Installation Instructions
Contents
1. MAXIMUM 2 1 8 2 125 in if Main Body was Shortened 1 1 2 in step 3 QO Rotate Adjuster Ring E to desired position and tighten the recessed 3 8 x 1 1 4 Cap Bolt F to lock in place JKS ACOS Pro Installation PN 2700 Page 7 of 8 Q 9 ADJUST BUMP SHOCK POSITION Operation The ideal bump shock position is determined by the vehicle suspension and varies for each application LJ 7 INSTALL BUMP SHOCK ON MAIN BODY OF ACOS PRO QO Apply a drop of medium strength thread locking compound to bottom few threads of Ride Height amp Bump Shock Adjustments Future ride height and bump shock adjustments should Q To properly set the bump shock position for be made with NO LOAD on the rear coil springs and the Main Body B QO Completely thread the Bump Shock Adapter H onto Main Body B until snug O Apply anti seize lubricant to threads of Bump Shock Assembly J Completely thread the Bump Shock Nut I onto Bump Shock Assembly J QO Completely thread the Bump Shock Assembly J with Bump Shock Nut I into Bump Shock Adapter H as far as possible u LJ 8 RE INSTALL REAR COIL SPRINGS Re install the rear coil springs per the factory service manual instructions for your vehicle HINT A coil spring compressor is useful for installation QO Also re install any of the components that were removed during Step 1 of this installation A ATTENTION INSTALLER IMPORTANT NOTE REGARDING SHO2. HINT When installed correctly the Reinforcement Ring A and Main Body B will sandwich the upper spring mount Once all six bolts have been installed tighten the 5 16 Nylock Nuts D to 40 ft lbs using a torque wrench PN 2700 Q 6 SET ADJUSTER RING FOR DESIRED RIDE HEIGHT QO Apply spray lubricant to threads of Main Body B Install Adjuster Ring E by threading clockwise onto Main Body B O Slide Isolator Pad G onto Main Body until flush with Adjuster Ring E IMPORTANT Vehicle ride height is determined by measuring the distance between the top of Main Body and bottom of Isolator Pad and then subtracting 3 4 0 75 in X 3 4 RIDE HEIGHT Represents increase in ride height over OE suspension A WARNING DO NOT EXCEED MAXIMUM RANGE OF ADJUSTMENT ADJUSTMENT RANGE MINIMUM 1 3 8 1 375 in MAXIMUM 3 1 4 3 250 in O Rotate Adjuster Ring E to desired position and tighten the recessed 3 8 x 1 1 4 Cap Bolt F to lock in place Page 3 of 8 Q 9 ADJUST BUMP SHOCK POSITION Operation The ideal bump shock position is determined by the vehicle suspension and varies for each application LJ 7 INSTALL BUMP SHOCK ON MAIN BODY OF ACOS PRO QO Apply a drop of medium strength thread locking compound to bottom few threads of Ride Height amp Bump Shock Adjustments Future ride height and bump shock adjustments should Q To properly set the bump shock pos
3. Portion of upper spring mount removed leaving a 2 to 21 4 hole SS QO With the center portion of the upper spring mount cut away a second hole must be cut through the attached spring mount bracket Begin by marking a 2 1 4 diameter hole in the bracket using the hole in the spring mount as a guide HINT Mark the hole location carefully the hole in the spring mount bracket must be concentric to the hole cut into the spring mount 1 17 1 QO Insert your cutting tool into the upper spring mount hole and cut the second 2 1 4 diameter hole through the spring mount bracket HINT Once again a plasma cutter is the best choice for cutting the spring mount bracket O Remove the excess threaded portion by cutting completely through the Main Body B at the location marked in the previous step HINT A band saw is useful for cutting the Main Body B although a sharp hack saw with an appropriate fine tooth blade or cutting wheel may also be used Use extreme care to avoid damaging remaining threads O Inspect end of Main Body B for damaged threads and repair as needed HINT A 16TPI thread restoring file or equivalent is useful for repairing threads Portion of spring mount bracket removed leaving a 2 hole JKS ACOS Pro Installation PN 2700 Page 6 of 8 Man bee aoe pa Q 5 INSTALL MAIN BODY OF ACOS Q 6 SET ADJUSTER RING FOR accurately mark all six hole locations on the REE DE
