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Before beginning the installation, thoroughly & completely read these instructions & the enclosed driver’s WARNING NOTICE. Affix the WARNING decal in the passenger compartment in clear view of all occupants. Please refer to the Parts List to insure that all parts & hardware are received prior to the disassembly of the vehicle. If any parts are found to be missing, contact SKYJACKER® Customer Service at 318-388-0816 to obtain the needed items. If you have any questions or reservations about installing this product, contact SKYJACKER® Technical Assistance at 318-388-0816.
Make sure you park the vehicle on a level concrete or asphalt surface. Many times a vehicle is not level (side-to-side) from the factory & is usually not noticed until a lift kit has been installed, which makes the difference more visible. Using a measuring tape, measure the front & rear (both sides) from the ground up to the center of the fender opening above the axle. Record this information below for future reference.
Driver Side Front:_______ Passenger Side Front:_______
Driver Side Rear:_______ Passenger Side Rear:_______
IMPORTANT NOTES:
• The draglink must be adjusted to center the steering wheel before the vehicle is driven. Failure to do so will cause computer errors, odd handling characteristics, & poor performance.
• For vehicles with 5" or more inches of lift, it is recommended to order a rear cam bolt kit for proper rear pinion angle (Skyjacker Part # CAM700). In some applications a replacement rear driveshaft may be required, Please contact Skyjacker Customer Service for more information at 318-388-0816.
• After the installation of a suspension lift, a qualified alignment facility is required to realign the vehicle to the OEM specifications.
1. Park the vehicle on flat level ground & set the emergency brake.
2. Raise the front of the vehicle & support the frame rails using jack stands.
3. Remove the front tires / wheels.
4. Disconnect the OEM front sway bar end links using a 18mm socket. JK401B: Save the OEM hardware. It will be reused later for Step # 27 of this installation.
5. Disconnect the OEM front track bar using a 21mm socket. (See Photo # 1)
6. If installing a new Skyjacker Steering Stabilizer (Part # 7003 / Sold Seperately), remove the OEM steering stabilizer using a 18mm socket. (See Photo # 2)
7. Disconnect & remove the OEM front shocks using a 18mm socket. Mark the location of the front driveshaft & yoke, then remove.
8. Remove the OEM front coil springs. (See Photo # 3)
9. Locate the new Skyjacker front bump stop spacers. Place the new bump stop spacers on the center of the OEM bump stop pads located on the front axle. Mark & drill using a 25/64" drill bit. (See Photo # 4)
10. Install the new bump stop spacers & new Skyjacker coil springs. Attach the new bump stop spacers to the axle using the supplied 3/8" x 4" button head bolts with one washer under each nut. (See Photo # 5)
11. Locate the OEM front track bar mount. Place the new Skyjacker relocation bracket inside the OEM mount. Drill the outer OEM holes all the way through the rearward plate using a 7/16" drill bit. (See Photo # 6) Note: It is recommended at this time to put a reinforced weld on the OEM bracket. Attach the bracket at the outer two locations using the supplied 7/16" x 2 1/2" fine thread bolts, washers, & nuts. Attach the bracket at the OEM location using the OEM hardware. Let the weight of the frame down onto the new coil springs. Attach the OEM track bar to the new bracket using the supplied 14mm x 80mm bolt, washers, & nut.
12. Remove the three upper left differential cover bolts. (See Photo # 7)
13. Hold the new Skyjacker differential bracket (D30 or D44) up to the differential. (See Photo # 8) Place the supplied thick 5/16" washers between the new differential bracket & differential. (See Arrow in Photo # 9) Attach using the supplied 5/16" x 1" coarse thread bolts, flat washers, & lock washers. (See Photo # 9) Note: Do not tighten
at this time.
14. Attach the new Skyjacker rear brace to the upper rear mounting bolt of the track bar bracket. (See Photo # 10)
15. Install the new Skyjacker support brace between the new differential bracket & rear mounting bolt of the track bar bracket using the OEM 14mm hardware, 5/16" x 1" fine
thread bolts, flat washers, & nuts. (See Photos # 11 & # 12) Note: Do not tighten at this time.
16. Clamp the new rear brace to the OEM spring perch & drill through the new rear brace & OEM spring perch using a 7/16” drill bit. Install the supplied 7/16" x 1” fine thread bolt, washers, & nut to the perch & tighten at this time. (See Photo # 13)
17. Once the 7/16" hardware has been tightened, complete the install by tightening all remaining 14mm & 5/16" hardware.
18. Reattach the front drive shaft. JK401: Assemble the new Skyjacker sway bar end links using the supplied bushings & steel sleeves. Attach the eyes using the supplied 1/4" snap pins. Attach the end link to the axle using the OEM hardware. (See Photo # 14) Attach the lower portion of the new sway bar end link using the supplied 1/2" x 2 1/2" button head bolt. Use one large USS washer under the nut. Reattach the front drive shaft.
