Manual

ManualsBrandsTuff Country ManualsFor the car43803 - Jeep Cherokee 87-01 3.5 EZ-Flex kit (w/rr springs)t

Part # 43803

1987 - 2001 Jeep Cherokee 4x4 Sport

3.5” EZ-Flex Suspension System with rear springs

Part

# Description

Qty.

XJ3F-CL01 Front coil spring 2

TJ3A-01M Front EZ-flex lower control arm 2

43800-02 Transfer case drop tube 2

44900-01 Front track bar relocation bracket 1

5U-123146R 1/2” x 3 1/4” x 6” round u-bolts 4

5U-122346R 1/2” x 2 3/4” x 6” round u-bolts 4

12NW Hardware bag 1

43800NB Hardware bag 1

43801NB1 Hardware bag 1

43803INST Instruction manual 1

MIRRORHANGER Rear view mirror hanger 1

WARNINGDECAL

Warning decal 1

Congratulations on your selection to purchase a Tuff

Country EZ-Ride Suspension System. We at Tuff

Country EZ-Ride Suspension are proud to offer a high

quality product at the industries most competitive pric-

ing. Thank you for your confidence in us and our prod-

uct.

If you desire to return your vehicle to stock, it is the

customers responsibility to save all stock hardware

and components.

The Tuff Country EZ-Ride Suspension product safety

label that is included in your kit box must be installed

inside the cab in plain view of all occupants.

Installation manual

3.5” EZ-Flex suspension system

with rear springs

1987 - 2001

Jeep Cherokee 4x4 Sport

Part # 43803

sj05142012rev.01

Important customer information:

Tuff Country EZ-Ride Suspension highly recommends

that a qualified or a certified mechanic performs this

installation.

It is the responsibility of the customer/installer to wear

safety glasses at all times when performing this instal-

lation.

It is the customers/installers responsibility to read and

understand all steps before installation begins. If you

have any questions or concerns, please contact our

technical department @ (801) 280-2777. Also, the OEM

manual should be used as a reference guide.

This vehicles reaction and handling characteristics

may differ from standard cars and/or trucks.

Modifications to improve and/or enhance off road per-

formance may raise the intended center of gravity.

Extreme caution must be utilized when encountering

driving conditions which may cause vehicle imbalance

or loss of control. DRIVE SAFELY! Avoid abrupt

maneuvers: such as sudden sharp turns which could

cause a roll over, resulting in serious injury or death.

It is the customers responsibility to make sure that a

re-torque is performed on all hardware associated with

this suspension system after the first 100 miles of

installation. It is also the customers responsibility to

do a complete re-torque after every 3000 miles or after

every off road use.

After the original installation, Tuff Country EZ-Ride

Suspension also recommends having the alignment

checked every 6 months to ensure proper tracking,

proper wear on tires and front end components. Tuff

Country EZ-Ride Suspension takes no responsibility

for abuse, improper installation or improper suspen-

sion maintenance.

Summary of content (11 pages)

PAGE 1
Installation manual 3.5” EZ-Flex suspension system with rear springs 1987 - 2001 Jeep Cherokee 4x4 Sport Part # 43803 sj05142012rev.01 Part # 43803 1987 - 2001 Jeep Cherokee 4x4 Sport 3.
PAGE 2
Limited lifetime warranty Notice to all Tuff Country EZ-Ride Suspension customers: It is your responsibility to keep your original sales receipt! If failure should occur on any Tuff Country EZ-Ride Suspension component, your original sales receipt must accompany the warranted unit to receive warranty. Warranty will be void if the customer can not provide the original sales receipt. Do not install a body lift in conjunction with a suspension system.
PAGE 3
Special note: Before installation begins, it is the customers/installers responsibility to make sure that all parts are on hand. If any parts are missing, please feel free to call one of our customer service representatives @ (801) 280-2777. Please follow instructions carefully: Hardware bag 12NW includes: Pre-installation measurements: Before installation begins, measure from the center of the hub, to the bottom of the fender well, and record measurements below.
PAGE 4
5. Place a pair of hydraulic floor jacks under the front axle and carefully raise up until they make contact with the front axle. Working on the driver side, remove the OE hardware that connects the track bar to the OE location. Save the OE hardware. 3. Working on the driver side, remove the sway bar endlink from the sway bar and axle location. Save the hardware and endlink. Repeat procedure on the passenger side 6. Working on the driver side, remove the lower control arm from the frame and axle mount.
PAGE 5
9. Locate the new coil springs. Working on the driver side, install the new coil spring into the OE location. Repeat procedure on the passenger side. 7. Working on the driver side, remove the coil spring clip from the axle. Save the clip and hardware. Repeat procedure on the passenger side. 10. Carefully raise up on both hydraulic floor jacks until the newly installed coil springs seat properly into the lower coil spring pockets.
PAGE 6
11. Locate the new EZ-Flex control arms. Set each control 13. Locate the new track bar relocation bracket. Install the arm to 16 1/2” from the center of eye to the center of eye. new bracket into the OE track bar pocket. 12. Working on the driver side, install the new EZ Flex lower control arm into the OE location using the OE hardware. Special note: Make sure that when installing the new lower control arms the sert fitting are facing the upward position. Do not tighten at this point.
PAGE 7
15. Make sure that newly installed track bar bracket is seating flush in the OE pocket. Using the new bracket as a guide, 18. Locate (1) 10 mm x 70 mm bolt, (2) 5/16 USS flat washcarefully drill a 3/8” hole into the OE bracket. ers and (1) 10 mm unitorque nut from hardware bag 43800NB. Install the track bar to the newly installed bracket and secure using the new 10 mm x 70 mm bolt and hardware. Make sure to use loctite and torque to 28 ft lbs.
PAGE 8
25. Working on the driver side, remove the hardware that attaches the transfer case cross member to the frame. The hardware may be discarded. Repeat procedure on the passenger side. 26. Carefully lower down on the on the hydraulic floor jack holding the transfer case cross member about 1 1/2”. This will allow enough room for the transfer case spacers to be installed. 27. Working on the driver side, spray some lubricant on the all thread that is threaded into the body of the vehicle.
PAGE 9
33. Working on the driver side, remove the u-bolts from the 30. Working on the driver side, add some loctite to the newly OE location. The u-bolts and hardware may be discarded. installed transfer case spacer hardware and torque to 28 ft The upper u-bolt plate can rest on top of the spring. Repeat lbs. Repeat procedure on the passenger side. Carefully procedure on the passenger side. remove the hydraulic floor jack from under the transfer case cross member. 34.
PAGE 10
passenger side. 37. Locate the new rear springs. Remove the bushings and sleeves from the new springs and add some lithium or moly base grease to the bushings and sleeves and re-install them back into the new springs. This will help prevent squeaking, the life of the bushings and will also improve ride quality. 39. Locate the proper u-bolts. Also, locate (8) 1/2” u-bolt washers and (8) 1/2” high nuts from hardware bag 12NW.
PAGE 11
Working on the driver side, install the new shock into the OE location using the OE hardware. Make sure to use loctite and torque to lower hardware to 38 ft lbs and the upper hardware to 12 ft lbs. Repeat procedure on the passenger side. 41. Re-install the rear brake line bracket back into the OE location. 42. Remove the hydraulic floor jacks from under the vehicle. 43. Check and double check to make sure that all steps have been performed properly and check again. 44.