WARNING
400 W. Artesia Blvd. Fax: (310) 747-3912
Compton, CA 90220 Ph: (877) 695-7812
www.trailmastersuspension.com
JEEP CHEROKEE (XJ) 3” SPRING KIT
‘84- ’01 TM3730-40013 w/ Rear Add-A-Leaf &
TM3730-40023 w/ Rear 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 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.
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
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.
OE Coil
Spring
Install Front Suspension
1. Carefully lower the front axle to ease in the new
coil spring installation. Using the factory isolators install the coil springs (TM3730-60010) into
the spring buckets
3. Disconnect the track bar from the axle and save
the hardware for reuse.
4. Using the appropriate tool, disconnect the steering linkage from the pitman arm and save the
hardware for reuse.
5. Unbolt the front sway bar end links from the
axle. Save the hardware for reuse.
6. Unbolt and remove the shocks from the vehicle.
Save the hardware for reuse.
7. Unbolt and remove the coil spring retainers from
the bottom of the spring.
8. Unbolt the brake line from the inner fender well
and straighten the Z-Shaped bend to the lower
hose.
9. 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.
2. 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).
TM373060010 Front
Coil Spring
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3. Now would be a good time to inspect the front
shocks for damage or fluid leakage. Replace if
necessary.
Prepare to Install Rear
Suspension
4. Re-attach brake hose to inner fender well using
the previously removed OE hardware..
5. Reinstall the steering linkage to the pitman arm
using the previously removed hardware.
6. Re-drill front track bar axle bracket over toward
drivers side ¾”, center-to- center.
7. Reinstall the front track bar to the newly drilled
hole in the axle using the previously removed
hardware.
8. Reinstall the sway bar end links to the axle
mounts using the previously removed hardware.
9. Reinstall the wheels and lower the vehicle to the
ground. Torque the lug nuts to factory specifications.
10. Torque all bolts to factory specifications. Retorque all bolts after 500 miles.
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.
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. Hold the 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.
7. Carefully remove “C” clamp. Lower axle, disassemble leaf spring.
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Add-A-Leaf kit: TM3730-40013 Installation
OE Rear Leaf
Spring
TM3730-60020
Add-a-Leaf
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.
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. 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.
5. 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.
6. Install the new rear shocks (TM73225010) to the
OE mounting locations.
7. Reinstall the sway bar end links to the rear axle
using the previously removed OE hardware.
8. 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.
9. Recheck the wheel lug torque on all four wheels
at this time.
10. Recheck all hardware for proper installation and
torque at this time.
11. On completion of the installation, have the headlights re-aligned.
12. Test drive and note location of steering wheel.
13. Adjust drag link to center steering wheel.
3. 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.
4. Repeat the installation on the other side of the
vehicle.
14. Align vehicle as soon as practical to minimum
factory caster and maximum factory toe-in
specifications.
15. After 100 miles recheck for proper torque on all
newly installed hardware.
16. Recheck all hardware for tightness after off road
use.
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Rear Leaf Spring kit: TM3730-40023 Installation
TM3730-60030
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 it from the rear axle
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
3. 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.
4. Repeat the installation on the other side of the
vehicle.
5. When the installation of the remaining side is
complete, torque the U-bolts to 95 ft. lbs.
6. Install the new rear shocks (TM73225010) to the
OE mounting locations.
7. Reinstall the sway bar end links to the rear axle
using the previously removed OE hardware.
8. 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.
9. 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 Ubolts to 120 ft. lbs. If the U-bolt threads are too
long you can trim the threads.
1. Install the new leaf spring (TM3730-60030) to
the hangers using the factory hardware. Do not
torque at this time.
2. 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.
10. Recheck the wheel lug torque on all four wheels
at this time.
11. Recheck all hardware for proper installation and
torque at this time.
12. On completion of the installation, have the headlights re-aligned.
13. Test drive and note location of steering wheel.
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14. Adjust drag link to center steering wheel.
WARNING
15. Align vehicle as soon as practical to minimum
factory caster and maximum factory toe-in
specifications.
16. After 100 miles recheck for proper torque on all
newly installed hardware.
17. Recheck all hardware for tightness after off
road use.
After Completing Installation
Engine Compartment
1. Connect both battery cables. Connect positive
cable first, then negative cable.
Miscellaneous
1. Adjust headlights.
2. Check all fasteners to ensure they are tight.
3. Ensure all wires, hoses, cables, etc. are prop-
erly
connected and there is ample slack.
4. Align vehicle to OE specifications. Retain align-
ment
results.
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.
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.
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Kit Parts List:
TM3730-40013 Kit:
1 3” Coil Spring (TM3730-60010)
1 Add-A-Leaf (TM3730-60020)
1 90-3856 Hardware bag, (Add-A-Leaf)
2 Bolt (5/16” x 5” Gr. 8)
2 Bolt (3/8” x 5” Gr. 8)
2 Hex Nut, (5/16”)
2 Hex Nut, (3/8”)
2 Absorber (shock, front, TM73245011)
2 Absorber (shock, rear, TM73225010)
TM3730-40023 Kit:
1 3” Coil Spring (TM3730-60010)
2 Rear Leaf Spring (TM3730-60030)
1 Rear U-Bolts (TM3730-50050)
2 Absorber (shock, front, TM73245011)
2 Absorber (shock, rear, TM73225010)
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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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