Jeep Cherokee 4 Suspension Lift PDF Installation Instructions

PRE-INSTALLATION
This kit is not recommended for trucks equipped with ABS brake systems or dual rear wheels. Use of this kit and/or larger tire and wheel combinations may reduce the effectiveness of ABS system and increase the amount of pedal pressure necessary to obtain a given braking distance.
1. Read carefully before proceeding with installation. This 4” lift kit is designed to be installed on ‘84-’86 Jeep Cherokee with standard “Command Trak” 5-speed transmissions. The original factory front drive shaft must be removed and replaced with new longer balanced drive shaft featuring 2 new universal joints, a new longer slip yoke and a new industrial flange on the transfer case end. The owners manual clearly states that the standard 5-speed transmission is not to be engaged and driven in 4-wheel drive on the highway or on smooth hard surfaces. This lift kit is not to be installed on vehicles with automatic “Select-Trak” transmissions. Contact your local dealer for new driveshaft.
2. Refer to OE service manual for proper disassembly/assembly procedures for OE components (like steering shaft, anything else). Consult the following instructions for special tools necessary for this installation.
3. Compare parts included in your system with the enclosed parts list. Placing hardware with compoents before you start may reduce installation time. Contact your Trail Master dealer if any parts are missing or appear to be different than those indicated on the parts list.

Part List:
5/16 Center Pin & Nuts (560400FCP) Left Lower Bracket (XJLR-D)
Right Lower Bracket (XJLR-P)
Left Upper Bracket (XJUR-D)
Right Upper Bracket (XJUR-P)
Left Sway Bar Bracket (XJSB-DO)
Right Sway Bar Bracket (XJSB-PO)
Coil Spring (210)
2” Add A Leaf, Rear (R1537S)
1/2 x 4-1/2 NC Bolt (12412CHHC)
1/2 Locknut (N12CL)
3/8 x 1-1/4 BC Bolt (38114CHHC)
10mm x 90mm Bolt (10M090H150)
10mm Locknut (N10MSL150)
3/8 Locknut (N38CL)
3/8 Flat Washer (W38F)
2-1/4 Spacer (23)
10mm Square Nut (N10MQ150)
10mm x 80mm Bolt (10M080H150)
Rear Extension Bracket (SBLA)
1/4 x 1 Bolt (14100CHHC)
Frt. Brake Bracket (T86FBB)
3/8 x 1 Bolt (38100CHHC)
5/16 Nut – Fine (N56FS)
5/16 Washer (W56F)
1/2 Washer (W12F)
2-1/2 Hen Clip (HC212)
Warning Label (WL002)

FRONT INSTALLATION INSTRUCTIONS

1. Position hydraulic floor jack under front axle on the passenger side next to the differential. Raise axle so the tires are approximately one foot (1’) off the ground. Place adjustable jack stands under frame rails at a point 8” behind the lower strut arm frame mounting points. Lower axle until the vehicle rests on the jack stands and the shocks are partially extended. Leave the floor jack positioned under the axle.

2. Remove skid plate, if equipped, and discard. Remove both front tires and shocks. Remove front sway bar from frame and retain all parts. Remove tracking arm end at axle mounting point on passen- ger side and allow to drop free.

3. On each side, remove lower strut arm at frame and release arm to swing down from frame. Save all nuts and bolts. On each side, remove the lower strut arm adjustment bracket from inside the frame pocket by removing the 2 nuts on the rear of the pocket.

4. Locate left and right lower drop down brackets in the kit. These are the two large welded brackets. With the ears facing away from you, the bracket with the ear on the left side is the passenger side bracket. The bracket with the ear on the right side is the driv- ers side bracket. On each side slide the bracket into the lower frame pocket and install the two 3/8 x 1-1/4 bolts, washers and locknuts in the strut arm adjust- ment bracket holes. Position the 2-1/4 tube spacer bushing into the bracket. Install the 1/2 x 4-1/2 bolt and washer, from outside to the inside, through the original lower strut arm mounting hole. Tighten only the 3/8 bolts at this time.