19. If installing a new Skyjacker steering stabilizer (Part # 7003 / Sold Seperately), install it at this time. (See Photo Below)
20. Install the new Skyjacker front shocks using a 18mm socket. (See Photo # 15)
21. Remove the OEM front lower control arms (one at a time) & install the new Skyjacker control arms using the OEM hardware. (See Photo # 16) Note: Install the control arms so the off-set bend is toward the inside of the vehicle.
22. Install the front tires / wheels & lower the vehicle to the ground.
23. Raise the rear of the vehicle & properly support the frame rails using jack stands.
24. Remove the rear tires / wheels.
25. Remove the OEM rear shocks using a 16mm socket. (See Photo # 17)
26. Disconnect the OEM rear track bar from the axle using a 21mm socket. (See Photo # 18).
27. Disconnect the OEM rear sway bar end links using a 18mm socket. JK401B: Relocate the OEM rear sway bar end links to the front of the vehicle & install using the OEM hardware saved from Step # 4.
28. Disconnect the OEM ABS lines & brake lines from the frame. (See Photo # 19)
29. Lower the differential & remove the OEM rear coil springs.
30. Place the new Skyjacker rear track bar relocation bracket over the OEM bracket on the axle. With the bracket seated flush, clamp the bracket in place, mark with a center punch, & drill the new center mounting holes using a 15/32" drill bit. (See Photo # 20)
31. Install the supplied 7/16" x 1" fine thread bolt, washer, & nut. (See Photo # 21)
32. It will be necessary to drill through the driver side bottom of the OEM bracket & through the new Skyjacker bracket. Drill using a 17/32" drill bit. Once drilled, install the supplied 1/2" x 1 1/4" fine thread bolt, washer, & nut. Install the 9/16" x 3 1/2" bolt, washers, & nut at the bottom location being sure to use the supplied crush sleeve. (See Arrow in Photo # 22)
33. Remove the three upper left differential cover bolts. (See Photo # 23)
34. Attach the new track bar brace to the differential using the supplied 5/16" x 1" coarse thread bolts. Do not tighten at this time. The end of the bracket should be between the new track bar bracket & the coil spring. Use the thick 5/16" washer between the bracket & the differential cover. Use a 5/16" lock washer under the head of each bolt. (See Photos # 24 & # 25) Do not tighten at this time.
35. Attach the new brace to the front side of the new track bar bracket between the bracket & the coil spring. Do not tighten at this time. (See Photo # 26)
36. Torque the 5/16" bolts at the differential & the 14mm bolt on the track bar to the OEM specifications.
37. Install the new Skyjacker rear coil springs. Note: Be sure to reuse the upper OEM rubber isolator pad.
38. Attach the new Skyajcker rear bump stop spacers to the OEM location on the axle using the supplied 5/16" x 1" fine thread bolts, washers, & nuts. (See Photo # 27) Note: Install the bump stop spacers so the angled end is towards the rear of the vehicle.
39. Raise the differential in order to load the rear coil springs & install the new Skyjacker sway bar end links using the supplied steel sleeves. Attach using the supplied 1/2" x 2 1/2" button head bolts & nuts. Note: If using an OEM wheel, the upper end link bolt will need to be installed from the outside in for wheel clearance. Use the large USS washer under the head of the bolts & the SAE washer under the
nuts. (See Photo # 27)
40. Attach the OEM ABS lines & the new Skyjacker brake line brackets to the frame using the OEM hardware. Attach the OEM brake line to the new brake line brackets using the supplied 1/4" x 1" fine thread bolts, washers, & nuts. (See Photo # 28)
41. Remove the OEM rear lower control arms (one at a time) & install the new Skyjacker control arms using the OEM hardware. (See Photo # 29)
42. Install the new Skyjacker rear shocks using a 16mm socket.. (See Photo # 30)
43. Install the rear tires / wheels & lower the vehicle to the ground.
• After the installation is complete, double check that all nuts & bolts are tight. Refer to the following chart for the proper torque specifications. (Do not retighten the nuts & bolts where thread lock compound was used.)
• With the vehicle placed on the ground, cycle the steering lock to lock & inspect the steering, suspension, brake lines, front & rear drivelines, fuel lines, & wiring harnesses for proper operation, tightness, & adequate clearance.
• Have the headlights readjusted to the proper settings.
• Have a qualified alignment center realign the vehicle to the OEM specifications.
• Retorque all the bolts after the first 100 miles.