Installation Instructions
Contents
1. J3310 J3311 Installation Instructions 1984 2001 Jeep XJ OFFROAD PRODUCTS 3 Front Coil Spring Rear Add A Leaf Lift Read and understand all instructions and warnings prior to installation of product and operation of vehicle Zone Offroad Products recommends this system be installed by a professional technician In addition to these instructions profession al knowledge of disassembly reassembly procedures and post installation checks must be known Minimum tool requirements include the following Assorted metric and standard wrenches hammer hydraulic floor jack and a set of jack stands See the Special Tools Required section for additional tools needed to complete this installation properly and safely PRODUCT SAFETY WARNING Certain Zone Offroad Products are intended to improve off road performance Modifying your vehicle for off road use may result in the vehicle handling differently than a factory equipped vehicle Extreme care must be used to prevent loss of control or vehicle roll over Failure to drive your modified vehicle safely may result in serious injury or death Zone Offroad Products does not recommend the combined use of suspension lifts body lifts or other lifting devices You should never operate your modified vehicle under the influence of alcohol or drugs Always drive your modified vehicle at re duced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt TEC2. suspension Note Make sure to reattach the sway bar end bracket fuel tank floor boards and wiring to the outer u bolt harness Check steering gear for clearance Test and inspect brake 12 Repeat procedure on the driver s side Note Take care not to overextend the rear brake line It may be necessary to remove the brake line retaining clip and free the line from the bracket at the frame to provide more slack 2 Perform steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating mobile or heated 14 Ifthe rear bracket line was removed from the frame bracket reattach it with the members Inspect rear brake hoses factory retaining clip at full extension for adequate slack Failure to perform hose check re placement may result in component 16 Bounce the rear of the vehicle to settle the suspension Torque the u bolts to 75 failure 90 ft lbs system 13 With both sides complete install the new shocks with the factory hardware Torque the upper hardware to 25 ft lbs and the lower nut to 50 ft lbs 15 Install the wheels and lower the vehicle to the ground 3 Perform head light check and adjustment gt Post INSTALLATION 4 Re torque all fasteners after 500 1 A complete front end alignment is required miles Always inspect fasteners and l 8 components during routine servic A Depending on vehicle model year transmission transfer case and or axle model ing a driveline v
3. HNICAL SUPPORT Difficulty Level Live Chat provides instant communication with Zone tech support Anyone can access live easy l 2 G 4 5 difficult chat through a link on www zoneoffroad com Bey Semen dneallevavern a 25 www zoneoffroad com may have additional information about this product including the lat Speci al Tools Required est instructions videos photos etc i l l T 50 Torx socket Send an e mail to tech zoneoffroad com detailing your issue for a quick response l l C Clamps Pair 888 998 ZONE Call to speak directly with Zone tech support R Tire Wheel Fitment wheel pd Special literature required OE Service Manual for model year of vehicle Refer to manual for proper disassembly reassembly procedures of OE and related components 31x10 50 tire 15x8 3 5 4 B S wheel Some trimming req d 2 Adhere to recommendations when replacement fasteners retainers and keepers are called ae out in the OE manual 3 Larger rim and tire combinations may increase leverage on suspension steering and related components When selecting combinations larger than OE consider the additional stress you could be inducing on the OE and related components 4 Post suspension system vehicles may experience drive line vibrations Angles may require tuning slider on shaft may require re placement shafts may need to be lengthened or trued and U joints may need to be replaced 5 Secure and properly block vehicle prior to installa
4. ibration may occur after the installation of this lift If the vibration is excessive a transfer case drop can be installed to reduce the rear driveline angle This kit Zone J5006 can be purchase at www zoneoffroad com J3310 J3311 Installation pg 5
5. le with a hydraulic jack and place jack stands under the frame rails just behind the lower control arm pockets 4 Remove the wheels 6 Support the front axle with a hydraulic jack Remove the shocks Save the lower shock hardware 7 Remove the upper mounting nut from the sway bar links Figure 2 Swing the sway bar up off of the links Save all hardware bushings 8 Remove the cotter pin and castellated nut from the drag link end at the pitman arm Figure 3 Thread the nut back on a couple of turns Strike the pitman arm near the drag link end to release the tapered seat Take care not to damage the end Remove the nut and the drag link from the pitman arm Save hardware 9 Remove the driver s and passenger s side coil spring retainer clip located on the back side of the axle coil seat Save clips and bolts J3310 J3311 Installation pg 2 10 11 12 13 14 15 Figure 3 Loosen the driver s and passenger s side lower control arm bolts at the axle Completely remove the passenger s side bolt and leave the driver s side in place This should allow the axle to lower enough to remove and install the coil springs Lower the axle with the hydraulic jack and remove the original coil springs Take care not to over extend the brake lines Install the new coil springs and rotate the ends so that they seat properly in the axle mounts Raise the axle until the coils seat in the upper mounts and have a s
