Tuff Country 44001 User Manual

Part # 44001
2007 Jeep JK
4” Suspension system

Parts contained in Box 1 of 2

Part

# Description Qty

.

JK4F-CL01 Front coil springs 2
JK4R-CL01 Rear coil springs 2
44000-05DP DS & PS front quick disconnect

sway bar end links 2
44000-06 DS & PS rear sway bar end links 2
44000-09 Front poly extended bump stops 2
44000-10 Rear poly extended bump stops 2
44000-12 Front 1/2” coil spring spacers 2
44000-13 Rear 1/2” coil spring spacers 2
44000-14 Front extended brake lines 1
44000-15 Rear extended brake lines 1
44000NB2 Hardware bag 1
44000NB3 Hardware bag 1
44000NB4 Hardware bag 1
44001INST Instruction manual (installer copy) 1
44001INST Instruction manual (customer copy) 1

MIRRORHANGER

Rear view mirror hanger 1

WARNINGDECAL

Warning decal 1
DECAL Window sticker 1

Parts contained in Box 2 of 2

Part

# Description Qty.

44000-04 Rear track bar relocation bracket 1
44000-07 Front adjustable track bar 1
44000NB1 Hardware bag 1

Congratulations on your selection to purchase a Tuff
Country EZ-Ride Suspension System. We at Tuff
Country are proud to offer a high quality product at the
industries most competitive pricing. Thank you for
your confidence in us, and our product.

Before installation begins, it is the customers/installers
responsibility to make sure that all parts are on hand.
If any parts are missing, please feel free to call one of
our customer service representatives @ (801)
280-2777.

This box works on the 4 door Jeep JK ONLY. THIS BOX
KIT WILL NOT WORK ON THE 2 DOOR JEEP JK. DO
NOT INSTALL THIS BOX KIT ON THE 2 DOOR JEEP JK,
IF INSTALL OCCURS, YOU WILL RUN INTO REAR
DRIVE LINE PROBLEMS.

Installation manual

4” Suspension system

2007

Jeep JK

Part # 44001

sj031907rev.01

Important customer information:

Tuff Country EZ-Ride Suspension highly recommends
that a qualified and/or certified mechanic performs
this installation.

If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware.

This vehicles reaction and handling characteristics
may differ from standard cars and/or trucks.
Modifications to improve and/or enhance off road
performance may raise the intended center of gravity.
Extreme caution must be utilized when encountering
driving conditions which may cause vehicle imbalance
or loss of control. DRIVE SAFELY! Avoid abrupt
maneuvers, such as sudden sharp turns which could
cause a roll over, resulting in serious injury or death.

It is the customers responsibility to make sure that a
re-torque is performed on all hardware associated with
this suspension system after the first 100 miles of
installation. It is also the customers responsibility to
do a complete re-torque after every 3000 miles or after
every off road use.

After the original installation, Tuff Country EZ-Ride
Suspension also recommends having the alignment
checked every 6 months to ensure proper tracking,
proper wear on tires and front end components. Tuff
Country EZ-Ride Suspension takes no responsibility
for abuse, improper installation or improper
suspension maintenance.

It is the responsibility of the customer or the
mechanic to wear safety glasses at all times when
performing this installation.

It is the customers/installers responsibility to read
and understand all steps before installation begins.
OEM manual should be used as a reference guide.

Make sure to use lock tite on all new and stock
hardware associated with this installation.

The Tuff Country EZ-Ride Suspension product safety
label that is included in your kit box must be installed
inside the cab in plain view of all occupants.

