JKS 9100 User Manual
INSTALLATION
INSTRUCTIONS
517-278-1226 • tech@jksmfg.com • www.jksmfg.com
491 W. Gareld Avenue, Coldwater, MI 49036
Product: Switchblade™ Swaybar System
Part Number: JKS9100
Applications: Wrangler TJ, 1997-06 (front)
Welcome
CONGRATULATIONS on purchasing a SwitchBlade™
Swaybar System from JKS Manufacturing. We are committed to providing you with the best products available and
your satisfaction is our rst priority.
PLEASE READ these Installation Instructions carefully,
and save them for future reference, as they contain important installation and maintenance information.
WE WELCOME your feedback regarding these Installation
Instructions and appreciate any suggestions you may have
to improve this document for other users.
Important
TUBULAR FRONT CROSSMEMBER must be intact and
free of damage in order to install this product.
CHECK BUMPER COMPATIBILITY before installing. It
may be necessary to modify or replace front bumper
to ensure proper clearance for this product.
STEERING STOP ADJUSTMENTS may be necessary to
prevent interference between tires and blade arms at
full steering lock.
Tools Required
Metric/Standard Socket Wrench Set
Torque Wrench
3/8” Allen Head Socket
3/4” & 14mm Open End Wrenches
Tie Rod End Remover *
Long Philips Screwdriver
Tape Measure
Angle Measuring Tool
Soft Mallet & Block of Wood *
(for seating bushings into crossmember)
Silicone Lubricant
Blue RTV Silicone Gasket Maker
Medium Strength Threadlocker
Hammer & 3/16” Pin Punch
(for driving 1/4” Dowel Pin into Indexing Head)
Die Grinder with Sanding or Grinding Wheel *
(or equivalent tool for removing debris from
crossmember)
Metal Cutting Tool *
(such as die grinder with cutting wheel or metal cutting
saw for cutting connecting rod and to clearance front
bumper)
Bolt Cutting Tool * (such as metal band saw or
equivalent tool for cutting bumper mounting bolts)
Factory Service Manual (recommended)
* Asterisk denotes tools that are not required for some applica-
tions. Thoroughly read instructions rst to determine which tools
will be required for your application.
JKS9100JKS Switchblade Swaybar Installation
Page 1
Parts
If the bumper interferes with this product, it will be
necessary to clearance the bumper or mounting sys-
tem to allow tment. Due to the number of possible
bumper congurations and other variables beyond
our control, we cannot provide instructions for this
procedure nor can we encourage it to be attempted.
If any bumper modications are necessary to install
this product, it is the sole responsibility of the installer or vehicle owner to ensure the work is performed
properly and neither structural integrity nor safety
have been compromised.
Installation
1. REMOVE FRONT BUMPER
Disconnect any auxiliary driving/fog lamps mount-
ed to front bumper, if equipped.
Remove the mounting hardware that secures the
front bumper to the chassis.
Remove the front bumper assembly from the
vehicle.
Remove the front bumper valence from the chas-
sis.
Description QTY
A
Blade Arm Assembly (Left-Hand) 1
B
Blade Arm Assembly (Right-Hand) 1
C
Torsion Bar 1
D
Torsion Bar Bushing 2
E
1/4” Dowel Pin 2
F
1/2” x 1-3/4” Socket Head Cap Screw 2
G
Gimbal Joint Assembly 2
H
Connecting Rod 2
I
Rod End 2
J
1/2” Flanged Locking Nut 2
K
1/2” Jam Nut 4
ATTENTION INSTALLER
BEFORE YOU INSTALL THIS PRODUCT, verify the
front bumper and its mounting system do not interfere
with the D-shaped tubular crossmember openings or
surrounding area, as illustrated below.
2. REMOVE FRONT SWAYBAR
Remove the mounting hardware that secures the
front swaybar links to the swaybar and axle housing. H I NT: If difcult to remove, use special factory
removal tool PN MB991113 (Miller Special Tools,
800-801-5420) or similar tie rod end removal tool.
Remove swaybar links from vehicle.
Remove swaybar mounting bolts and bushing
retainers from chassis.
2 Page
JKS9100
JKS Switchblade Swaybar Installation
Remove front swaybar from vehicle.
CROSS MEMBER
CHASSIS
RAIL
BUSHING
TORSION BAR
CROSS MEMBER
CHASSIS
RAIL
BUSHING
TORSION BAR
BUSHING
TORSION BAR
CROSS MEMBER
CHASSIS
RAIL
HI N T: To guide torsion bar through bushing at far end of
crossmember, insert a Philips head screwdriver through
bushing and into center hole of torsion bar as illustrated
below. Pry torsion bar up using screwdriver while pushing
it through the bushing from the opposite end.
3. PREPARE FRONT CROSS MEMBER
The SwitchBlade Swaybar mounts through the tubular
crossmember that connects the chassis rails together immediately forward of the steering box. Crossmember must
be intact and free of damage in order to install this product.
Inspect the inside surface at each end of the
crossmember for any debris or deformation that
could interfere with installation of Torsion Bar
Bushings (D).
Clean any mud, dirt, rust, burs, slag, or other de-
bris from inside ends of crossmember.
HI N T: A die grinder with sanding wheel or similar tool is
useful for removing stubborn debris.
4. INSTALL TORSION BAR
Insert a Torsion Bar Bushing (D) into each end of
the tubular crossmember. HINT: A block of wood
and soft mallet may be useful to fully seat bushing
into crossmember. Do not use brute force – only
light tapping with mallet. A light application of
silicone lubricant to outer surface of bushing may
also be used. If bushings are still difcult to insert,
contact JKS at 877-533-7557 for technical assis-
tance.
Use caution to avoid damaging bushings when installing torsion bar.
5. INSTALL BLADE ARMS
Locate the Blade Arm Assemblies (A & B) and
identify their correct mounting location by reading the label applied to the Indexing Heads. “RH”
indicates Right-Hand side, and “LH” indicates LeftHand side. Hint: When installed correctly, the 1/4”
through-hole will be on bottom of Indexing Head.
BLADE ARM ASSEMBLY
Wipe down the Torsion Bar (C) with a light applica-
tion of Silicone lubricant.
Install Torsion Bar (C) by guiding it through the
Torsion Bar Bushings (D) until it is centered.
JKS9100JKS Switchblade Swaybar Installation
Slide the splined opening of the Indexing Head on
to end of Torsion Bar (C). HI NT: It may be neces-
sary to gently tap side of Indexing Head with a
rubber mallet to fully engage splines. Use a clean,
soft towel to protect the polished nish.
Slowly pivot the Blade Arm Assembly (A) up or
down until the 1/4” through-hole in Indexing Head
aligns with the access groove in the Torsion Bar
Bushing (D) as illustrated below.
Insert a 1/4" Dowel Pin (E) into the through-hole as
shown below.
Drive the 1/4” Dowel Pin (E) into through-hole until
it is centered as shown below. HI N T: A hammer
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