5. Install the original lower strut arm adjustment brack- ets into the drop down brackets, just installed, using original nuts.

6. Remove upper strut arm ends from the frame brack- ets, on each side, and lower to the hole in the ear of the drop down bracket. Install the “Z” brackets pro- vided in the kit, positioning the large hole at the bot- tom so that the 1/2 x 4-1/2 bolt passes through the large hole. Install the 1/2 washer and locknut, finger tighten (the “Z” brackets will only fit one way). Posi- tion the 2” tube spacer bushing, provided in the kit, into the upper strut arm pocket. Line up the top hole of the “Z” bracket on the outside of the pocket and insert the 10mm x 80mm bolt with washer through the bracket and spacer. Finger tighten into frame. Position the free end of the upper strut arm between the ear on the lower bracket and the “Z” bracket, line up the holes and install the 10mm x 90mm bolt and washer from the outside to the inside. Install washer and locknut; tighten all bolts and nuts in this step.

7. Install lower strut arm ends in the drop down brack- ets using the original bolts and nuts, then tighten.

8. Remove coil spring retaining clips at axle. Lower axle sufficiently to remove coil springs. Install new coils and original retaining clips. Be sure coils are seated properly. Raise axle slightly to compress springs.

9. Locate original tracking arm mounting hole on the passenger side of the axle. Measure 3/4” from the center of the original hole on the same horizontal line toward the drivers side of the bracket, mark and center punch. Using drill with 3/8” drill bit, drill a hole through the center punched front of the bracket only. Repeat the same 3/4” measurement on the back of the bracket and center punch. Insert the 3/8” drill bit through the newly drilled hole and drill through the center punched mark on the back of the bracket. Position the free end of the tracking arm between the newly drilled holes and insert the original bolt. Locate the opening between the rear of the tracking arm bracket and the front axle, approximately 1-1/2” below the coil spring. The opening faces the driver’s side of the vehicle. Insert the square nut into the small opening, align with the original bolt and tighten. Suggestion: to position the square nut in the small opening, tape the nut to common screw driver using a loop of masking or duct tape.

10. Install new longer Trail Master shocks. 11. Attach front sway bar drop down brackets to the frame using the original bolts. Install the sway bar to the drop down brackets using the 3/8 x 1-1/4 bolts, washers and locknuts provided in the kit. Re-assem- ble the axle in original position. 12. Install the front wheels and lower vehicle to the ground.

REAR INSTALLATION INSTRUCTIONS

1. Place hydraulic floor jack under center of rear axle housing and raise vehicle until wheels are 8” to 10” off the ground. Position adjustable jack stands on each side of the frame rails just in front of the leaf springs and lower the floor jack until the weight of the vehicle rests on both jack stands. Both wheels must be off the ground. Remove both wheels. Leave hydraulic floor jack in position so shocks are partially extended and remove both rear shocks.

2. Locate brake line tee on the driver’s side of the rear axle housing. Remove bolt and carefully separate tee from axle housing. Insert 2” tube spacer between tee and axle housing. Secure with 6mm x 80mm bolt and washer provided in the kit.

3. On vehicles equipped with brake equalizer, locate differential mounting bracket for brake equalizer, loosen top bolt and take bottom one out. Swing bracket up to extend and install extension bracket (flat bracket with hole in each end) to rear differential mounting bracket using 1/4 x 1 bolt, washer and locknut provided. Bolt opposite end of extension bracket to differential at original location using stock bolt.

4. Remove rear axle U-bolts on each side and lower axle away from springs. Remove center bolt from springs on both sides and remove lower leaf. Insert the add-a-leaf, provided in the kit, and replace bot- tom leaf. Tighten center bolt making sure leafs are straight with one another.

5. Raise axle to the springs. Secure axle to springs with original U-bolts. Ensure the sway bar bracket is attached to U-bolt top plate on both sides.

6. Install new shocks…

Download Jeep Cherokee 4 Suspension Lift PDF Installation Instructions