JKS 9800 User Manual

INSTALLATION

INSTRUCTIONS

517-278-1226 • tech@jksmfg.com • www.jksmfg.com

491 W. Gareld Avenue, Coldwater, MI 49036

Product: Telescoping Trackbar™

Part Number: JKS9800

Applications: Jeep® Wrangler YJ, 1987-95

Welcome

CONGRATULATIONS on purchasing a new Telescoping Trackbar™ 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.

Important

COMPATIBLE WITH the front of 1987-95 Wrangler YJ models only. Do not attempt to modify or install this product on any other application or location.

NOT COMPATIBLE WITH coil-spring conversion systems.

NEVER UNLOCK TRACKBAR when operating vehicle on public roads.

CHECK TORQUE SPECIFICATIONS regularly.

Tools Required

 Metric/Standard Socket Wrench Set

 Torque Wrench

 1-1/8” and 9/16” Open-End Wrenches

 Drill with 1/2” Drill Bit

 Grease Gun with Zerk Fitting Coupler

 Wheel Bearing Grease

 Welder *

* 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.

Parts

Description

Outer Tube (Chassis End)

Slip Shaft (Axle End)

1/2” Ovalok Nut

3/4” Teon Lined Rod End

3/4” Jam Nut

Polyurethane Dust Boot

1/2” x 3” GR8 Bolt

3/8” x 1-3/4” GR8 Bolt

3/8” Nylock Nut

Clamp

Grease Zerk Cap

Grease Zerk

1/8” Shoulder Spacer (narrow)

1.85” OE Bracket Spacer

5/16” Shoulder Spacer (wide)

1/2” x 4-1/2” GR8 Bolt

JKS9800JKSTelescoping Trackbar Installation

Page 1

Installation

 1. REMOVE ORIGINAL EQUIPMENT (OE)

FRONT TRACK BAR

 Remove front track bar and mounting hardware –

including U-bracket from chassis – according to the factory service manual instructions for your vehicle.

 Also remove any aftermarket track bar relocation

or riser bracket from axle, if installed. Such parts are commonly supplied with suspension lift kits.

IMPORTANT: It will be necessary for the OE pitman arm to be installed on the steering box if aftermarket relocation/riser bracket is removed from the axle. However, if special circumstances require the relocation/riser bracket to be retained, it will also be necessary to retain the drop pitman arm.

 2. MOUNT TELESCOPING TRACKBAR TO

CHASSIS BRACKET

 Insert 1.85” Spacer (N) into chassis rail bracket

where the OE track bar originally mounted. HINT: The 1.85” Spacer (marked with an “X”) prevents the OE bracket from collapsing.

 Insert a 5/16” (wide) Shoulder Spacer (O) into

each side of the Rod End (D) at the Chassis End (A) of Telescoping Trackbar. HI NT: The Shoulder

Spacers must “sandwich” the Rod End to allow full exibility of the joint when installed.

 Insert a 1/8” (narrow) Shoulder Spacer (M) into

each side of Rod End (D) at the Axle End (B) of Telescoping Trackbar. HI N T: Shoulder Spacers

must “sandwich” the Rod End to allow full exibility of the joint when installed.

 Mount Axle End (A) of trackbar to axle bracket and

secure with a 1/2” x 3” Bolt (G) and 1/2” Ovalok

Nut (C).

 Tighten 1/2” x 3” Bolt (G) to 75 ft-lb. using a torque

wrench.

 4. TIGHTEN TELESCOPING TRACKBAR

 With the vehicle on a level surface, tighten the

Clamp (J) using a 9/16” wrench.

 Tighten the 3/4” Jam Nuts (E) located at each end of

the trackbar, but DO NOT thread out Rod Ends (D).

IMPORTANT: Rod Ends have been properly installed from the factory. Avoid unthreading Rod Ends prior to

installation, as this may sacrice strength

 5. LUBRICATE TELESCOPING TRACKBAR

 Lubricate the Grease Zerk (L) located on the

Clamp (J) of Telescoping Trackbar using common wheel bearing grease or equivalent.

Operation

Telescoping Trackbar should remain in the “locked” position when vehicle is operated on public roads. Once off-road, the trackbar can be “unlocked” by loosening the Clamp (J) using a pair of 9/16” wrenches.

 Mount Chassis End (A) of trackbar behind the

chassis rail bracket and secure with the 1/2” x 4-1/2” Bolt (P) and 1/2” Ovalok Nut (C). HINT: When installed correctly, Grease Zerk (L) will point

up and JKS decal will face forward.

 Tighten 1/2” x 4-1/2” Bolt (P) to 75 ft-lb. using a

torque wrench.

 3. MOUNT TELESCOPING TRACKBAR TO

AXLE BRACKET

 Using a 1/2” drill bit, enlarge the hole on the axle

where the OE track bar originally mounted.

2 Page

Troubleshooting

If slippage occurs on Chassis End of Telescoping Trackbar, weld the 1.85” OE Bracket Spacer (N) in place.

Maintenance

Telescoping Trackbar is factory lubricated, but should be greased regularly as part of vehicle maintenance schedule.

Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability. Always lubricate afterwards to evacuate any moisture.

Check torque specications regularly.

JKS9800

JKSTelescoping Trackbar Installation