Instructions - Trail Master Suspension
Contents
1. 400 W Artesia Blvd IME SB IZILI Compton CA 90220 Fax 310 747 3912 Ph 877 695 7812 www trailmastersuspension com JEEP WRANGLER 4 DOOR Jk 3 SPRING KIT 07 13 WARNING Installation of a Trail Master suspension lift kit will change the vehicle s center of gravity and handling characteristics both on and off road You must drive the vehicle safely Extreme care must be taken to prevent vehicle rollover or loss of control which could result in serious injury or death Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fas tened WARNING Before you install this kit read and understand all instructions warnings cautions and notes in this instruction sheet and in the vehicle owner s manual CAUTION Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components We recommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation Installation of this kit without proper knowledge of the factory recom mended procedures may affect the performance of these components and the safety of the vehicle We strongly recommend that a certified mechanic famil iar with the installation of similar components install this kit WARNING This kit should only be installed on a vehicle that is in good work2. See Front Brake Save the hardware for reuse Line Drop 7 Unclip the ABS line from the axle 8 Lower the rear differential so that the springs 5 16 X 1 come loose Remove the OE coil springs and bolt the OE isolators Label the springs as to which side they were removed Left and Right so that they are reinstalled in the side in which they were removed 16 Reconnect the front brake line to the front brake line drop 35 TM20010 using the supplied 5 16 X 1 bolt and hardware 17 Reinstall the front track bar to the axle using the previously removed hardware BY car Upper Rear a er Pocket oan es L las mr 18 Reattach the transfer case skid plate using the previously removed hardware Torque the hard ware to 87 ft Ibs 19 Reinstall the wheels and lower the vehicle to the ground Torque the lug nuts to factory specifica tions 20 Torque all bolts to factory specifications Re torque all bolts after 500 miles Prepare to Install Rear Suspension Install Rear Suspension 1 Jack the rear of the vehicle with the floor jack under the differential and place jack stands un der the frame just in front of the lower control arm frame mounts Leave the jack stands high enough to let the floor jack down and still have the rear tires suspended in the air Keep the 1 Install the passenger side track bar drop bracket 82 TM20011 into the upper track bar mounting position using the previousl
3. Connect both battery cables Connect positive cable first then negative cable Miscellaneous 1 Adjust headlights 2 Check all fasteners to ensure they are tight 3 Ensure all wires hoses cables etc are prop erly connected and there is ample slack 4 Align vehicle to OE specifications Retain align ment results Dynamic Vehicle Check 1 Check steering and suspension in all positions to ensure that there is no bind and adequate clearance between all moving fixed and heated members Check operation of clutch brake sys tem and parking brake Check operation of trans mission and transfer case Ensure there is full en gagement in all gears and 4WD ranges Check battery connections and electrical component op erations Test drive vehicle WARNING Re torque all fasteners after 500 miles and after off road use All suspension lift components should be visually inspected and fasteners re torqued during routine vehicle servicing CAUTION Trail Master does not recommend any particular wheel and tire combinations for use with its sus pension lifts and cannot assume responsibility for the customer s choice of wheels and tires Refer to your owner s manual for recommended tire sizes and warnings related to the use of over sized tires Larger wheel and tire combinations increase stress and wear on steering and sus pension components which leads to increased maintenance and higher risk for component fail u
