User guide

ManualsBrandsRugged Ridge ManualsCar2-Inch Lift Kit without Shocks, 04-06 Jeep Wrangler Unlimited (LJ)

INSTALLATION INSTRUCTIONS

1997-02 WRANGLER 2" Lift 18401.30 / 18415.30

1997-02 WRANGLER 4" Lift 18401.40 / 18415.40

2003-06 WRANGLER 2" Lift 18401.31 / 18415.31

2003-06 WRANGLER 4" Lift 18401.41 / 18415.41

2003-06 WRANGLER UNLIMITED 2" Lift 18401.32 / 18415.32

2003-06 WRANGLER UNLIMITED 4" Lift 18401.42 / 18415.42

1997-02 2" LIFT COMPONENT BOX LISTING :

Four Coil Springs

Four Lower Links

One Track Bar Relocation Bracket

Three Transfer Case Lowering Brackets

Hardware Kit

1997-02 4" LIFT COMPONENT BOX LISTING :

Four Coil Springs

Four Lower Links

T One rack Bar Relocation Bracket

Two Transfer Case Lowering Brackets

Two Transmission Lowering Brackets

Hardware Kit

2003-06 2" LIFT COMPONENT BOX LISTING :

Four Coil Springs

Four Lower Links

One Track Bar Relocation Bracket

Two Transfer Case Lowering Brackets

Two Transmission Lowering Brackets

Hardware Kit

2003-06 4" LIFT COMPONENT BOX LISTING :

Four Coil Springs

Two Lower Front Links

Two Lower Rear Links

Two Rear Bump Stop Brackets

One Rear Track Bar Relocation Bracket

One Front Double Disconect Link

One Rear Swaybar End Links

Two Transfer Case Lowering Brackets

Two Transmission Lowering Brackets

Hardware Kit

A FEW WORDS ABOUT SAFETY:

Your safety and the safety of other motorists is very important. As the owner of a modied suspension vehicle you are the

person choosing the combination of suspension, wheels, tires and drive train that best t your intended use. Likewise, you

are the person responsible for the safety and legality of the vehicle you modify. In modifying your vehicle’s suspension,

balance your off-road capabilities against how the vehicle may actually be used off-road and on-road.

It is not practical or possible to warn about all hazards associated with modifying your suspension for improved off road

capabilities. To help you make informed decisions about safety, we have provided certain information in the form of

“Notices” and “Warnings”. This information alerts you to potential hazards that could hurt you or others.

Notice: This is a caution against anything which may cause damage to the vehicle or its equipment if the caution is

ignored. The Notice includes information about how you can avoid or reduce those risks.

Warning: This is a signal telling you that you CAN be KILLED or SERIOUSLY HURT if you don’t follow the Warning. The

Warning includes information about what you must or must not do in order to reduce the risk of injury to yourself and others.

WARNING

HIGHER ROLLOVER RISK

The suspension of this vehicle has been modied by the owner to

improve off-road capabilities. As a result, this vehicle may handle

differently than as factory equipped including increased ride-height;

reduced lateral stability and risk of roll-over or other accident. Also,

owner’s choice of larger tire and wheel combinations may require

additional braking force or increased stopping distances.

• Failure to drive this vehicle safely may result in serious injury or damage. Avoid

Sharp Turns or abrupt maneuvers. Do not drive the vehicle under any speed or

maneuvering conditions which may cause the vehicle to trip, roll, lose traction or

compromise your ability to safely brake in an emergency.

• Familiarize yourself with all vehicle manufacturers and Rugged Ridge™ warnings,

instructions and limited warranties before driving this modied suspension vehicle.

Follow recommended maintenance procedures and routinely inspect your vehicle

components for unusual wear or off-road damage.

• Always wear seat belts and/or appropriate off-road restraints, reduce your speed,

tread lightly

and safely enjoy your off-road vehicle.

PRE-INSTALLATION NOTES:

Notice: This kit should only be installed by a professional

mechanic or individual with signicant automotive experience.

• Refer to parts list and inventory your kit to insure all parts and

hardware pieces are available before beginning installation.

Contact your independent dealer immediately if parts are missing.

• Installed lift will vary depending on vehicle options and

conguration. As a reference and important guide should technical

assistance be required, establish base ride-height measurements

before beginning installation. Park vehicle on hard, level surface.

