Trail Master TM3440, TM20013 User Manual

400 W. Artesia Blvd. Fax: [phone]

Compton, CA 90220 Ph: [phone]

www.trailmastersuspension.com

JEEP WRANGLER (TJ) 4” SPRING KIT

‘97- ’06 KIT# TM3440-20013

WARNING

Installation of a Trail Master suspension lift kit will
change the vehicle’s center of gravity and handling
characteristics both on- and off-road. You must drive
the vehicle safely! Extreme care must be taken to
prevent vehicle rollover or loss of control, which
could result in serious injury or death. Avoid sudden
sharp turns or abrupt maneuvers and always make
sure all vehicle occupants have their seat belts fas­tened.

WARNING

Before you install this kit, read and understand all
instructions, warnings, cautions, and notes in this
instruction sheet and in the vehicle owner’s manual.

CAUTION

Proper installation of this kit requires knowledge of
the factory recommended procedures for removal
and installation of original equipment components.
We recommend that the factory shop manual and
any special tools needed to service your vehicle be
on hand during the installation. Installation of this kit
without proper knowledge of the factory recom­mended procedures may affect the performance of
these components and the safety of the vehicle. We
strongly recommend that a certified mechanic famil­iar with the installation of similar components install
this kit.

WARNING

This kit should only be installed on a vehicle that is in
good working condition. Before you install the kit,
thoroughly inspect the vehicle for corrosion or defor­mation of the sheet metal. If the vehicle is suspected
to have been in a collision or misused, do not install
this kit. Off-road use of your vehicle with this kit in­stalled may increase the stress applied to the factory
components. Failure to observe this warning may
result in serious personal injury and/or severe dam­age to your vehicle.

WARNING

Many states and municipalities have laws restricting
bumper heights and vehicle lifts. Consult state and
local laws to determine if the changes you intend to
make to the vehicle comply with the law.

WARNING

The installation of larger tires may reduce the effec­tiveness of the braking system.

WARNING

Always wear eye protection when operating power
tools.

WARNING

Before you install this kit, block the vehicle tires to
prevent the vehicle from rolling.

WARNING

DO NOT combine suspension, body, or other lift de­vices. Use of vehicle with combined lifts may result
in unsafe and/or unexpected handling characteris­tics.

NOTE

Lift height may vary depending on vehicle configura­tion, engine size, additional accessories, the factory
suspension package, and vehicle’s condition.

NOTE

Trail Master recommends using thread locking com­pound on the threads of all kit nuts and bolts unless
specified otherwise in these instructions.

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Before Starting Installation

NOTE

Kit parts are prefaced by the word kit and appear in

bold print.

Torque Specifications:

See factory service manual for torque values when

reusing OE fasteners.

1. Carefully read all warnings and instructions
completely before beginning.

2. Verify all parts have been received in this kit by
checking the parts list at the end of this docu­ment.

3. Only install this kit on the vehicle for which
it is specified. If anytime during the installation
you encounter something different from what is
outlined in the instructions, call technical support
at [phone]. Park vehicle on a clean, dry,
flat, level surface and block tires so vehicle can­not roll in either direction.

4. Park vehicle on a clean, dry, flat, level surface
and block tires so vehicle cannot roll in either
direction.

5. Measure ride height with the vehicle supporting
its own weight on level ground. To settle the
suspension, the vehicle should be driven for­ward at least 10 feet immediately prior to taking
these measurements. Ride height is the meas­urement from the center of the axle straight up
(vertical) to the fender lip. Record this measure­ment for all four wheels.

NOTE

Adhere to recommendations when replacement fas­teners, retainers and keepers are called out in the fac­tory service manual. When re-assembling the vehicle it
is recommended by the vehicle manufacturer that cer­tain fasteners are replaced in order to maintain proper
retention characteristics. This system may not include
all replacement hardware as recommended by the fac­tory service manual. Additional replacement hardware
should be obtained prior to installation of this system
to meet the requirements of the factory service man­ual.

See factory service manual for torque values when re-using

OE fasteners.

Bolt Size Grade 5 (ft.-lbs.) Grade 8 (ft.-lbs.)

1/4”-20 10 10
1/4”-28 10 12.5
5/16”-18 17 22.5
5/16”-24 20 25
3/8”-16 30 40
3/8”-24 35 45
7/16”-14 50 65
7/16”-20 55 70
1/2”-13 75 100
1/2”-20 80 115
9/16”-12 105 135
9/16”-18 115 150
5/8”-11 150 195
5/8”-18 160 210
3/4”-16 175 225

Wheel & Tire Requirements

The factory wheel and tire combination will fit once this
kit is installed.

Engine Compartment

1. Disconnect both battery cables. Disconnect
negative cable first, then positive cable.

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Prepare to Install Front
Suspension

WARNING

Compressed coil springs can expand violently causing
serious personal injury. Before removing the coil
springs, lower the axle housing as far as possible to al­low the coil springs to expand.

1. Loosen, but do not remove, lug nuts on each
front wheel.

2. Jack the rear of the vehicle with the floor jack
under the differential and place jack stands un­der the frame just behind the lower control arm
frame mounts. Leave the jack stands high
enough to let the floor jack down and still have
the front tires suspended in the air. Keep the
floor jack under the differential with slight pres­sure for support. Remove the front wheels.

WARNING

Use extreme caution when lifting vehicle from ground.
To prevent serious personal injury, ensure the lifting de­vice is securely placed.

3. Disconnect the track bar from the axle and save
the hardware for reuse.

OE Coil
Spring

Install Front Suspension

1. On the passenger side, with the axle supported,
remove the passenger side lower control arm
from the vehicle. Be sure to leave the driver
side control arms in place to keep the front axle
from rolling over

2. Install the arm (82-TM30011) into the mounting
pockets on the frame using the previously re­moved OE bolts and hardware.

4. Unbolt the front brake line brackets from the
frame. Save the hardware for reuse.

5. Unbolt the front sway bar end links and remove
them from the vehicle. Save the hardware for
reuse.

6. Remove the shocks on both sides of the vehicle.
It may be necessary that you slightly raise the
axle to unload the shocks for removal. Save the
hardware for reinstallation.

7. If your vehicle came equipped with a skid plate
loosen the driver side bolt and remove the (2)
passenger side bolts.

8. Lower the jack carefully, remove the OE coil
springs and the OE isolators. Label the springs
as to which side they were removed, Left and
Right so that they are reinstalled in the side in
which they were removed.

OE Bolts

82-TM30011
Control Arm

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