65.

Important Note: The 3/8” center pins are stronger than stock and usually require enlarging the spring pad hole to 9/16"ually come with spacers installed for use w/ floating type degree shims. If required remove spacers so pin does not bottom out on axle tube. If using steel Rubicon Express shims, remove the spacers and replace with the shims These steel shims will require reaming to 3/8” for 3/8” pins.

O

N M


Step 3: Rear Bump Stops


P. After installing the leaf springs and U-bolts install the new Rear Bump Stops.


Step 8: Install Front Track Bar


Q. Re-install rear shocks.

R. Tighten Upper Shock Bolt.

S. Tighten Lower Shock Bolt.

T. Install Tires

U. Important! Bleed front and rear brake lines

Important Note: Some require bar pins to be installed through the top shock eyes (use light grease).

Important Note: When lifting any vehicle, basic dynamics are changed. It is important for you to take your vehicle to a professional for alignment after installation. When doing so, make sure he is setting caster for lifted vehicle (not stock specs).

Important Note: Test drive and note location of steering wheel. Adjust drag link to center steering wheel if needed. Retighten all bolts after 50 miles and again after every off road excursion.

Reminder: Do not re-install the rear sway bar. It will NOT be reused

R

S

U


PRODUCT: XJ Duroflex Short Arm Suspension READ ...

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