Installation Instructions
Contents
1. Using a torque wrench tighten the 1 2 Bolt to 25 ft lbs PN 1100 Q 7 POST INSTALLATION INSTRUCTIONS Before operating vehicle off road test for proper bump stop operation by fully cycling the suspension and checking for obstructions Add remove or replace BumpStop Spacers if necessary until maximum unobstructed suspension compression is achieved Operation Future BumpStop length adjustments should be made with NO LOAD on the coil springs and the suspension at FULL DROOP Depending on the springs used it may be necessary to spread the coils apart when inserting or removing the 2 00 BumpStop Spacer A Maintenance Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability 2010 JKS Manufacturing Inc amp Aftermarketing LLC Revision Date 5 8 2010 Page 3 of 32. DETERMINE BUMPSTOP LENGTH JKS Adjustable BumpStops can be installed in six 6 possible configurations 0 75 1 25 2 00 2 75 3 25 or 4 00 depending on the individual spacer s used Q Determine the ideal BumpStop length for your application by considering factors such as gt Clearance between vehicle tires and body panels during full suspension compression gt Clearance between axle housing and chassis or drivetrain during full suspension compression gt Length of existing bump stop extension if installed Choose the spacer s that provides maximum unobstructed suspension compression for your application from the list below 0 75 BumpSitop Configuration SPACER 0 75 only HARDWARE 1 2 x 1 1 4 Bolt Split Washer 1 25 BumpStop Configuration SPACER 1 25 only HARDWARE 1 2 x 1 1 2 Bolt Split Washer 2 00 BumpSitop Configuration SPACER 2 00 only HARDWARE 1 2 x 2 Stud only 2 75 BumpStop Configuration SPACERS 2 00 0 75 HARDWARE 1 2 x 2 Stud 1 2 x 1 1 4 Bolt Split Washer 3 25 BumpStop Configuration SPACERS 2 00 1 25 HARDWARE 1 2 x 2 Stud 1 2 x 1 1 2 Bolt Split Washer 4 00 BumpStop Configuration SPACERS 2 00 1 25 0 75 HARDWARE 1 2 x 2 Stud 1 2 x 2 1 2 Bolt Split Washer PN 1100 1 2 X 2 1 2 BOLT 1 2 SPLIT WASHER lt gt 0
3. 75 SPACER 1 25 l SPACER 2 00 SPACER 1 2 X 2 STUD Illustration of 4 00 BumpStop Configuration Page 2 of 3 LJ 4 INSTALL 2 00 BUMPSTOP SPACER ON LOWER SPRING MOUNT FOLLOW THESE STEPS FOR 2 00 2 75 3 25 or 4 00 CONFIGURATION ONLY For 0 75 or 1 25 configuration bypass these steps and proceed directly to section 5 RE INSTALL COIL SPRINGS O Locate the BumpStop Spacers and hardware required for your application as indicated in section 3 DETERMINE BUMP STOP LENGTH O Thread 1 2 x 2 Stud D halfway into hole in center of lower spring mount until one inch of threads remain visible 1 MAX wand IMPORTANT Do NOT thread 1 2 x 2 Stud more than one inch into the 2 00 spacer QO Apply anti seize lubricant to protruding half of 1 2 x 2 Stud D O Thread 2 00 BumpStop Spacer A onto 1 2 x 2 Stud D HINT Recessed end must face up as illustrated above O Tighten the 2 00 BumpStop Spacer A using an adjustable oil filter wrench or similar tool HINT A rubber strap type oil filter wrench will prevent damage to the finish when tightening aluminum spacer Other types of adjustable oil filter wrenches are also effective for gripping the spacer although it may be necessary to protect the finish with tape or a rag first JKS Adjustable BumpStop Installation RE INSTALL COIL SPRINGS Re install the coil sp