4. suspension at full droop extend the Bump Shock Assembly J to the desired position Once the Bump Shock Assembly J is properly adjusted for your application lock in place by turning the Bump Shock Nut I clockwise until it contacts the Bump Shock Adapter H IMPORTANT The suspension must be fully cycled to test for bump shock alignment and interference issues before the vehicle can be safely operated The bump shock must contact the center portion of the lower spring pad at full compression and there should be no interference between the bump shock and coil spring at full extension If you encounter any interference issues contact JKS Manufacturing immediately for technical assistance JKS Technical Department Phone 308 762 6949 E mail tech jksmfg com PN 2700 the suspension at FULL DROOP NEVER TURN Adjuster Ring E while under tension and ALWAYS APPLY SPRAY LUBRICANT to threads of Main Body B or Bump Shock Assembly J before adjusting Bump Shock Pressure The Bump Shock Assembly J is pre charged with the proper amount of Nitrogen gas to suit most applications IT SHOULD NOT BE NECESSARY TO ADJUST BUMP SHOCK PRESSURE ON MOST VEHICLES The Nitrogen charge is factory preset at 150 psi For applications that require a higher or lower compression rate the gas pressure can be manually adjusted to a minimum of 100 psi and a maximum of 200 psi To adjust pressure the bump shock assembly must
5. QO QO QO QO QO 000 QOQOQOQO Asterisk denotes tools that are not required for some applications Thoroughly read instructions first to determine which tools will be required for your application JKS ACOS Pro Installation Installation LJ 1 REMOVE REAR COIL SPRINGS O Remove the rear coil springs per the factory service manual instructions for your vehicle HINT A coil spring compressor is useful for removal O Depending on the application it may be necessary to completely or partially remove any of the following components before spring can be free from upper mount Shock Absorber Swaybar Brake Line Track Bar Q 2 PREPARE UPPER SPRING MOUNT The factory upper spring mount and bracket must be modified in order to install the ACOS Pro This modification is not reversible and should only be performed by an experienced mechanic or fabricator Q Remove the rubber bump stop and bump stop holder from the upper spring mount O Remove the factory rubber isolator pad from the upper coil spring mount 1S CD AN pper Spring Mount lt Rubber Isolator Pad PN 2700 Remove the Bump Shock Assembly J Bump Shock Nut 1 Bump Shock Adapter H Isolator Pad G and Adjuster Ring E from the Main Body B of the ACOS Pro Turn the Main Body B upside down and position the threaded end over the protruding portion of the upper spring mount Mark a straight and level line
6. Rubber Bump Stop QO Paint any exposed metal on the upper spring mount to prevent corrosion JKS ACOS Pro Installation PN 2700 Page 2 of 8 L 4 CUT UPPER SPRING RETAINER The majority of the factory spring retainer must be permanently removed from the upper spring mount in order to install the ACOS Pro This modification is not reversible and should only be performed by an experienced mechanic or fabricator O Mark a location on the upper spring retainer that is 1 away from the upper spring mount Cut away the upper spring retainer as indicated in the picture below HINT A die grinder with cut off wheel or reciprocating saw is useful for cutting upper spring retainer Modified Upper _ Spring Retainer JKS ACOS Pro Installation INSTALL MAIN BODY OF ACOS PRO ON UPPER SPRING MOUNT Place the Reinforcement Ring A above the upper spring mount and align the mounting holes Hint On Cherokee XJ and Comanche MJ models it will be necessary to first remove a factory mounting stud for the air intake box that interferes with the Reinforcement Ring A die grinder with cut off wheel is useful for removing the mounting stud Position the Main Body B against the bottom of the upper spring mount and align the mounting holes DDD ui Q LZ____ N Insert a 5 16 x 1 1 4 Cap Bolt C through each hole Loosely secure with a 5 16 Nylock Nut D from above the spring mount