4. Front Suspension WARNING Compressed coil springs can expand violently causing serious personal injury Before removing the coil springs lower the axle housing as far as possible to al low the coil springs to expand 1 Loosen but do not remove lug nuts on each front wheel 2 Jack the rear of the vehicle with the floor jack under the differential and place jack stands un der the frame just behind the lower control arm frame mounts Leave the jack stands high enough to let the floor jack down and still have the front tires Suspended in the air Keep the floor jack under the differential with slight pres sure for support Remove the front wheels WARNING Use extreme caution when lifting vehicle from ground To prevent serious personal injury ensure the lifting de vice is securely placed 3 Disconnect the track bar from the axle and save the hardware for reuse 4 Unbolt the front brake line brackets from the frame Save the hardware for reuse 5 Unbolt the front sway bar end links from the axle Save the hardware for reuse 6 Disconnect the lower shock mounts Save the hardware for reuse Remove shocks if you pur chased kit TM3325 40053 7 Unbolt the 1 driver side skid plate bolt and loosen the 2 passenger side skid plate bolts 8 Lower the jack carefully remove the OE coil springs and the OE isolators Label the springs as to which side they were removed Left and Right so that th
5. SAVE WITH VEHICLE RECORDS Product Information Part Number Date Purchased Purchased From Vehicle Information VIN Vehicle Measurements Axle Center to Fender Lip on level ground at nde E y a e A Ooo a OSS i Bump Stop to Contact Point on level ground at a T OOOO Tire amp Wheel Intonmation Tire Size Tire Brand Actual Tire Diameter measured Wheel Size Installer Information Shop Name Installer T Number Fax Number Attach Copy of Purchase Receipt Copy of Vehicle Wheel Alignment Results Before Starting Installation Wheel amp Tire Requirements The factory wheel and tire combination will fit once sakit 1e ieee Kit parts are prefaced by the word kit and appear in bold print Torque Specifications See factory service manual for torque values when reusing OE fasteners 1 Carefully read all warnings and instructions com pletely before beginning SA See factory service manual for torque values when re using 2 Verify all parts have been received in this kit by OE fasteners checking the parts list at the end of this document Bolt Size Grade 5 ft Ibs Grade 8 ft lbs 3 Only install this kit on the vehicle for which it 1 4 20 10 10 is specified If anytime during the installation you 1 4 28 10 12 5 encounter something different from what is outlined 5 16 18 17 22 5 in the instructions call technical support at 877 0 16
6. 2 2 Flat Washer M12 1 Bolt M14 2 00 x 75mm 10 9 1 Flange Nut M14 2 Flat Washer M14 2 Bump Stop front 82 TM10001 1 90 TM60007 Hardware bag Front Bump Stop 2 Self Tapping Bolt 3 8 x 2 2 Bump Stop rear 82 TM20012 1 90 TM60008 Hardware bag Rear Bump Stop 4 Bolt M8 1 25 x 20mm 4 Nylock Nut M8 4 Washer M8 4 Alignment Plate 35 TM20041 4 Brake Line Drop 35 TM20010 1 90 TM60005 Hardware bag Brake Line Drop 4 Bolt 5 16 x 1 Gr 8 4 Nylock Nut 5 16 8 Hardened Washer 5 16 10 TM3330 40053 Kit 1 3 Coil Spring TM3330 60030 front 1 3 Coil Spring TM3330 60040 rear Box TM3330 40010 3 1 Track Bracket rear 82 TM20011 1 Sleeve 35 TM30010 rear 1 90 TM60006 Hardware bag Track Bar Bracket 1 Bolt M12 1 75 x 30mm 10 9 1 Flange Nut M12 2 Flat Washer M12 1 Bolt M14 2 00 x 75mm 10 9 1 Flange Nut M14 2 Flat Washer M14 2 Bump Stop front 82 TM10001 1 90 TM60007 Hardware bag Front Bump Stop 2 Self Tapping Bolt 3 8 x 2 2 Bump Stop rear 82 TM2001 2 1 90 TM60008 Hardware bag Rear Bump Stop 4 Bolt M8 1 25 x 20mm 4 Nylock Nut M8 4 Washer M8 4 Alignment Plate 35 TM20041 4 Brake Line Drop 35 TM20010 1 90 TM60005 Hardware bag Brake Line Drop 4 Bolt 5 16 x 1 Gr 8 4 Nylock Nut 5 16 8 Hardened Washer 5 16 2 Absorber shock front TM73265005 2 Absorber shock rear TM73265006 Revis