4. Installation Instructions Product Adjustable BumpStops Part Number PN 1100 Applications Wrangler JK 2007 front only Wrangler TJ 1997 06 front or rear Grand Cherokee ZJ 1993 98 front only Cherokee XJ 1984 01 front only Comanche MJ 1986 92 front only Welcome CONGRATULATIONS on purchasing a set of new Adjustable BumpStops from JKS Manufacturing We are committed to providing you with the best products available and your satisfaction is our first priority PLEASE READ these Installation Instructions carefully and save them for future reference as they contain important installation and maintenance information JKS Adjustable BumpStop Installation MAY BE INSTALLED IN SIX 6 POSSIBLE CONFIGURATIONS depending on individual spacer s used Use appropriate hardware for your configuration Refer to page 2 for details Tools Required Metric Standard Socket Wrench Set Torque Wrench Adjustable Oil Filter Wrench for tightening 2 00 BumpStop Spacer Tape Measure 27 64 Drill Bit 1 2 NC x 13 TPI Tap Anti Seize Lubricant Coil Spring Compressor Hydraulic Floor Jack amp Jack Stands Factory Service Manual recommended OO0O0000 000 Asterisk denotes tools that are not required for some applications Thoroughly read instructions first to determine which tools will be required for your application PN 1100 Pictured with 6 Split Washers only 2 supplied needed for insta
5. llation DESCRIPTION QTY 2 00 BumpStop Spacer 1 25 BumpStop Spacer 0 75 BumpStop Spacer 1 2 x 2 Stud 1 2 x 2 1 2 Bolt 1 2 x 1 1 2 Bolt 1 2 x 1 1 4 Bolt Split Washer IO Timol W gt PO PO P PO PO MININ 3 25 BumpStop configuration pictured Page 1 of 3 Installation REMOVE COIL SPRINGS Raise and support the vehicle chassis with jack stands gt FRONT INSTALLATION Position behind front lower suspension arm brackets gt REAR INSTALLATION Position in front of rear lower suspension arm brackets Remove the coil springs per the factory service manual instructions for your vehicle HINT A coil spring compressor is useful for removal 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 HINT Refer to factory service manual for procedures not covered in these instructions Shock Absorber Swaybar Brake Line ABS Wire Lower Suspension Arm Track Bar Steering Drag Link Spring Retainer Clip PREPARE LOWER SPRING MOUNT Locate the dimple in the center of the lower spring mount on the axle housing Using the dimple as a guide drill a 27 64 hole through the center of the lower spring mount Tap the hole with a 1 2 NC x 13 TPI tap JKS Adjustable BumpStop Installation Q 3
6. rings per the factory service manual instructions for your vehicle DO NOT lower vehicle to ground until all BumpStop Spacers have been installed and properly tightened HINT A coil spring compressor is useful for installation Also re install any of the components that were removed during the REMOVE COIL SPRINGS section of this installation INSTALL REMAINING BUMPSTOP SPACERS IF REQUIRED FOR 0 75 or 1 25 CONFIGURATION Q Q Locate the BumpStop spacers and hardware required for your application refer to DETERMINE BUMP STOP LENGTH section Slide BumpStop Spacer s through coil spring and position on center of lower spring mount Apply anti seize lubricant to appropriate 1 2 Bolt F or G Place Split Washer H on bolt and insert through spacer s Thread bolt into hole in lower spring mount Using a torque wrench tighten the 1 2 Bolt to 25 ft lbs FOR 2 75 3 25 or 4 00 CONFIGURATION Q Locate the remaining BumpStop Spacers and hardware required for your application refer to DETERMINE BUMP STOP LENGTH section Slide additional BumpStop Spacer s through coil spring and position on 2 00 BumpStop Spacer A HINT When stacking spacers make sure they interlock before inserting hardware Apply anti seize lubricant to appropriate 1 2 Bolt E F or G Place Split Washer H on bolt and insert through spacer s Thread bolt into hole on top of 2 00 BumpStop Spacer A
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