400 W. Artesia Blvd. Fax: (310) 747-3912
Compton, CA 90220 Ph: (877) 695-7812
www.trailmastersuspension.com
JEEP CHEROKEE (XJ) 4.5” COIL SPRING KIT
‘84- ’01 KIT# TM3745-40013 w/ Add-A-Leaf
Or TM3745-40023 w/ Leaf Spring
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 man ual.
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 c ondition.
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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2
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 serv ice manual for torque value s 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
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 e x pand.
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 secu rely place d .
Install Front Suspension
1. Support the front axle using jack stands.
2. On the passenger side, with the axle supported,
remove the passenger side upper and 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. Install the long end
of the control arm into the frame mount. (Don’t
fully tighten until vehicle is back on the ground).
3. If your vehicle is equipped with a transmission
skid plate, unbolt and remove it from the vehicle.
4. Unbolt and remove the front sway bar end links
from the axle. Save the hardware for reuse.
5. Unbolt and remove shocks from the vehicle.
Save the hardware for reuse
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. Unbolt the front coil spring retainer clamps.
10. 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.
3. Install the arm (82-TM30011) into the mounting
pockets on the frame using the previously removed OE bolts and hardware.
OE Bolts
82-TM30011
Control Arm
4. Repeat steps 1 through 3 on the remaining side
of the vehicle.
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5. Carefully lower the front axle to ease in the new
coil spring installation. Using the factory isolators install the coil springs (TM3745-60010) into
the spring buckets
move the OE hardware from one side of cross
member. Install 1” spacers (90-TM10002) and
10mm x 60mm bolts and 10mm washers.
Tighten hardware to 55 ft/lbs.
6. Raise the front axle into place. Make sure the
coil spring seats properly on the lower spring
perch. Reinstall the spring retainers (do not
over tighten the retainer bolt it strips easily).
7. Install the front shocks (TM73265015) using the
previously removed OE bolts and hardware.
Torque the upper mounting hardware to 17 ft./
lbs. and the lower to 35 ft./lbs.
8. Install the sway bar end link mounts (82-
TM20042) to the OE sway bar using the supplied 3/8” X 1 1/2”bolts, spacer (35-TM30018)
and hardware.
9. Install offset sway bar links (82-TM30029) into
the sway bar mounts (82-TM20042) using the
supplied 3/8” X 2 1/2” bolts and hardware.
3/8” Nylock Nut
3/8” x 1 1/2” Bolt
82-TM20042
Sway Bar Mount
3/8” USS Flat Washer
35-TM30018
Spacer
Sway Bar End
3/8” Nylock
Nut
12. Reinstall the OE front track bar to the front track
bar mount using the previously removed OE bolt
and hardware.
13. If you previously removed the transmission skid
plate, reinstall it using the previously removed
OE hardware.
14. Install the front brake line brackets (35-
TM20021 drvr and TM20022 pass) to the
frame and secure using the provided 5/16” X 1”
bolts and hardware.
15. Secure the OE brake line brackets to the drop
brackets using the previously removed OE hardware.
16. Reinstall the ABS lines to the vehicle using the
previously removed OE hardware.
17. 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.
3/8” x 2 1/2” Bolt
DRIVER SIDE VIEW
FROM FRONT OF
VEHICLE
60859H
OE Bolt
Sleeve
3/8” SAE
Washer
61150 Sleeve
Offset Sway Bar
Link
82-TM30029
Axle
Mount
10. Install the lower end of the sway bar end link to
the front axle mount using the previously removed OE bolt and hardware.
11. Install transfer case drop spacers by supporting
one side of transfer case with floor jack. Re-
18. Reinstall the front wheels and lower the vehicle
to the ground. Torque the lug nuts according to
the wheel manufacturers recommendations.
19. Torque the front arm mounting bolts.
20. 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.
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Add-A-Leaf kit: TM3745-40013 Installation
OE Rear Leaf
Spring
TM3730-60020
Add-a-Leaf
Prepare to Install Rear
Suspension
In order to properly install the add-a-leaf
spring, it will be necessary to contain the elas-
ticity in the leaf spring with “C” clamps when
the center bolts are removed. Some springs
have a factory helper spring consisting of one
or more flat leaves installed at the bottom of
the leaf pack. DO NOT install the add-a-leaf
spring in or below the helper spring.
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.
factory spring mounting bolts and remove the leaf
spring from the driver side only at this time.
8. Hold the leaf spring assembly securely together
with “C” clamp. Spread apart spring leaf alignment
clamps. Remove the spring center bolts. A hammer and drift punch may be used to drive them out
if necessary.
9. Carefully remove “C” clamp and disassemble
the leaf spring.