Carefully measure the four corners of the vehicle (front and

rear –both sides) from the ground up to the center of the fender

opening above the axle. Record below and save.

Driver Side Front: Passenger Side Front:

Driver Side Rear: Passenger Side Rear:

The following Warning label is included with your

Rugged Ridge™ suspension kit and should be

placed on the vehicle visor or other conspicuous

location after installation:

RECOMMENDED TOOLS :

! Warning: Improper use of air and power tools can cause serious injury. Familiarize yourself with tool manufacturers

warnings and instructions before use. Always wear approved safety glasses.

IMPORTANT NOTES :

• 6-Speed Transmission models may require additional modifications. Options are Trimming of the console or

bending of the shifter, raising the transfer case to a 1” drop (4 inch kit).

• On models outfitted with extra bolt-on equipment and accessories, Rugged Ridge offers new coil spring

isolator pads made from polyurethane to boost ride height 3/4", front or rear

Summary of content (7 pages)

PAGE 1
INSTALLATION INSTRUCTIONS 1997-02 WRANGLER 2" Lift 18401.30 / 18415.30 1997-02 WRANGLER 4" Lift 18401.40 / 18415.40 2003-06 WRANGLER 2" Lift 18401.31 / 18415.31 2003-06 WRANGLER 4" Lift 18401.41 / 18415.41 2003-06 WRANGLER UNLIMITED 2" Lift 18401.32 / 18415.32 2003-06 WRANGLER UNLIMITED 4" Lift 18401.42 / 18415.42 A Few Words About Safety: Your safety and the safety of other motorists is very important.
PAGE 2
FRONT: 1. Secure and properly block the tires of vehicle on a level concrete or asphalt surface. 2. Jack up front of vehicle and install jack stands under frame behind the lower link rear brackets. Remove tires and front shocks. Now remove the track bar bolt on passenger side end only and lower track bar down (it may be necessary to pry bar loose). (See picture #1.) 3. Remove drag link assembly from pitman arm and lower it down. (For 4" lifts, remove pitman arm also.
PAGE 3
7. 21/2" Lifts: Reattach track bar in original axle mount (it may be necessary to rotate steering wheel left or right to align bolt hole). 4" Lifts: Locate the front track bar mounting bracket on the axle, measure straight across to the right (inward) 3/4" and put a mark. Center punch and drill a 7/16" hole through both front and back plates, keeping the drill as straight and square to the bracket as possible (see picture #6).
PAGE 4
and replace the lower links with new Rugged Ridge extended links (one side at a time). See picture #9. Only start these bolts and nuts, do not tighten at this time. NOTE: so that the links may be greased while on the vehicle, install them with the zirc fittings positioned as follows: front eye of link has fitting pointing out the end, rear eye of link should have the fitting pointing down. Once both links are installed, tighten each lower link being sure to realign the marks on the eccentric cams.
PAGE 5
3. After removing both coil springs, remove the bump stops (it may help to use channel lock pliers working bump stop back and forth). Remove 10mm bolt from inside bump stop cup. Install bump stop spacer and original cup using furnished 10mm bolts Reinstall factory bump stop. (See picture #13.) Picture #14-A Picture #14-B ‹ 4. Referring to pictures 14 A & B, place new rear track bar relocation bracket in position and place track bar in new bracket (do not start its bolt).
PAGE 6
9. 21/2" Lifts: Reattach sway bar links to axle housing and skip to step 10, unless purchased extended rear sway bar end links. ‹ 4" Lifts: Assemble the rear extended sway bar links by applying grease to the polyurethane bushings and inserting them into each eye along with a sleeve . Install using original bolts. (See picture #15, White arrow.) Picture #17 10. Install new shocks (see picture #16), install tires and lower rear to the ground.
PAGE 7
Post Installation Checks/Alignment: • After installation is complete, double check that all nuts and bolts are tight. (Do not retighten nuts and bolts where Loctite was used.) Check to ensure there is adequate clearance between all rotating, mobile and fixed members. • Rotate driveshafts and check for interference at differential yoke and cardan joint. If necessary, lightly dress casting(s) and/or U-joint tabs in order to eliminate binding. • Check clearance between inner side wall of tires and links.