7. 24 20 25 695 7812 Park vehicle on a clean dry flat level 3 8 16 30 40 surface and block tires so vehicle cannot roll in ei 3 8 24 35 45 ther direction 7 16 14 50 65 4 Park vehicle on a clean dry flat level surface E z T and block tires so vehicle cannot roll in either direc SC sal TR 1 2 20 80 115 9 16 12 105 135 5 Measure ride height with the vehicle supporting 9 16 18 115 150 its own weight on level ground To settle the sus 5 8 11 150 195 pension the vehicle should be driven forward at 5 8 18 160 210 least 10 feet immediately prior to taking these 3 4 16 175 995 measurements Ride height is the measurement from the center of the axle straight up vertical to the fender lip Record this measurement for all four Engine Compartment wheels 1 Disconnect both battery cables Disconnect negative cable first then positive cable Adhere to recommendations when replacement fas teners retainers and keepers are called out in the fac tory service manual When re assembling the vehicle it is recommended by the vehicle manufacturer that cer tain fasteners are replaced in order to maintain proper retention characteristics This system may not include all replacement hardware as recommended by the fac tory service manual Additional replacement hardware should be obtained prior to installation of this system to meet the requirements of the factory service man ual Prepare to Install
8. chanical aspects of any suspension lift product may accelerate ordi nary wear of original equipment components Further installation of certain Trail Master Suspension products may void the vehicle s factory warranty as it pertains to certain covered parts it is the con sumer s responsibility to check with their local dealer for warranty coverage before installation of the lift Warranty and Return policy Trail Master Suspension warranties its full line of products to be free from defects in workmanship and materials Trail Master Suspension s obligation under this warranty is limited to repair or replacement at Trail Master Suspension s option of the defective product Any and all costs of removal installation freight or incidental or consequential damages are expressly excluded from this warranty Trail Master Suspension is not responsible for damages and or warranty of other vehicle parts related or non related to the installation of Trail Master Suspension product A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will assume all risk and responsibility for potential dam ages incurred as a result of their chosen modifications Warranty coverage does not include consumer opinions regarding ride comfort fitment and design Warranty claims can be made directly with Trail Mas ter Suspension or at any factory authorized Trail Master Suspension dealer IMPORTANT To validate the warranty on
9. ey are reinstalled in the side in which they were removed OE Coil a a Spring PE w Le j E 1 be i i i k tagi 1 P t 3 Install Front Suspension 1 Place the front bump stop extension 90 TM10001 on the lower spring mount Center the extension and mark with a center punch 90 TM10001 Bump Stop Extension 2 Use the previously applied mark to drill a hole in the lower spring mount using a 5 16 drill bit Pre tap the hole using the supplied 3 8 X 2 self tapping screw 3 With the front axle supported unbolt the lower 7 Install the coil spring and bump stop spacer at front control arm from the front axle mounts the same time Secure the bump stop extension using the 3 8 self tapping bolt DO NOT over 4 Using a chisel remove the alignment plates tighten from the factory mounts 8 Raise the front axle into place Make sure the coil spring seats properly on the lower spring perch 5 Reinstall the front lower control arms to the axle mounts using the supplied alignment plates Rotate the plates so that the large lobe is facing toward the front of the vehicle Torque to 95 ft 9 Now would be a good time to Inspect the front Ibs shocks for damage or fluid leakage Replace if necessary 10 If you purchased kit TM3330 40020 install the front shock extension bracket 82 TM20005 us ing the previously removed OE bolt and hard ware and the 8mm X 20mm bolt and ha
10. ing condition Before you install the kit thoroughly inspect the vehicle for corrosion or defor mation of the sheet metal If the vehicle is suspected to have been in a collision or misused do not install this kit Off road use of your vehicle with this kit in stalled may increase the stress applied to the factory components Failure to observe this warning may result in serious personal injury and or severe dam age to your vehicle KIT TM3330 40020 amp TM3330 40053 WARNING Many states and municipalities have laws restricting bumper heights and vehicle lifts Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law WARNING The installation of larger tires may reduce the