7. around the protruding portion of the upper spring mount where the diameter is exactly 2 1 4 HINT Machinist calipers are useful for measuring diameter Cut Line 2 Diameter BOTTOM VIEW Page 5 of 8 O Cut away the center portion of the upper spring Q 3 SHORTEN MAIN BODYOF 4 DRILLUPPERSPRINGMOUNT mount as indicated in the picture below HINT A plasma cutter is useful for cutting the ACOS PRO QO Temporarily install the Bump Shock Adapter H upper spring mount Plasma cutting experience On vehicles with 4 0 5 5 rear coil springs it will be and Bump Shock Assembly J on Main Body and a very steady hand are necessary to necessary to shorten the Main Body B to provide B of ACOS Pro Thread Bump Shock ensure a clean accurate cut Use extreme sufficient clearance between the Bump Shock Assembly into Main Body completely caution when operating a plasma cutter near the fuel tank any if 7 ASSEMOY ANG ANE pad Q Place the Main Body B against the upper Disregard this step on vehicles with 6 0 springs or taller spring mount ensuring that the top of the Bump as this modification will not be necessary Shock Assembly J passes cleanly through the large hole created in section 2 QO Measuring 1 5 from the threaded end mark a HINT Main Body B must be perfectly centered line on the Main Body B over spring mount to prevent obstruction of Bump Shock Assembly J threads Das Top of Bump Shock
8. 8
9. A E rencicr puns ct PRO ON UPPER SPRING MOUNT DESIRED RIDE HEIGHT equivalent HINT Hole locations should align Q Position the Main Body B against the bottom Q Apply spray lubricant to threads of Main Body with spring mount bracket as indicated below of the upper spring mount and align the B Install Adjuster Ring E by threading mounting holes clockwise onto Main Body B O Slide Isolator Pad G onto Main Body until flush with Adjuster Ring E IMPORTANT Vehicle ride height is determined by measuring the distance between the top of Main Body and bottom of Isolator Pad and then subtracting 1 4 0 25 in 60 BOTTOM VIEW O Inserta 5 16 x 1 1 4 Cap Bolt C through each hole Loosely secure with a 5 16 Nylock Nut D from above the spring mount HINT It is not necessary to install the supplied Reinforcement Ring A on rear applications O Once all six bolts have been installed tighten the 5 16 Nylock Nuts D to 40 ft lbs using a torque wrench X 1 4 RIDE HEIGHT Represents increase in ride height over OE suspension IN WARNING DO NOT EXCEED MAXIMUM RANGE OF ADJUSTMENT O Using a 1 4 bit drill a pilot hole at each hole location Enlarge each hole with a 3 8 drill bit Q Paint any exposed metal on the upper spring mount to prevent corrosion ADJUSTMENT RANGE MINIMUM 1 3 4 1 750 in MAXIMUM 3 5 8 3 625 in
10. CK ABSORBERS To prevent the coil springs from becoming unseated during maximum suspension extension correct length shock absorbers must be installed JKS ACOS Pro Installation your vehicle you must first decide the point at which suspension compression should be limited Take into consideration coil springs shock absorbers tire clearance or any other factors that cause the vehicle to bottom out IMPORTANT Because it replaces the original rubber bump stop the bump shock should determine the limit of compression travel The bump shock should be fully compressed when the suspension reaches maximum desired compression With the vehicle on level ground and the suspension at full droop extend the Bump Shock Assembly J to the desired position Once the Bump Shock Assembly J is properly adjusted for your application lock in place by turning the Bump Shock Nut I clockwise until it contacts the Bump Shock Adapter H IMPORTANT The suspension must be fully cycled to test for bump shock alignment and interference issues before the vehicle can be safely operated The bump shock must contact the center portion of the lower spring pad at full compression and there should be no interference between the bump shock and coil spring at full extension Interference issues may exist on applications in which the rear axle has been moved rearward to increase the vehicle s wheelbase Resolving this problem may require remova
