1984-2001 Jeep Cherokee Hard-Arm Suspension Installation Manual

1984-2001 Jeep Cherokee Hard-Arm Suspension Installation Manual - Tool requirements 1. 175A or greater mig welder 2. Plasma cutter and or a good 4.5″ grinder with cut off wheels. 3. Four large jack stands, ramps or a 4-post drive on lift works best. 4. Various wrenches and shop tools for removing and installing control arms. 5. A 1 7/16 wrench is needed to tighten the upper control arm jam nuts, and a 46mm wrench is needed to tighten the lower control arm jam nuts. Front Arms Installation Procedures 1. Raise truck up on jack stands, ramps or lift. 2. Remove transfer case skid plate if equipped. 3. Put a floor or bottle jack under the transfer case to support it.

4. Remove cross-member by removing the two bolts on each side and the four center bolts. 5. Wire wheel or grind paint away for welding. 6. Find the front of the new cross member. Reference your old cross member for proper transmission mount location. The plates where the new control arms mount should angle the control arms out. Openings should face forward . Put the eight-flange plate bolts in, the nuts and lock washers go on the inside and tighten. 7. On automatic cross members the 45 degree angle plates will align. On manual transmission do NOT align the 45 degree plates. A 1 inch drop is needed for clearance issues. The 45 degree plates are opposite. 8. Center the new cross member and secure it using the two mounting holes on each side. 9. Make three welds on each side where the cross member contacts the uni-body frame rail, one on the end and one down each side. Make sure these are good welds ! 10. Remove jack from transfer case. 11. Remove upper and lower short arms on one side only. 12. Cut the lower control arm mount off of the uni-body as close as possible using a plasma cutter or cut off wheel. Upper mount does not need to be removed. 13. Grind any extra off to make it look as neat as possible. 14. Spray paint bare metal to prevent rusting.

15. Install control arm. Upper control arm mount should be angled in with gold Johnny Joint at frame side. Adjust the arm to an initial length of 36 inches. Reuse the stock OEM bolt at axle side with rubber bushing. The gold Johnny Joint should be installed at the frame side with the new gold 9/16s bolt. 16. Install one upper arm temporarily to hold axle from rotating. This is a temporary install and does not matter what length. Do not tighten the arm as it will need to be changed in the final setup. 17. Drive side upper control arm is bent to clear hi-pinion housings. Use the gold 7/16s bolt at the adjuster side where it connects to the lower long arm. The supplied silver 10mm bolts are used at the axle upper bushing end. 18. Repeat steps 15 to 17 for the other side. 19. The upper arms should not be set until the vehicle is lifted front and rear, with the track set. This will be done in the final installation procedure. 20. Remove the OEM brakelines, trackbar, disconnects, shocks and springs. 21. If you purchased the PD-XJ45 you will need to drill out the OEM trackbar mount to 9/16s and install the new trackbar using the supplied bolt. 22. If you purchased PD-XJ65 or PD-XJ80 please follow the Drop Trackbar instructions below. Drop Track Bar Installation. 1. Remove factory trackbar and OEM frame bracket. 2. Removing the spring maybe necessary to remove and install OEM bolts, and weld in bracket. 3. Hold bracket in OEM location and mark where you will need to weld.

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