Limited lifetime warranty

Notice to all Tuff Country EZ-Ride Suspension
customers: It is your responsibility to keep your
original sales receipt! If failure should occur on any
Tuff Country EZ-Ride Suspension component, your
original sales receipt must accompany the warranted
unit to receive warranty. Warranty will be void if the
customer can not provide the original sales receipt. Do
not install a body lift in conjunction with a suspension
system. If a body lift is used in conjunction with any
Tuff Country EZ-Ride Suspension product, your Tuff
Country EZ-Ride Suspension WARRANTY WILL BE
VOID. Tuff Country Inc. (“Tuff Country” ) suspension
products are warranted to be free from defects in
material and workmanship for life if purchased,
installed and maintained on a non-commercial vehicle;
otherwise, for a period of twelve (12) months, from the
date of purchase and installation on a commercial
vehicle, or twelve thousand (12,000) miles (which ever
occurs first). Tuff Country does not warrant or make
any representations concerning Tuff Country Products
when not installed and used strictly in accordance
with the manufacturer’s instructions for such
installation and operation and accordance with good
installation and maintenance practices of the
automotive industry. This warranty does not apply to
the cosmetic finish of Tuff Country products nor to
Tuff Country products which have been altered,
improperly installed, maintained, used or repaired, or
damaged by accident, negligence, misuse or racing.
(“Racing is used in its broadest sense, and, for
example, without regards to formalities in relation to
prizes, competition, etc.) This warranty is void if the
product is removed from the original vehicle and
re-installed on that or any other vehicle. This warranty
is exclusive and is in lieu of any implied warranty of
merchantability, fitness for a particular purpose or
other warranty of quality, whether express or implied,
except the warranty of title. All implied warranties are
limited to the duration of this warranty. The remedies
set forth in this warranty are exclusive. This warranty
excludes all labor charges or other incidental of
consequential damages. Any part or product returned
for warranty claim must be returned through the
dealer of the distributor from whom it was purchased.
Tuff Country reserves the right to examine all parts
returned to it for warranty claim to determine whether
or not any such part has failed because of defect in
material or workmanship. The obligation of Tuff
Country under this warranty shall be limited to
repairing, replacing or crediting, at its option, any part
or product found to be so defective. Regardless of
whether any part is repaired, replaced or credited
under this warranty, shipping and/or transportation
charges on the return of such product must be prepaid
by the customer under this warranty.

Important information that needs to be read before
installation begins:

The stock wheels will work in conjunction with this
suspension system but installing a larger tire on the
stock wheels will cause rubbing on the sway bar and
the control arms. Tuff Country recommends when
purchasing new wheels that you purchase wheels with
a 4.5” back spacing. Tuff Country recommends a
35x12.50 tire package. If larger than a 35x12.50 tire is
installed on your vehicle in conjunction with part #
44001; Tuff Country assumes no liability and the
warranty will be VOID. Also, the new JK’s have a
larger braking system, a minimum of a 16” wheel are
required for use in conjunction with the installation of
the suspension system.

This suspension system is designed for minimum off
road use. If you are going to use your vehicle for more
that minimum off road use, Tuff Country EZ-Ride
Suspension highly recommends that the front and rear
drive shafts are changed if your vehicle is going to be
used for off road use. Please contact Tuff Country or
your local Tuff Country dealer and order your new
front and rear drive shafts. Part #’s are: 40800 (front
drive shaft for 2 door and 4 door), 40801 (rear drive
shaft for 4 door only) and 40802 (rear drive shaft for 2
door only).

Tuff Country EZ-Ride Suspension packages (2) sets of
instruction sheets with this box kit. (1) is for the
installer and (1) is for the customer. The (1) for the
customer has some post installation procedure
literature and it is the installers responsibility to make
sure that the customer receives a copy of the
installation manual along with the literature.

Before installation begins, Tuff Country EZ-Ride
Suspension highly recommends that the installer
performs a test drive on the vehicle. During the test
drive, check to see if there are any uncommon sounds
or vibrations. If uncommon sounds or vibrations occur
on the test drive, uncommon sounds or vibrations will
be enhanced once the suspension system has been
installed. Tuff Country EZ-Ride Suspension highly
recommends notifying the customer prior to
installation to inform the customer of these issues if
they exist.

New longer front and rear shocks are needed after this
suspension system has been installed and the front
and rear shocks need to be ordered as a separate part
#. If you have not already ordered your front and rear
shocks, please feel free to contact Tuff Country or
your local Tuff Country dealer and order your new
front and rear shocks. Tuff Country recommends
installing a 26” fully extended nitrogen gas shock in
the front and a 30” fully extended nitrogen gas shock
in the rear.

Hardware bag 44000NB1 includes:

Description

Quantity

1/2” x 1 1/2” bolt 2
7/16” USS flat washer 4
1/2” unitorque nut 2
9/16” x 3” bolt 1
1/2” USS flat washers 2
9/16” unitorque nut 1
BLR06 (brake line relocation bracket) 1
5/16” x 1” bolt 1
1/4” USS flat washer 2
5/16” unitorque nut 1
S10074 (lower shock sleeves) 4
S10153 (cross member sleeves) 3
S10154 (alignment bracket) 4
BP21 (rear shock clevis mount) 2

Hardware bag 44000NB2 includes:

Description

Quantity

S10094 (small QD stud) 2
S10096 (QD pin) 2
S10097 (QD over size washer) 2
S10098 (large QD lock washer) 2
S10099 (large QD jam nut) 2
S10142 (large QD stud) 2
S10143 (12 mm x 70 mm bolt) 2
S10144 (12 mm jam nut) 2
S10145 (12 mm nylock nut) 2
S10146 (9/16” x 1 3/8” special washer) 2
S10147 (3/8” thin jam nut) 2
S10148 (QD “L” bracket) 2