11. Y Welcome Parts CONGRATULATIONS on your purchase en a O of a new JKS ACOS Pro system At JKS A Reinforcement Ring Manufacturing we are committed to providing Installa tion you with the best products available and your 7 or aaa satisfaction is our first priority i 2 Instructions PLEASE READ these Installation Instructions es carefully and save them for future reference as they contain important installation F 3 8 x 1 1 4 Cap Bolt Ea operation and maintenance information G Isolator Pad Es H Bump Shock Adapter ES Before You Begin Bump Shock Nut Ke Bump Shock Assembly 1 Familiarize yourself with the supplied parts as illustrated in the following column 2 Thoroughly read all procedures for your application to ensure you have the tools and experience necessary to complete this installation Front Installation gt Pages 2 4 Rear Installation gt Pages 5 8 3 If you are not completely comfortable with any of the procedures described on the following pages do not attempt this installation Contact the JKS Technical Department at 308 762 6949 to locate a qualified installation specialist in your area Product ACOS Pro Part Number PN 2700 Applications Jeep Wrangler TJ 1997 06 front or rear Jeep Grand Cherokee ZJ 1993 98 front only Jeep Cherokee XJ 1984 01 front only Jeep Comanche MJ 1986 92 front only JKS ACOS Pro Installation PN 2700 Page 1 of 8 Install
12. ation HINT On most vehicles the bump stop holder is F ro n t f n S t a f a ft j O n 7 secured to the upper spring retainer with a single 4 REMOVE FRONT COIL SPRINGS bolt However on some Cherokee XJ and Important Comanche MJ models the bump stop holder is O Remove the front coil springs per the factory welded to the spring retainer In this case you will MOST VEHICLES REQUIRE additional parts service manual instructions for your vehicle need to cut or grind away the flared portion of the or modifications to accommodate the HINT A coil spring compressor is useful for bump stop holder before proceeding to Step 2 immediate increase in ride height provided by email O Remove the factory rubber isolator pad from the the ACOS Pro system O Depending on the application it may be upper coil spring retainer necessary to completely or partially remove any S DO NOT EXCEED maximum range of of the following components before spring can Q 3 DRILL UPPER SPRING MOUNT be free from upper mount adjustment see illustration on page 3 pp Remove the Bump Shock Assemb O Bum INSTALLATION of this product is not A SOEC ASSE Shock Nut I Bump Shock Adapter H Isolator Pad G and Adjuster Ring E from the reversible and should only be performed by an Swaybar Main Body B of the ACOS Pro experienced mechanic or fabricator Brake Line O Slide the Main Body B over the spring retainer ABS Wire until the flange rests flush against
13. be removed from the vehicle Nitrogen pressure is adjusted through the Schrader valve on top of the bump shock Care should be taken when discharging the bump shock to ensure that no oil is lost Most shops that service off road racing or motorcycle shock absorbers can adjust bump shock pressure Maintenance Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability Page 4 of 8 Rear Installation Important MOST VEHICLES REQUIRE additional parts or modifications to accommodate the immediate increase in ride height provided by the ACOS Pro system COMPATIBLE WITH 4 REAR COIL SPRINGS or taller This product can not be installed with springs shorter than 4 DO NOT EXCEED maximum range of adjustment see illustration on page 7 INSTALLATION of this product is not reversible and should only be performed by an experienced mechanic or fabricator Tools Required Plasma Cutter Hydraulic Floor Jack and Jack Stands Metric Standard Socket Wrench Set Torque Wrench 1 4 amp 5 16 Allen Wrenches Machinist Calipers or equivalent Tape Measure Band Saw or equivalent 16TPI Thread Restoring File or equivalent 1 4 and 3 8 Drill Bits Transfer Punch or equivalent Spray Lubricant WD 40 or similar Anti Seize Lubricant Medium Strength Threadlocker Coil Spring Compressor Satin Black Spray Paint Factory Service Manual recommended O O O QO QO