Install Rear Suspension
Add-a-leaf will be placed in the spring as-
sembly progressively according to length. For
example, if the existing leaves are 32” long and
25” long and the add-a-leaf is 28” long, place
the add-a-leaf between the existing leaves.
3. Unbolt and remove the shocks from both sides
of the vehicle. It may be necessary that you slightly
raise the axle to unload the shocks for removal.
4. Unbolt the rear sway bar end links from the axle
mount. Save the hardware for reuse.
5. Support the rear axle with a floor jack and remove the U-bolts on the driver side. Loosen the Ubolts on the passenger side.
6. Lower the rear axle. Be sure not to over extend
the rear brake line and rear axle vent line.
7. While supporting the rear leaf spring, remove the
1. Insert the add-a-leaf (TM3730-60020). Reclamp and bolt the leaf pack back together using
the supplied center bolts from pack (90-3856)
with the heads of the bolts facing down and the
nut on the top. When you are finished you may
need to trim the excess thread from the center
bolts, so that it does not hit the U-bolt bracket on
top of the leaf springs. Bend the alignment
clamps back around the leave.
2. Assemble the leaf spring rear shackles using
the supplied rear shackles (82-TM20044),
shackle bushings (TM40560), shackle sleeve
(TM30032) and Zerk fitting (90-4303).
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3. Install the rear shackle assembly (82-TM20044)
to the rear spring mount using the OE bolts and
hardware.
4. Install the leaf spring into the new rear shackles
and OE front hangers using the factory hardware. Do not torque at this time.
5. Make sure the pins fit into the holes on the
spring perch. Use your floor jack to raise the
axle to the spring making sure the head on the
factory leaf fit into the holes on the spring perch.
6. Secure the assembly with the OE U-bolts and
hardware. Do not tighten the U-bolts at this
time. Make sure the spring sits flush on the axle
perch. If there is a gap grinding down the heads
of the bolts may be necessary.
7. Repeat the installation on the other side of the
vehicle.
8. When the installation of the remaining side is
complete, torque the U-bolts to 95 ft. lbs. If the
threads are too long you can trim the threads.
9. Install the new rear shocks (TM73265006) to the
OE mounting locations.
10. Reinstall the sway bar end links to the rear axle
using the previously removed OE hardware.
17. On completion of the installation, have the headlights re-aligned.
18. Test drive and note location of steering wheel.
19. Adjust drag link to center steering wheel.
20. Align vehicle as soon as practical to minimum
factory caster and maximum factory toe-in
specifications.
21. After 100 miles recheck for proper torque on all
newly installed hardware.
22. Recheck all hardware for tightness after off road
use.
HIGH SPEED WOBBLE:
This is fairly common with y-type steering on lifted
ZJ's. It is a condition where front tires will shimmy
after hitting a bump. Avoid bias ply tires and wheels
with excessive offset. Check for worn or loose
parts. In most cases a reduction of positive castor
will eliminate this condition. A good rule of thumb is
minimum factory caster and maximum factory toe
in. Note that lift heights increased with coil spacers
(or taller coils) may exhibit wobble that cannot be
corrected with alignment.
11. Install the rear brake line drop (35-TM20023) to
the OE hole in the frame using the previously
removed OE hardware.
12. Reconnect the rear brake line drop (35-
TM20023) using the supplied 5/16” X 1” bolt
and hardware.
13. Reinstall the wheels and tires and lower the vehicle to the ground. Torque according to manufacturers specification. If you are using aftermarket wheels follow the manufacturers recommended specifications.
14. Torque the spring mounts at this time. The front
bolts are torqued to 250 ft. lbs. and the rear
bolts are torqued to 185 ft. lbs.
15. Recheck the wheel lug torque on all four wheels
at this time.
16. Recheck all hardware for proper installation and
torque at this time.
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Rear Leaf Spring kit: TM3745-40023 Installation
TM3745-60020
Rear Leaf Spring
Prepare to Install Rear
Suspension
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 wheels and tires.
3. 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.
4. If your vehicle is equipped with factory sway bar,
unbolt the rear sway bar end links from the axle
mount. Save the hardware for reuse.
into the holes on the spring perch.
5. Secure the assembly with the supplied U-bolts
(TM3730-50050) and hardware. Do not tighten the
U-bolts at this time. Make sure the spring sits flush
on the axle perch. If there is a gap grinding down
the heads of the bolts may be necessary.
6. Repeat the installation on the other side of the vehicle.
7. When th e i nstallation of the rem aining s ide is com plete, torque the U-bolts to 95 ft. lbs.
8. Ins tall the new rear shocks (TM73265006) to the OE
mounting locations.
9. Reinstall the sway bar end links to the rear axle using the previously removed OE hardware.
5. Support the rear axle with a floor jack and remove
the OE U-bolts on the driver side. Slightly loosen
the OE U-bolts on the passenger side.