Hardware bag 44000NB3 includes:

Description

Quantity

S10149 (12 mm x 50 mm bolt) 2
S10144 (12 mm jam nut) 2
12 mm flat washer 4

Hardware bag 44000NB4 includes:

Description

Quantity

3/8” x 1” bolt 2
3/8” lock washer 2
3/8” crimp lock nut 2
S10152 (rear spring retaining washer) 2

Special note: Before installation begins, it is the
customers/installers responsibility to make sure that
all parts are on hand. If any parts are missing, please
feel free to call one of our customer service
representatives @ [phone].

Recommended tools selection:

Torque wrench
Standard socket set
Standard wrench set
Metric socket set
Metric wrench set
Tape measure
Hydraulic floor jacks

Torque settings:

5/16” 15—18 ft lbs.
3/8” 28—32 ft lbs.
7/16” 30—35 ft lbs.
1/2” 65—85 ft lbs.
9/16” 85—120 ft lbs.
5/8” 95—130 ft lbs.
3/4” 100—140 ft lbs.

Please follow instructions carefully:

Before installation begins, measure from the center of
the hub, to the bottom of the fender well, and record
measurements below.

Pre-installation measurements:

Driver side front:_______________________________
Passenger side front:___________________________
Driver side rear:________________________________
Passenger side rear:____________________________

At the end of the installation take the same
measurements and compare to the pre-installation
measurements.

Post installation measurements:

Driver side front:______________________________
Passenger side front:__________________________
Driver side rear:_______________________________

Passenger side rear:___________________________

Front end installation:

1. To begin installation, block the rear tires of the vehicle so
that the vehicle is stable and can’t roll backwards. Safely lift
the front of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and the
passenger side. Next, remove the front wheels and tires
from both sides.

2. Place a pair of hydraulic floor jacks under the front
differential. Place one on the driver side and one on the
passenger side.

3. Working on the driver side, remove the stock upper
mounting hardware that connects the stock shock into the
stock location. The stock hardware may be discarded.
Next, remove the stock hardware that connects the stock
shock into the stock lower location and save the stock
hardware for later re-installation. The stock shock may be
discarded. Repeat procedure on the passenger side.

Special Note: New longer front shocks are needed, if
you have not already ordered your new front shocks,
please contact Tuff Country or your local Tuff Country
dealer and order the proper shocks. Tuff Country
recommends using a 26” fully extended nitrogen gas
shock.

Photo # 1
Photo # 2

4. Working on the driver side, remove the stock hardware
that connects the stock track bar to the stock location. Save
the stock hardware for later re-installation. Repeat
procedure on the passenger side.

Photo # 3
Photo # 4

5. Working on the driver side, remove the stock sway bar
end link from the stock axle mount and the stock sway bar.
The stock hardware and the stock end link may be
discarded. Repeat procedure on the passenger side.

Photo # 5
Photo # 6

6. Working on the driver side, remove the stock brake line
bracket hardware that attaches the stock brake line
bracket to the stock frame rail. The stock hardware may be
discarded. Repeat procedure on the passenger side.

Photo # 7

7. Carefully lower down on both hydraulic floor jacks
enough so that the stock coil springs can be removed.

8. Working on the driver side, remove the stock coil spring
from the stock location and discard. Repeat procedure on
the passenger side. Special note: keep the stock spring
isolator in place, we do not want to remove it.

Photo # 8

9. Working on the driver side, remove the stock bump stop
from the stock bump stop cup and discard. Repeat
procedure on the passenger side.

Photo # 9

10. Working on front drive shaft, place a reference mark on
the front drive shaft and the pinion flange. Remove the
stock front drive shaft from the stock front differential and
save the stock hardware for later re-installation. Let the
stock front drive shaft hang.

Photo # 10
Photo # 11

11. Locate the new front bump stops. Working on the
driver side, install the new front bump stop into the stock
location. Repeat procedure on the passenger side. Special

note: using some lithium base grease will help make
installation easier.

Photo # 12

12. Tuff Country offers a 1/2” spacer for the front of vehicles
that have a bigger bumper or a wench so that the vehicle
will sit level. If this is the case on the vehicle that you are
working on, install the 1/2” coil springs spacer on the driver
and passenger side.

