Trail Master TM3415-20010, TM3415-20012, TM3415-20013 User Manual

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400 W. Artesia Blvd. Fax: (310) 747-3912
Compton, CA 90220 Ph: (877) 695-7812
www.trailmastersuspension.com
JEEP WRANGLER (TJ) 1.5” POLY SPACER KIT
‘97- ’06 KIT# TM3415-20010/TM3415-20012/TM3415-20013
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
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.
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 (877) 695-7812. 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
Wheel & Tire Requirements
The factory wheel and tire combination will fit once this kit is installed.
Torque Specifications:
See factory service manual for torque values when reusing OE fasteners.
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
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.
Engine Compartment
1. Disconnect both battery cables. Disconnect negative cable first, then positive cable.
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Prepare to Install Front Suspension
10. Remove the front bump stops and unbolt the bump stop-mounting cups.
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. Place the vehicle in neutral. Place your floor jack under the front axle and raise the vehicle. Place jack stands under the frame rails and lower the frame onto the stands. Remove the jack and place the vehicle back in gear, set the emergency brake, and place blocks both in front and behind the rear wheels. 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.
Front Spring Pocket
Front Bump Stop Mount
OE Bolt
Front Bump Stop Mounting Cup
Install Front Suspension
3. Unbolt and remove the transmission skid plate from the vehicle.
4. Unbolt the front sway bar end links from the axle. Save the hardware for reuse.
5. Unbolt the lower front shock mount on both sides of the vehicle. If you purchased kits TM3415-20012 or TM3415-20013 unbolt and remove the front shocks from the vehicle. It may be necessary that you slightly raise the axle to unload the shocks for removal.
6. Unbolt the front track bar from the front axle mount and secure up and out of the work area. Save the hardware for reinstallation.
7. Unbolt the all the ABS mounting clips from the vehicle.
8. Unbolt the front brake line brackets from the frame.
9. Lower the front axle enough to remove the coil springs from the front spring pockets. Save the factory isolators for re-use. Be sure to support the axle while the springs and shocks are re­moved.
1. Install the front poly spacers (15-11515) and iso­lator over the bump stop mount. Reinstall the bump stop cup using the previously removed OE hardware.
15-11515 Front Poly Spacer
Front Spring Isolator
Front Bump Stop Mount
Front Bump Stop Mounting Cup
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2. Install the OE bump stop to the mounting cup.
Front Bump Stop Mounting Cup
OE Bump Stop
3. Reinstall the front coil springs. Jack up the front axle making sure the front coil spring seats properly on the lower spring perch.
4. If you purchased kit TM3415-20010 reinstall the front shock to the front axle mount using the previously removed OE hardware. Torque the lower hardware to 35 ft./lbs.
5. If you purchased kit TM3415-20012 or TM3415-
20013) Install your new front shocks (TM72215007 or TM73215007) using the OE
hardware. Torque the upper mounting hard­ware to 17 ft./lbs. and the lower to 35 ft./lbs.
6. Reinstall the ABS and brake line brackets to the vehicle using the previously removed OE hard­ware.
7. On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component. Use zip ties to secure these items to the steering components. At full droop, cycle the steering from lock to lock while observing the reaction of these components. Reposition them if needed.
8. Reinstall the front wheels and lower the vehicle to the ground. Torque the lug nuts according to the wheel manufacturers recommendations.
9. Reinstall the OE front track bar to the axle mount using the previously removed OE hard­ware. Torque the track bar mounting bolt ac­cording to manufacturers specifications.
Front Coil Spring
Front Shock
Prepare to Install Rear
1. Block the front tires and raise the rear of the ve­hicle. Support the frame with jack stands for­ward of the rear springs.
2. Remove the rear wheels.
3. Unbolt the rear track bar from the rear axle mount and secure up and out of the work area. Save the hardware for reinstallation.
4. Unbolt the lower rear shock mount on both sides of the vehicle. If you purchased kits TM3415- 20012 or TM3415-20013 unbolt and remove the rear shocks from the vehicle. It may be neces­sary that you slightly raise the axle to unload the shocks for removal.
5. Unbolt and remove the rear sway bar end links from the vehicle. Save the hardware for reuse.
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6. Unbolt the rear brake line brackets from the ve­hicle.
7. Lower the rear axle enough to remove the coil springs from the rear spring pockets. Save the factory isolators for re-use. Be sure to support the axle while the springs and shocks are re­moved.
8. Remove the rear bump stops and unbolt the bump stop-mounting cups.
Rear Bump Stop Mount
Rear Bump Stop Mounting Cup
2. Install the OE bump stop to the mounting cup.
Rear Bump Stop Mounting Cup
OE Bump Stop
Install Rear Suspension
1. Install the rear poly spacers (15-11515) and iso- lator over the bump stop mount. Reinstall the bump stop cup using the previously removed OE hardware.
Rear Bump Stop Mount
15-11515 Rear Poly Spacer
3. Reinstall the rear coil springs and isolator. Jack up the rear axle making sure the rear coil spring seats properly on the lower spring perch.
Rear Coil Spring
Rear Bump Stop Mounting Cup
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4. If you purchased kit TM3415-20010 reinstall the rear shock to the rear axle mount using the pre­viously removed OE hardware. Torque the lower hardware to 35 ft./lbs.
11. Adjust drag link to center steering wheel.
12. Align vehicle as soon as practical to minimum factory caster and maximum factory toe-in specifications.
13. Recheck all bolts after 50 miles and again after every off road excursion.
Rear Shock
5. If you purchased kit TM3415-20012 or TM3415-
20013) Install your new rear shocks (TM72215008 or 73215008) using the OE hard-
ware. Torque the upper mounting hardware to
17 ft./lbs. and the lower to 35 ft./lbs.