14. ition for be made with NO LOAD on the front coil springs and Main Body B QO Completely thread the Bump Shock Adapter H onto Main Body B until snug O Apply anti seize lubricant to threads of Bump Shock Assembly J Completely thread the Bump Shock Nut 1 onto Bump Shock Assembly J QO Completely thread Bump Shock Assembly J with Bump Shock Nut 1 into Bump Shock Adapter H as far as possible a LJ 8 RE INSTALL FRONT COIL SPRINGS QO Re install the front coil springs per the factory service manual instructions for your vehicle HINT A coil spring compressor is useful for installation QO Also re install any of the components that were removed during Step 1 of this installation A ATTENTION INSTALLER IMPORTANT NOTE REGARDING SHOCK ABSORBERS To prevent the coil springs from becoming unseated during maximum suspension extension correct length shock absorbers must be installed JKS ACOS Pro Installation your vehicle you must first decide the point at which suspension compression should be limited Take into consideration coil springs shock absorbers tire clearance or any other factors that cause the vehicle to bottom out IMPORTANT Because it replaces the original rubber bump stop the bump shock should determine the limit of compression travel The bump shock should be fully compressed when the suspension reaches maximum desired compression With the vehicle on level ground and the
15. l of the entire upper spring mount from the chassis and re welding it at the correct angle If you encounter any interference issues contact JKS Manufacturing immediately for technical assistance JKS Technical Department Phone 308 762 6949 E mail tech jksmfg com PN 2700 suspension at FULL DROOP NEVER TURN Adjuster Ring E while under tension and ALWAYS APPLY SPRAY LUBRICANT to threads of Main Body B or Bump Shock Assembly J before adjusting Bump Shock Pressure The Bump Shock Assembly J is pre charged with the proper amount of Nitrogen gas to suit most applications IT SHOULD NOT BE NECESSARY TO ADJUST BUMP SHOCK PRESSURE ON MOST VEHICLES The Nitrogen charge is factory preset at 150 psi For applications that require a higher or lower compression rate the gas pressure can be manually adjusted to a minimum of 100 psi and a maximum of 200 psi To adjust pressure the bump shock assembly must be removed from the vehicle Nitrogen pressure is adjusted through the Schrader valve on top of the bump shock Care should be taken when discharging the bump shock to ensure that no oil is lost Most shops that service off road racing or motorcycle shock absorbers can adjust bump shock pressure Maintenance Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability 2009 JKS Manufacturing Inc amp Aftermarketing LLC Revision Date 7 24 2009 Page 8 of
16. the upper spring mount Hint The Main Body must be Tools Requi red e Cower Suspension aim perfectly centered over the spring retainer O Hydraulic Floor Jack and Jack Stands tae Bal QO Metric Standard Socket Wrench Set Steering Drag Link Q Torque Wrench Lower Spring Retainer Clip QO 1 4 amp 5 16 Allen Wrenches a QO Die Grinder with Cut Off Wheel Q 2 PREPARE UPPER SPRING MOUNT or reciprocating saw Q Remove the rubber bump stop bump stop OQ Grinding Wheel holder and OE spacer if equipped from the O Tape Measure upper spring retainer QO 1 4 and 3 8 Drill Bits QO Transfer Punch or equivalent O Spray Lubricant WD 40 or similar QO Anti Seize Lubricant oY LX QO Medium Strength Threadlocker ma a eT CA Q Coil Spring Compressor Spring O Using the flange of the Main Body B as a O Satin Black Spray Paint Mount ly template accurately mark all SIX hole locations i Rubber on the upper spring mount using a transfer Q Factory Service Manual recommended Upper Spring Isolator Pad punch or equivalent Remove Main Body from Retainer spring mount s Asterisk denotes tools that are not required for some eS applications Thoroughly read instructions first to O Using a 1 4 bit drill a pilot hole at each hole determine which tools will be required for your FA OE Spacer if equipped location Enlarge each hole with a 3 8 drill bit application lt D Bump Stop Holder p Z as
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