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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
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.
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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