effec tiveness of the braking system WARNING Always wear eye protection when operating power tools WARNING Before you install this kit block the vehicle tires to prevent the vehicle from rolling WARNING DO NOT combine suspension body or other lift de vices Use of vehicle with combined lifts may result in unsafe and or unexpected handling characteris tics Lift height may vary depending on vehicle configura tion engine size additional accessories the factory suspension package and vehicle s condition Trail Master recommends using thread locking com pound on the threads of all kit nuts and bolts unless specified otherwise in these instructions INSTALLATION WORKSHEET
11. ion Page 1 Notice to Owner Operator Dealer and Installer Vehicles that have been enhanced for off road performance often have unique handling characteristics due to the higher center of gravity and larger tires This vehicle may handle react and stop differently than many passenger cars or unmodified vehicles both on and off road You must drive your vehicle safely Extreme care should always be taken to prevent vehicle rollover or loss of control which can result in seri Ous injury or even death Always avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking Trail Master Suspension reminds you to fasten your seat belts at all times and re duce speed We will gladly answer any questions concerning the design function maintenance and cor rect use of our products Please make sure your Dealer Installer explains and delivers all warning notices warranty forms and instruction sheets included with Trail Master Suspension product Application listings in this catalog have been carefully fit checked for each model and year denoted How ever Trail Master Suspension reserves the right to update as necessary without notice and will not be held responsible for misprints changes or variations made by vehicle manufacturers Please call when in question regarding new model year vehicles not listed by specific body or chassis styles or vehicles not Originally distributed in the USA Please note that certain me
12. rdware 35 TM20041 J Alignment Plate Front Shock gt 12mm X 75mm bolt p E 82 TM20005 p 1 Front Shock i 6 Carefully lower the front axle to ease in the new Extension coil spring installation Using the factory isola tors install the coil springs TM3330 60030 into the spring buckets wii OE bolt EEE Smm X pas s 20mm bolt aa i ENY 11 Carefully raise the front axle and install the lower shock mount to the shock extension bracket 82 TM20005 using the 12mm X 75mm bolt and hardware 12 If you purchased kit TM3330 40053 Install your new front shocks TM73265005 and install the lower shock mount to the axle mount using the previously removed OE hardware f 90 TM10001 g Bump Stop 13 Torque the 12mm and OE shock hardware to i ft lbs Torque the 8mm hardware to 17 ft lbs 14 Reinstall the OE front sway bar end link into Original mounting bracket on the axle using the previously removed OE hardware Torque to manufacturers specifications 15 Install the front brake line drop 35 TM20010 to 3 Unbolt and remove the rear track bar from the the OE hole in the frame using the previously vehicle Save the hardware for reuse removed OE hardware 4 Disconnect the upper shock mounts Save the hardware for reuse Remove shocks if you pur chased kit TM3325 40053 5 Unbolt the lower sway bar end links Save the hardware for reuse 35 TM20010 6 Unbolt the brake line bracket from the frame
13. re Larger wheel and tire combinations also al ter speedometer calibration braking effective ness center of gravity and handling characteris tics Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle All warranty information instruction sheets and other documents regarding the installation of this product must be retained by the vehicle owner Information contained in the instructions and on the warranty card will be required for any war ranty claims The vehicle owner needs to under stand the modifications made to the vehicle and how they affect vehicle handling and perform ance Failure to provide the customer with this Information can result in damage to the vehicle and severe personal injury Kit Parts List TM3330 40020 Kit 1 3 Coil Spring TM3330 60030 front 1 3 Coil Spring TM3330 60040 rear Box TM3330 40010 2 2 Shock Extension Bracket front 82 TM20005 1 90 TM60003 Hardware bag Front Shock Ext 2 Bolt M12 1 75 x 75mm 10 9 2 Nylock Nut M12 4 Washer M12 2 Bolt M8 1 25 x 20mm 2 Nylock Nut M8 4 Washer M8 2 Shock Extension Bracket rear 82 TM30005 1 90 TM60004 Hardware bag Rear Shock Ext 4 Bolt M10 1 25 x 80mm 10 9 4 Washer M10 Box TM3330 40010 3 1 Track Bracket rear 82 TM20011 1 Sleeve 35 TM30010 rear 1 90 TM60006 Hardware bag Track Bar Bracket 1 Bolt M12 1 75 x 30mm 10 9 1 Flange Nut M1