13. Locate the new front coil springs, working on the driver
side, install the new front coil spring into the stock location.
Make sure that the new coil spring seats properly into the
lower coil spring seat. Carefully raise up on the hydraulic
floor jack holding the driver side of the front differential until
it reaches ride height. Repeat procedure on the passenger
side.

Photo # 13
Photo # 14

14. Locate the new driver and passenger side brake line

relocation brackets and hardware that are packaged with
the front extended brake lines. Working on the driver side,
secure the new brake line relocation bracket to the stock
location on the frame rail and secure using the new
hardware provided. Repeat procedure on the passenger
side.

15. Locate the new front driver and passenger side
extended brake lines. Working on the driver side, remove
the stock brake line from the stock hard mount and the
caliper. The stock brake line may be discarded. Install the
new brake line to the hard mount and the caliper using the
stock and new hardware provided with the new brake lines.
Repeat procedure on the passenger side. Using some
shock ties, tie the new extend brake lines to the stock ABS
lines. Special note: There is a driver and passenger

side extended brake line, refer to the photo’s to make
sure that you install the driver side extended brake line
on the driver side and the passenger side extended
brake line on the passenger side. Also, after the
completion of the installation, bleed the brake lines
and top off the brake fluid.

Photo # 15 / Photo # 16

Photo # 17

(driver side shown)

16. Locate the stock front drive shaft hardware that was
removed in step # 10. Install the stock front drive shaft back
to the front differential flange and secure using the stock
hardware. Make sure to use thread locker or lock tite and
torque to 30 ft lbs. Special note: Make sure that the

marks line up that were scribed in step # 10.

Photo # 18

17. Locate the stock front track bar mounting hardware that
was removed in step # 4. Also, locate the new adjustable
front track bar and the joint end. Install the joint end in the
new front track bar and adjust the front adjustable track bar
to 33” from center of eye to center of eye. Working on the
driver side, install the new front adjustable track bar to the
stock location and secure using the stock hardware. Make
sure to use thread locker or lock tite and torque to 75 ft lbs.
Next, install the new front adjustable track bar to the
passenger side stock location and secure using the stock
hardware. Make sure to use thread locker or lock tite and
torque to 75 ft lbs. Special note: With the new front

adjustable track bar, fine tuning of the tracking can be
addressed when the vehicle is getting aligned.

Photo # 19

18. Locate (2) S10142 (large QD stud), (2) S10098 (large
QD stud lock washer) and (2) S10099 (large QD stud jam
nut) from hardware bag 44000NB2. Working on the driver
side, install the new large QD stud to the stock lower sway
bar mounting location and secure using the lock washer
and jam nut. Make sure to sure thread locker or lock tite
and torque to 65 ft lbs. Repeat procedure on the
passenger side.

Photo # 20

19. Locate (2) S10148 (QD “L” brackets), (2) S10094 (small
QD stud) and (2) S10147 (3/8” thin jam nut) from hardware
bag 44000NB2. Working on the driver side, remove the
stock body mount nut and install the new “L” bracket using
the stock hardware. Make sure to use thread locker or lock
tite and torque to 75 ft lbs. Now install the small QD stud
to the “L” bracket and secure using the 3/8” thin jam nut.
Make sure to use thread locker or lock tite and torque to 16

ft lbs. Repeat procedure on the passenger side.

Photo # 21

20. Locate the new driver and passenger side sway bars
end links. Also, locate (2) S10096 (QD pins) and (2)
S10097 (QD over size washers) from hardware bag
44000NB2. Working on the driver side, secure the new
sway bar end link to the bottom QD stud and secure using
the over size washer and pin. Repeat procedure on the
passenger side.

Photo # 22

21. Locate (2) S10143 (12 mm x 70 mm bolts), (2) S10145
(12 mm jam nut) and (2) S10146 (9/16” x 1 3/8” washer)
from hardware bag 44000NB2. Working on the driver side,
secure the top of the new end link to the stock sway bar
and secure using the new 12 mm hardware and washer.
Make sure to use thread locker or lock tite and torque to 55

ft lbs. Repeat procedure on the passenger side.

Photo # 23
Photo # 24

22. If you are going to disconnect the sway bar, remove the
pin from the lower QD stud and swing it up to the small stud
and secure using the pin.

