Installation Instructions
Contents
1. Part 014312 jiSUSPENSION se UK KE oA gras R HARDCOR 3 Suspension System Jeep Wrangler JK 2007 2014 Rev 031314 491 W Garfield Ave Coldwater MI 49036 Phone 517 279 2135 Web live chat www bds suspension com E mail tech bds suspension com Read And Understand All Instructions And Warnings Prior To Installation Of Re System And Operation Of Vehicle THANK YOU BEFORE YOU START BDS Suspension Co recommends this system be installed by a professional technician In addition to these instructions professional knowledge of disassembly reassembly procedures and post installation checks must be known FOR YOUR SAFETY Certain BDS Suspension 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 rollover Failure to drive your modified vehicle safely may result in serious injury or death BDS Suspension Co 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 reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt BEFORE INSTALLATION e Special literature required OE Service Manual fo2. as far back in the slot as possible most rearward setting max caster Just snug the cam hardware so that the cams are retained within the stops Final torque will be completed with the weight of the vehicle on the suspension Fig 7 FIGURE 6 FIGURE 7 25 Repeat cam bolt installation on the driver s side 26 Cut or bend the tab on the factory bracket so it will set flat against the frame Fig 8a Install the provided front brake line brackets 01715 with the 1 4 stud to the original brake line frame mount with the factory hardware Attach brakeline to the new brake stud with provided 1 4 nuts and washers as shown in figure 8b BP 704 2011 or newer models reattach the brakeline routing bracket to the axle with fac tory hardware FIGURE 8A Stem Gi iF a Sa x i re Pi h i i a g i his 27 Install the wheels and torque lug nuts to manufacturer s specifications 28 Lower the vehicle to the ground and bounce the front to settle the suspension Torque the front lower control arm bolts at the axle where the octagon washers were installed to 110 ft lbs Make sure the washers are rotated so the bolt is in the rear most position with the octa gon washers retained between the factory stops 29 Reattach the front track bar to the axle with the OE hardware Have an assistant turn the steering wheel to aid in aligning the track bar bolt Torque the track bar bolt to 125 135 ft lbs REAR INSTALLATION 1 Bl
3. hardware BP 749 tighten to 10 ft lbs Fig 14 Note do not disconnect brakeline shown for inst sheet pictures only _ FIGURE 14 Reinstall wheels and torque to factory specifications Lower vehicle to ground Install the rear track bar into the new relocation bracket with the original track bar hardware An assistant may be needed to push on the body of the vehicle to help align the track bar in the bracket With the track bar installed torque the 9 16 bracket hardware and OE track bar hardware to 125 ft lbs Double check all hardware for proper torque Have a front end alignment performed to correct caster angle Check all fasteners after 500 miles and at regularly scheduled maintenance intervals WE WANT TO SEE YOUR RIDE Grab photos of your BDS equipped truck in action and send them in for a chance to be featured Send it in to our Bad Ass Rides customer gallery at bds suspension com bar and post them on the BDS Fan Page on Facebook at facebook com BDSSuspensions Don t forget about your BDS swag BDS offers t shirts hoodies decals and more available on the BDS website or through your local BDS distributor Thank you for choosing BDS Suspension For questions technical support and warranty issues relating to this BDS Suspension product please contact your distributor installer before contacting BDS Suspension directly
4. 011 and newer models disconnect brakeline from the axle retain hardware 7 Disconnect the steering drag link from the pitman arm Remove the tie rod end nut and dislodge the tie rod end from the pitman arm with the appropriate puller or pickle fork Save tie rod end nut 8 2012 models only Locate and install the 124314 Exhaust Extension Kit with the instructions included in the kit 9 Lower the front axle and remove the coil springs from the vehicle 10 Make a mark in the center of the lower coil spring mount pad Drill a 3 8 hole at the mark This hole will be used to attach the provided bump stop extension to the axle Fig 2 11 Place a provided bump stop extension inside one of the new front coil springs and install the spring in the vehicle Make sure the spring is seated properly in the axle mount Note The new front coil springs are the taller set 12 Attach the bump stop extension to the axle through the hole that was drilled earlier using a 3 8 x 3 bolt nut and 3 8 USS washers BP 749 Torque bolt to 20 30 ft lbs Repeat the spring bump stop installation of the other side of the vehicle Fig 3 FIGURE 2 FIGURE 3 13 Install the new shocks with the OE lower hardware and new upper bushings hardware Torque the lower bolt to 60 ft lbs and the upper nut until the bushings begin to swell 14 Reattach the drag link to the pitman arm with the OE tie rod end nut Torque nut to 65 ft lbs NON RUBICON MODELS ONL