6. Lower the rear axle. Be sure not to over extend the
rear brake line and rear axle vent line.
7. While supporting the rear leaf spring, remove the
factory spring mounting bolts and remove the leaf
spring from the driver side only at this time.
Install Rear Suspension
1. Assemble the leaf spring rear shackles using the
supplied rear shackles (82-TM20044), shackle
bushings (TM40560), shackle sleeve (TM30032)
and Zerk fitting (90-4303).
2. Install the rear shackle assembly (82-TM20044) to
the rear spring mount using the OE bolts and hardware.
3. Install the new leaf spring (TM3745-60020) into the
new rear shackles and OE front hangers using the
factory hardware. Do not torque at this time.
4. Make sure the pins fit into the holes on the spring
perch. Use your floor jack to raise the axle to the
spring making sure the head on the factory leaf fit
10. Install the rear brake line drop (35-TM20023) to the
OE hole in the frame using the previously removed
OE hardware.
11. Reconnect the rear brake line drop (35-TM20023)
using the supplied 5/16” X 1” bolt and hardware.
12. Reinstall the wheels and tires and lower the vehicle
to the ground. Torque according to manufacturers
specification. If you are using aftermarket wheels
follow the manufacturers recommended specifications.
13. Torque the spring mounts at this time. The front
bolts are torqued to 250 ft. lbs. and the rear bolts
are torqued to 185 ft. lbs. Torque the U-bolts to 120
ft. lbs. If the U-bolt threads are too long you can
trim the threads.
14. Recheck the wheel lug torque on all four wheels at
this time.
15. Recheck all hardware for proper installation and
torque at this time.
16. On completion of the installation, have the headlights re-aligned.
17. Test drive and note location of steering wheel.
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18. Adjust drag link to center steering wheel.
19. Align vehicle as soon as practical to minimum factory caster and maximum factory toe-in specifications.
20. After 100 miles recheck for proper torque on all
newly installed hardware.
21. Recheck all hardware for tightness after off road
use.
HIGH SPEED WOBBLE:
This is fairly common with y-type steering on lifted ZJ's.
It is a condition where front tires will shimmy after hitting
a bump. Avoid bias ply tires and wheels with excessive
offset. Check for worn or loose parts. In most cases a
reduction of positive castor will eliminate this condition.
A good rule of thumb is minimum factory caster and
maximum factory toe in. Note that lift heights increased
with coil spacers (or taller coils) may exhibit wobble that
cannot be corrected with alignment.
WARNING
Re-torque all fasteners after 500 miles and after off
road use. All suspension lift components should be
visually inspected and fasteners re-torqued 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
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.
. Information
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.
Kit Parts List:
TM3745-40013 Kit:
1 BOX ONE: TM3745-40013-1
4 Shackle Bushing, (rear, TM40560)
2 Shackle Sleeve, (rear TM30032)
2 Shackle, (rear, 82-TM20044)
2 Zerk Fitti ng, (rear, 90-4303)
1 Brake Line Drop (drvr, 35-TM20021)
1 Brake Line Drop (pass, 35-TM20022)
1 Brake Line Drop (rear, 35-TM20023)
2 90-TM60005 Hardware bag, (
2 Bolt (5/16” x 1” Gr. 8)
2 Nylock Nut, (5/16”)
4 Hardened Washer, (5/16”)
4 Spacer (T-Case 1”, 90-TM10002)
4 Bolt (M10-1.50 x M60)
4 Flat Washer, (M10)
2 Sway Bar Mount (front, 82-TM20042)
2 Offset Sway Bar Link (front, 82-TM30029)
4 Bushing (Front, 45359)
2 Sleeve (Front, 60859H)
2 Sleeve (Front, 61150)
2 Spacer (Front, 35-TM30018)
1 90-TM60013 Hardware bag,
2 Bolt (3/8” x 1 1/2” Gr. 8)
2 Bolt (3/8” x 2 1/2” Gr. 8)
4 Nylock Nut, (3/8”)
4 SAE Hardened Washer, (3/8”)
2 USS Hardened Washer, (3/8”)
2 Control Arms (Front, 82-TM30011)
1 3.5” Coil Spring (TM3745-60010, front)
1 Add-A-Leaf (TM3730-60020, rear)
1 U-Bolts (Rear, TM3730-50050)
2 Absorber (shock, front, TM73265015)
2 Absorber (shock, rear, TM73265006)
TM3745-40023 Kit:
1 BOX ONE: TM3745-40013-1
1 3.5” Coil Spring (TM3745-60010, front)
1 Leaf Spring (TM3745-60020, rear)
1 U-Bolts (Rear, TM3730-50050)
2 Absorber (shock, front, TM73265015)
2 Absorber (shock, rear, TM73265006)
9
Brake Line Drop)
(Front Sway Bar)
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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