Photo # 25

23. Locate the new front shocks. Special note: New
longer front shocks are needed, if you have not already
ordered your new front shocks, please contact Tuff
Country or your local Tuff Country dealer and order the
proper shocks. Tuff Country recommends using a 26”
fully extended nitrogen gas shock. Also, locate the stock

lower hardware that was removed in step # 3. Locate (2)
S10074 sleeve from hardware bag 44000NB1. Install the
new poly bushings and S10074 sleeve into the bottom part
of the new shock. Special note: Make sure to use a

lithium or moly base grease prior to inserting the new
bushings and sleeves into the new lower eyelet of the
new shock. This will increase the life of the bushing as
well as prevent squeaking. Working on the driver side,

install the new shock into the stock lower mounting location
and secure using the stock hardware. Make sure to use
thread locker or lock tite and torque to 65 ft lbs. Now install
the new shock into the stock upper location using the new
hardware provided in the new shock. Make sure to use
thread locker or lock tite and torque to 22 ft lbs. Tuff

Country EZ-Ride Suspension highly recommends that
the shocks are installed with shock boots. If shock
boots are not installed, damage may occur to the
piston of the new shock. Repeat procedure on the

passenger side.

Photo # 26

24. Working on the driver side, remove the stock front lower
control arm from the axle mount and save the stock
hardware for later re-installation. Let the stock front lower
control arm hang from the frame mount. Repeat procedure
on the passenger side.

25. Working on the driver side, remove the alignment knock
outs on the lower control arm axle mount. Repeat
procedure on the passenger side.

Photo # 27

26. Locate the alignment brackets from hardware bag
44001NB1. Working on the driver side, hold (1) alignment
bracket in the slots on the lower control arm axle mount and
scribe a mark where the round hole will be located. Repeat
procedure on the passenger side. Special note: This step

needs to be performed on the inside and outside tabs
on the lower control arm mount.

Photo # 28

27. Working on the driver side and using a dremil tool,
carefully remove the material from the marks that were
scribed in step # 26. Repeat procedure on the passenger
side.

Photo # 29

28. Locate the stock lower control arm hardware that was
removed in step # 24. Working on the driver side, re-install
the stock lower control arm back to the axle mount and
secure using the stock hardware and the new alignment
brackets. Make sure to use thread locker or lock tite and
torque to 95 ft lbs. Repeat procedure on the passenger
side. Special note: Make sure to use the alignment

brackets on the inside and the outside tabs of the lower
control arm mount. Also, make sure that the new
alignment brackets seat properly in the slots of the
stock lower control arm mount.

Photo # 30

29. Locate (3) S10053 (cross member sleeves) from
hardware bag 44000NB1. Working on the driver side,
remove the (2) stock bolts holding the cross member to the
bottom side of the stock frame rail. Save the stock
hardware for later re-installation. Working on the driver
side, remove the (1) stock bolt holding the cross member to
the bottom side of the stock frame rail. Save the stock
hardware for later re-installation. Install the cross member
using the spacer sleeves and the stock hardware into the
stock locations. Make sure to use thread locker or lock tite
and torque all (3) bolts to 55 ft lbs.

Photo # 31
Photo # 32

30. Carefully remove both hydraulic floor jacks from under
the front differential.

31. Install the tires and wheels and carefully lower the
vehicle to the ground.

32. Check and double check to make sure that all steps
were performed properly and check again.

Front end installation complete!

Rear end installation:

33. To begin installation, block the front tires of the vehicle
so that the vehicle is stable and can’t roll forward. Safely lift
the rear of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and
passenger side. Next, remove the wheels and tires from
both sides.

34. Place a pair of hydraulic floor jacks under the rear
differential. Place one on the driver and passenger side.

35. Working on the driver side, remove the stock shock
from the stock upper and lower location and save the stock
hardware for later re-installation. The stock shock may be
discarded. Special note: New longer rear shocks are

needed, if you have not already ordered your new rear
shocks, please contact Tuff Country or your local Tuff
Country dealer and order the proper shocks. Tuff
Country recommends using a 30” fully extended
nitrogen gas shock. Repeat procedure on the passenger

side.

Photo # 33
Photo # 34

36. Working on the driver side, remove the stock sway bar
end link from the stock upper and lower location. The stock
end link and the stock upper mounting hardware may be
discarded. Save the stock lower mounting hardware for
later re-installation. Repeat procedure on the passenger
side.

Photo # 35
Photo # 36

37. Working on the driver side, remove the clip that
connects the ABS line to the upper control arm mount.
Repeat procedure on the passenger side.

Photo # 37

38. Working on the driver side, remove the stock brake line
bracket from the frame mount location. The stock hardware
may be discarded. Repeat procedure on the passenger
side.

Photo # 38

39. Locate the new driver and passenger side brake line
relocation brackets and hardware that are packaged with
the rear extended brake lines. Working on the driver side,
secure the new brake line relocation bracket to the stock
location on the frame rail and secure using the new
hardware provided. Repeat procedure on the passenger