6. light amount of pressure on them Reinstall the driver s and passenger s side coil retainers and torque to 20 ft lbs Reattach the passenger s side lower control arm bolt nut washers Snug the bolt but do not tighten completely Both lower control arm bolts with be tightened with the weight of the vehicle on the suspension Install the new shocks with the provided upper bushings hardware Leave the upper nut loose J3310 J3311 Installation pg 3 Attach the shock to the axle with the original shock hardware Torque bolts to 20 ft lbs Go back and tighten the upper shock stem nut until the stem bushings begin to swell Install the thin jam nut on the stem and tighten it against the first nut Reattach the drag link to the pitman arm with the original castellated nut Torque the nut to 60 ft lbs Align the cotter pin hole with the slots in the nut and install the cotter pin Never loosen the nut to align the cotter pin only tighten If the original cotter pin is damaged replace it with a new one Install the wheels and torque the lug nuts to the manufacturer s specs See ve hicle owner s manual Remove the jack stands and lower the vehicle to the ground Bounce the front of the vehicle to settle the suspension Attach the sway bar links to the sway bar with the original hardware bushings Tighten nuts until the bushings begin to swell Reconnect the front track bar to the axle mount with the original hardware Torque bolt
7. te each leafs position and orien tation front to rear The leaf lengths get shorter as they go from the top leaf in a pyramid shape Fig ure 4 Insert the supplied add a leaf in the appropriate position to form a pyra mid shape Using the C clamps on each side of the center pin hole compress the leafs together while aligning the new center pin through all of leaf center pin holes from the bottom up With the pack completely compressed together with the clamps fasten the center pin with the provided nut Torque nut to 20 ft lbs Cut off any access center pin Do not use the center pin to compress the pack together Remove the C clamps from the leaf pack and ensure the individual leafs are all inline with each other Install the provided bend over style clamps on the leaf pack Figure 5 Install one clamp on each side of the center pin about 12 from the center pin Bend the ends of the clamps over to secure them to the spring Figure 4 Post Installation Warnings 1 Check all fasteners for proper Figure 5 torque Check to ensure for adequate clearance between all 11 Raise the axle to the leaf spring aligning the center pin with the center pin hole rotating mobile fixed and heated in the axle Fasten with the provided u bolts nuts and washers Snug u bolts members Verify clearance between but do not tighten completely U bolt torque with be set with the weight of the exhaust and brake lines fuel lines vehicle on the
8. tion of Zone Offroad Products Always wear safety glasses when using power tools 6 If installation is to be performed without a hoist Zone Offroad Products recommends rear alterations first 7 Due to payload options and initial ride height variances the amount of lift is a base figure Final ride height dimensions may vary in accordance to original vehicle attitude Always measure the attitude prior to beginning installation Kit Contents Qty Part Qty Part 4 Leaf Spring Clamp 2 3 Front Coil Spring 2 5 16 center pin nut 2 3 Add A Leaf 2 Front Shock 4 U bolts nuts washers 2 Rear Shock N J INSTALLATION INSTRUCTIONS impo rtant measure l Park the vehicle on an appropriate work surface Ensure that the vehicle is in arl park for automatic transmission or in first gear for manual transmissions and the before starting parking brake is applied Block the wheels for added safety Measure from the center of the wheel up to the bottom edge of the wheel opening 22 Front INSTALLATION 2 Remove the bolt mounting the front track bar to the passenger s side of the axle Figure 1 Save track bar bolt and nut tab Allow the track bar to hang free LF RF LR RR Step 2 Note The track bar bolt may require a T 50 Torx socket on early models Figure 1 3 Raise the front of vehic
9. to 50 ft lbs Note To aid in aligning the track bar hole have an as sistant turn the steering wheel to shift the trackbar in the correct direction Torque the lower control arm bolts to 85 ft lbs Check all hardware for proper torque REAR INSTALLATION Block the front wheels for safety Raise the rear of the vehicle with a hydraulic jack and support with jack stands at the frame rails just ahead of the leaf spring hanger Remove the wheels Support the rear axle with a hydraulic jack Remove the shocks Save all shock hardware Complete the following one side at a time starting with the passenger s side 16 17 18 19 20 21 22 23 24 l 2 3 4 Step 4 Note The upper factory shock bolts are prone to corrosion Take care 5 removing the bolts they can break easily 6 Step 6 Note 7 Slightly loosening the driver s side u bolts will allow the axle to lower 8 from the spring with less restric tion 9 10 With the rear axle well supported with a hydraulic jack remove the leaf spring u bolts The sway bar link bracket will be free with the removal of the outer u bolt Lower the axle from the spring Remove the factory bend over style leaf spring clamps These will not be re used Place C clamps on each side of the leaf spring center pin to hold the leaf pack together Remove the leaf spring center pin and then release the C clamps This will allow the leaf pack to come apart Take no
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