14. this purchase please be sure to mail in the warranty card Claims not covered under warranty e Parts subject to normal wear this includes bushings bump stops ball joints tie rod ends and heim joints e Discontinued products at Trail Master Suspension s discretion e Bent or dented product e Finish after 90 days e Leaf or coil springs used without proper bump stops e Products with evident damage caused by abrasion or contact with other items e Damage caused as a result of not following recommendations or requirements called out in the installa tion manuals e Products used in applications other than listed in Trail Master Suspension s catalog e Components or accessories used in conjunction with other manufacturer s systems e Warranty claims without Proof of Purchase Trail Master Suspension accepts no responsibility for any altered product improper installation lack of or improper maintenance or improper use of our products E Mail info trailmastersuspension com Website www trailmastersuspension com Ph 877 695 7812 12
15. w would be a good time to inspect the rear shocks for damage or fluid leakage Replace if necessary 11 If you purchased kit TM3330 40020 install the upper rear shock and extension bracket 82 TM30005 to the upper mount using the sup plied 10mm X 80mm bolts and hardware 82 TM30005 Rear Shock y Extension 10mm X a e 80mm bolt 12 If you purchased kit TM3330 40053 install the new rear upper shock TM73265006 the upper shock mount to the upper mount using the previ ously removed OE hardware 13 Install the lower rear shock mount to the axle mount using the previously removed OE hard ware Torque to 85 ft Ibs 14 Install the rear brake line drop 35 TM20010 to the OE hole in the frame using the previously removed OE hardware mE 35 TM20010 SEN Rear Brake Line Drop E 5 16 X 1 bolt 15 Reconnect the rear brake line drop 35 TM20010 using the supplied 5 16 X 1 bolt and hardware 16 Reconnect the rear track bar and the rear lower sway bar end links Torque to factory specifica tions 17 At full droop cycle the steering from lock to lock while observing the reaction of these components Reposition them if needed 18 Reinstall the rear wheels and lower the vehicle to the ground Torque the lug nuts to factory specifications 19 Torque all bolts to factory specifications Re torque all bolts after 500 miles After Completing Installation Engine Compartment 1
16. y removed OE bolt hardware and sleeve 35 TM30010 floor jack under the differential with slight pres 2 Secure the rear track bar drop bracket 82 sure for Support TM20011 to the frame using the 1 supplied 2 Pemoveduereacwheels 14mm X 75mm bolt 12mm X 30mm bolt and l l hardware 1 5 Raise the rear differential and make sure that r the coil springs are in their saddles 35 TM30010 q Sleeve 1 a 60040 Rear Coil Spring 2 TM20011 Track Bar Drop Bracket 30mm Bolt 14mm X X 6 Install the rear bump stop extensions 82 TM20012 to the rear axle bump stop pad using the supplied 8mm X 20mm bolts and hardware 82 TM20011 Track Bar Drop 3 ey OE Track sgt Bar Bolt i k g v pi y t m meee L 4 T a a A a ew a Ty 1 Yr y i J Smm X A 20mm Bolts Torque the 14mm track bar drop hardware ac cording to the torque chart on page 9 and the OE bolt to 125 ft lbs Carefully lower the front axle to ease in the new coil spring installation Using the factory isola tors install the coil springs TM3330 60040 into the spring buckets Reinstall the rear track bar to the axle mount us ing the previously removed OE hardware Install the rear track bar to the track bar drop bracket using the supplied 14mm X 75mm bolt and hardware Torque to 100 ft lbs Reconnect the lower sway bar links to the axle using the previously removed OE hardware 10 No
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