5. N MODELS ONLY 124320 20 Locate the new front sway bar links 911110 Lightly grease and install the provided sleeves 46 into the pre installed bushings at each end of the links 21 Attach the new links to the outer mounting surface of each end of the front sway bar using a 1 2 x 3 bolt nut and 1 2 washers Install the links so that they offset toward the outside of this vehicle when installed Run the bolt from the inside out Leave hardware loose 22 Attach the lower end of the new sway bar links to the inside mounting surface of the OE axle tab Fasten the links with the OE sway bar link mounting hardware Torque the upper and lower sway bar link hardware to 60 ft lbs ALL MODELS 23 With the front axle still supported with a jack remove the passenger s side lower control arm bolt at the axle The OE lower control arm mounts are perforated from the factory so that they can be changed to slots for alignment cams The perforated sections must be removed to accepted the new cam washers supplied in this kit Soecial tools are made to perform this operation but are not necessary The perforat ed sections can be removed with a rotary grinding tool chisel or a combination of both only the rear section needs to be removed Fig 6 24 When the perforated sections are removed from the lower control arm mount reinstall the control arm to the axle with the factory bolt with octagon shaped washers Rotate the cam so that the bolt will be
6. Y 124310 15 Install the new sway bar link disconnect ball stud to the original sway bar link mount on the axle Attach the stud so that the ball is toward the center of the vehicle Use one 1 2 SAE washer on each side of the mount and fasten with a 1 2 nut BP 912 Torque nut to 65 ft lbs Fig 4 16 Locate the new sway bar link assemblies Ensure that they are adjusted to equal length The links should be adjusted between 9 and 9 1 4 from the center of the bushing to the very end of the disconnect Do not lock off the jam nuts at this point Fig 3 17 Lightly grease and install the provided sleeves 46 in the new sway bar links assemblies Attach the new sway bar link assembly to the sway bar with a 1 2 x 3 bolt nut and 2 SAE washers BP 912 The link will mount to the outside of the sway bar with a 1 3 8 OD extra thick 1 2 washer positioned between the bushing and the sway bar BP 912 Torque 12 bolt to 65 ft lbs 18 19 Connect the sway bar links to the ball studs on the axle Adjust the sway bar link ends so that they are square on the ball stud and lock off the jam nut securely Locate the existing inner fender bolt up near the front body mount Remove the bolt and attach the new lanyard to the inner fender with the bolt Torque bolt to 10 ft lbs Slide the male clip up the lanyard and attach the female clip to it This will be the stowed position for the lanyard when not in use RUBICO
7. e The bracket mounts to the back and outside faces of the OE mount and against the front inside surface on left hand drive models On right hand drive models the bracket mounts to the front and outside faces of the OE mount and against the inside rear surface Fig 11a 11b 13 Using the bracket as a template mark the outside hole to be drilled Remove the bracket and drill a 1 2 hole at the mark FIGURE 11A LHD SHOWN FIGURE 11B 14 Reinstall the track bar bracket with the 9 16 hardware BP 748 along with the provided crush sleeve 48 inside the factory mount Run the bolt through the new bracket OE mount and sleeve Fig 12 Leave hardware loose 15 16 17 18 19 20 21 22 23 FIGURE 12 LHD SHOW fine Fasten the new bracket to the frame through the outer holes using the provided 7 16 hardware BP 748 The bottom hole uses the larger diameter USS washer on the inside to go against the slot in the frame Torque 7 16 hardware to 40 ft lbs Fig 13 Install the sway bar drop spacers between the frame and the OE sway bar mounts with 10mm x 60mm bolts and washers BP 709 Torque bolts to 30 ft lbs Install brakeline relocation brackets as shown there are drv and pass side brackets they will be located into the factory locating tab The the factory brakeline will be mounted towards the center of the vehicle on the inside of the relocation bracket Attach with OE and new 1 4 x 1
8. e nut 3 8 16 x 3 bolt 3 8 USS washer 3 8 16 prevailing torque nut 1 4 20 x 1 bolt 1 4 20 nylock nut 1 4 20 x 3 4 type 23 bolt Rear Bump Stop Spacer 3in wide x 2in Tall Bump Stop Spacer Rear Brakelline Bracket DS Rear Brakeline Bracket PS Front Brake Line Bracket Sway Bar Drop Bracket Rear Track Bar Bracket Bolt Pack Bolt Pack 1 4 20 prevailing torque nut 1 4 SAE flat washer Bolt Pack 10mm 1 50 x 60mm bolt 10mm 1 50 prevailing torque nut 3 8 USS flat washer 9 16 12 x 3 bolt 9 16 SAE washer 9 16 12 prevailing torque nut 7 16 14x 1 1 4 bolt 7 16 SAE washer 7 16 USS washer 7 16 14 prevailing torque nut zm 2 Door Coil Springs Part Qty Description 034312 2 3 Front Coil Springs 2 door taller 034209 2 3 Rear Coil Springs 2 door 4 Door Coil Springs Part Qty Description 034311 2 3 Front Coil Springs 4 door taller 034319 2 3 Rear Coil Springs 4 door 124320 Front Sway Bar Links Standard JK Part Qty Description 46 2 750x 120 x 1 45 Sleeve 911110 2 Front Sway Bar Link B12X3G5 2 1 2 x 13 x 3 Bolt N12PT 2 1 2 x 13 Torque Nut W12S 4 1 2in Washer SB34BK 4 3 4 ID Hourglass Bushing 124310 Sway Bar Disconnects Rubicon JK Part Qty Description 01316 2 13 5in Lanyard A168 2 Disconnect Assembly 01302 2 Disconnect Stud 46 2 750x 120x 1 45 Sleeve 912 1 Bolt Pack S