6. Reinstall the sway bar end links using the previ­ously removed OE hardware.
7. Reinstall the rear brake line brackets to the vehi­cle using the previously removed OE hardware.
8. On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component. Use zip ties to secure these items to the steering components.
9. Torque all bolts to factory specs and double check your work.
10. Test drive and note location of steering wheel.
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7. At full droop, cycle the steering from lock to lock while observing the reaction of these components. Reposition them if needed.
8. Reinstall the rear wheels and lower the vehicle to the ground. Torque the lug nuts according to the wheel manufacturers recommendations.
9. Reconnect the positive battery cable, then the negative battery cable.
Dynamic Vehicle Check
1. Check steering and suspension in all positions
to ensure that there is no bind and adequate clearance between all moving, fixed, and heated members. Check operation of clutch, brake sys­tem, and parking brake. Check operation of trans­mission and transfer case. Ensure there is full en­gagement in all gears and 4WD ranges. Check battery connections and electrical component op­erations. Test-drive vehicle.
WARNING
Re-torque all fasteners after 500 miles and after off road use. All suspension lift components should be visually inspected and fasteners re­torqued during routine vehicle servicing.
CAUTION
Trail Master does not recommend any particular wheel and tire combinations for use with its sus­pension lifts and cannot assume responsibility for the customer’s choice of wheels and tires. Refer to your owner's manual for recommended tire sizes and warnings related to the use of over­sized tires. Larger wheel and tire combinations increase stress and wear on steering and sus­pension components, which leads to increased maintenance and higher risk for component fail­ure. Larger wheel and tire combinations also al­ter speedometer calibration, braking effective­ness, center of gravity, and handling characteris­tics. Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle.
NOTE
All warranty information, instruction sheets, and other documents regarding the installation of this product must be retained by the vehicle owner. Information contained in the instructions and on the warranty card will be required for any war­ranty claims. The vehicle owner needs to under­stand the modifications made to the vehicle and how they affect vehicle handling and perform­ance. Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury.
Kit Parts List:
TM3415-20010 Kit: 4 Coil Spacer (15-11515, front & rear) TM3415-20012 Kit:
4 Coil Spacer (15-11515, front & rear) 2 Absorber (shock, front, TM72215007)
2 Absorber (shock, rear, TM72215008)
TM3415-20013 Kit:
4 Coil Spacer (15-11515, front & rear) 2 Absorber (shock, front, TM73215007)
2 Absorber (shock, rear, TM73215008)
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Revision Page:
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Notice to Owner Operator, Dealer and Installer:
Vehicles that have been enhanced for off-road performance often have unique handling characteristics due to the higher center of gravity and larger tires. This vehicle may handle, react and stop differently than many passenger cars or unmodified vehicles, both on and off–road. You must drive your vehicle safely! Extreme care should always be taken to prevent vehicle rollover or loss of control, which can result in seri­ous injury or even death. Always avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking! Trail Master Suspension
reminds you to fasten your seat belts at all times and re­duce speed! We will gladly answer any questions concerning the design, function, maintenance and cor­rect use of our products.
Please make sure your Dealer/Installer explains and delivers all warning notices, warranty forms and instruction sheets included with Trail Master Suspension
product.
Application listings in this catalog have been carefully fit checked for each model and year denoted. How­ever, Trail Master Suspension
reserves the right to update as necessary, without notice, and will not be held responsible for misprints, changes or variations made by vehicle manufacturers. Please call when in question regarding new model year, vehicles not listed by specific body or chassis styles or vehicles not originally distributed in the USA.
Please note that certain mechanical aspects of any suspension lift product may accelerate ordi­nary wear of original equipment components. Further, installation of certain Trail Master Suspension
products may void the vehicle’s factory warranty as it pertains to certain covered parts; it is the con­sumer’s responsibility to check with their local dealer for warranty coverage before installation of the lift.
Warranty and Return policy: Trail Master Suspension materials. Trail Master Suspension’s Trail Master Suspension’s
warranties its full line of products to be free from defects in workmanship and
obligation under this warranty is limited to repair or replacement, at
option, of the defective product. Any and all costs of removal, installation, freight or incidental or consequential damages are expressly excluded from this warranty. Trail Master Suspension is not responsible for damages and / or warranty of other vehicle parts related or non-related to the installation of Trail Master Suspension
product. A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will assume all risk and responsibility for potential dam­ages incurred as a result of their chosen modifications. Warranty coverage does not include consumer opinions regarding ride comfort, fitment and design. Warranty claims can be made directly with Trail Mas-
ter Suspension or at any factory authorized Trail Master Suspension dealer. IMPORTANT! To validate the warranty on this purchase please be sure to mail in the warranty card.
Claims not covered under warranty-
• Parts subject to normal wear; this includes bushings, bump stops, ball joints, tie rod ends and heim joints
• Discontinued products at Trail Master Suspension’s
discretion
• Bent or dented product
• Finish after 90 days
• Leaf or coil springs used without proper bump stops
• Products with evident damage caused by abrasion or contact with other items
• Damage caused as a result of not following recommendations or requirements called out in the installa­tion manuals
• Products used in applications other than listed in Trail Master Suspension’s
catalog
• Components or accessories used in conjunction with other manufacturer’s systems
• Warranty claims without “Proof of Purchase”
Trail Master Suspension
accepts no responsibility for any altered product, improper installation, lack of
or improper maintenance, or improper use of our products.
E-Mail: info@trailmastersuspension.com Website: www.trailmastersuspension.com Ph: (877) 695-7812
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