9. nce Test and inspect brake system E AK AN 4 Dh Ke i ISUSEENSION KE A pe In an effort to reduce the risk of rollover crashes the National Highway Traffic Safety Administration NHTSA established the Federal Motor Vehicle Safety Standard FMVSS No 126 requir ing all new passenger vehicles under 10 000 MV No 126 lbs GVWR include an electronic stability COMPLIANT control ESC system as standard equipment X A Effective August 2012 this law requires after market products to be compliant with these same standards FITMENT GUIDE 35x12 50 on 16x8 with 4 5 backspacing Perform steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating mobile or heated members Inspect rear brake hoses at full extension for adequate slack Failure to perform hose check replacement may result in component failure Longer replacement hoses if needed can be purchased from a local parts supplier Perform head light check and adjustment Re torque all fasteners after 500 miles Always inspect fasteners and components during routine servicing 014312 Box Kit Part 01828 749 01928B 3296 JKBL D JKBL P 01715 01975B 01948B 748 704 709 TDA Qty Description A 1 nu a N N NH NH NHN NB HK NA N N N N A A N WU N OctoCam JK Bolt Pack 5 16 18 x 7 8 bolt 5 16 SAE washer 5 16 18 prevailing torqu
10. ock the front wheels for safety 2 Disconnect the rear track bar from the frame passenger s side Retain hardware Fig 9 Raise the rear of the vehicle and support the frame with jack stands in front of the lower control arm mounts Remove the wheels Remove the shocks Save the upper and lower mounting hardware Disconnect the sway bar from each frame rail discard hardware Allow the sway bar to rest on the exhaust oy e w Disconnect brakeline brackets from the frame Save hardware Fig 8 8 Lower the axle and remove the rear springs t Ti p Do not overextend the brakelines or ABS wires It may be necessary to remove these from their retaining clips temporarily 9 Install the new rear springs in the vehicle making sure the OE upper rubber isolator is in place Raise the axle to slightly compress the spring 10 Install the new shocks with the OE hardware Tighten upper mounting hardware to 30 ft lbs and lower hardware to 55 ft lbs 11 Install the provided bump stop spacers on the axle so that the 3 tall side is up Use the existing holes in the axle to attach bump stop pad Fasten the bump stop spacer to the axle with 5 16 x 7 8 bolts nuts and 5 16 SAE washers BP 749 Torque bolts to 20 ft lbs Fig 10 FIGURE 10 a in alan a k Ea bike Ce J m 12 Temporarily install the new track bar bracket 01948 into the OE frame bracket with the new provided 9 16 hardwar
11. r model year of vehicle Refer to manual for proper disassembly reassembly procedures of OE and related components e Adhere to recommendations when replacement fasteners retainers and keepers are called out in the OE manual e 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 e Post suspension system vehicles may experience drive line vibrations Angles may require tuning slider on shaft may require replacement shafts may need to be lengthened or trued and U joints may need to be replaced e Secure and properly block vehicle prior to installation of BDS Suspension components Always wear safety glasses when using power tools e If installation is to be performed without a hoist BDS Suspension Co recommends rear alterations first e 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 BEFORE YOU DRIVE Check all fasteners for proper torque Check to ensure for adequate clearance between all rotating mobile fixed and heated members Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring harness Check steering gear for cleara
12. way Bar Disconnects 1 2 13 x 3 bolt 1 2 13 prevailing torque nut 1 2 SAE flat washer 1 2 20 prevailing torque nut 1 3 8 OD x 3 16 Thk flat washer No N O N N Part Qty Description 01839 1 Exhaust Extension Drv TROUBLESHOOTING 01840 1 Exhaust Extension Pass INFORMATION FOR YOUR VEHICLE 814 1 Bolt Pack 2 8mm 1 25mmx 70mm bolt 1 Will not fit 2wd models 2 8mm 1 25mmx 60mm bolt 2 Exhaust modification may be required 4 5 16 SAE washer INSTALLATION INSTRUCTIONS 1 Park the vehicle on a clean flat surface and block the rear wheels Drill with 3 8 and 1 2 drill sizes for safety Rotary grinder or chisel to remove control arm cam knock out 2 Measure from the center of the wheel up to the bottom edge of the wheel opening LF RF LR RR FRONT INSTALLATION 1 Disconnect the front track bar from the axle Left Hand Drive models shown in Figure 1 Save hardware Fig 1 FIGURE 1 Raise the front of the vehicle and support the frame with jack stands behind the front lower control arm pockets Remove the wheels Support the front axle with a hydraulic jack Remove the front shocks from the vehicle Retain lower mounting hardware Disconnect the sway bar links from the axle and sway bar oe SE Se Disconnect the brakelines from the frame to keep them from being over extended retain hardware they will be reattached later in the installation 2
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