PART NUMBER : 44905
1997 — 2003 JEEP TJ WRANGLER & RUBICON
4” EZ FLEX SUSPENSION SYSTEM
Part # Description Qty.
TJ4F-CL01 Front Coil Springs 2
TJ4R-CL01 Rear Coil Springs 2
44905-01 Front Track Bar Relocation Bracket 1
44905-02 Rear Track Bar Relocation Bracket 1
44905-03 Shifting Linkage Bracket 1
44905-05 Driver Side Quick Disconnect 1
44905-06 Passenger Side Quick Disconnect 1
44905-07 Front and Rear EZ Flex Control Arms 4
TJ24-03 Rear Sway Bar End Links 2
YJSA-1 Pitman Arm 1
44900NB Hardware Bag 1
44905NB Hardware Bag 1
44905NB1 Hardware Bag 1
44900SL Sleeve Bag 1
44905SL Sleeve Bag 1
44905INST Instruction Sheet 1
Congratulations on your selection to purchase a Tuff
Country EZ-Ride Suspension System. We at Tuff
Country EZ-Ride Suspension are proud to offer a
high quality product at the industries most
competitive pricing. Thank you for your confidence in
us and our product.
For a list of all parts, please refer to the Parts
Description Page, at the end of the Installation
Manual.
Make sure to use thread locker or lock tite on all new
and stock hardware associated with the installation
of this suspension system.
It is the responsibility of the installers to make sure
that the rear view mirror hanger is hung from the rear
view mirror. The rear view mirror hanger has
instructions on proper post installation procedure.
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.
IMPORTANT CUSTOMER INFORMATION
Tuff Country EZ-Ride Suspension highly
recommends that a qualified or a certified mechanic
performs this installation.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware.
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.
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.
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.
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 reinstalled 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.
Tuff Country
IMPORTANT INFORMATION THAT NEEDS TO BE
READ BEFORE INSTALLATION BEGINS:
This suspension system will not fit on the 2003
Jeep’s with automatic transmission. If you have any
questions, please feel free to contact Tuff Country or
one of your local Tuff Country dealers.
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 front and rear shocks.
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.
The new front and rear EZ-Flex control arms are
shipped without any lithium or moly base greased
packed into them. It is the customers or installers
responsibility to make sure that the new front and
rear EZ-Flex control arms are packed with a lithium
or moly base grease before installation. If the new
EX-Flex front and rear control arms are not packed
with a lithium or moly base grease the arms may
wear out and fail. Tuff Country EZ-Ride Suspension
takes no responsibility for not properly packing the
front and rear EZ-Flex control arms. Warranty will be
void if the new EZ-Flex control arms are not packed
with a lithium or moly base grease. If you have any
questions or concerns about packing the new front
and rear EZ-Flex control arms with a lithium or moly
base grease, please do not hesitate to contact Tuff
Country.
Hardware Bag 44900NB Includes:
Description Quantity
M12-1.75 Nylon Lock Nut 1
M10-1.5 Nylon Lock Nut 1
M12-1.75 x 75 MM Bolt 1
M10-1.5 x 75 MM Bolt 1
M12 Flat Washers 2
M10 Flat Washers 2
1/2” Flat Washers 2
3/8” x 1 1/4” Bolt 1
3/8” Flat Washer 4
3/8” Unitorque Nut 1
5/16” x 1 1/4” Bolts 2
5/16” Flat Washers 4
5/16” Unitorque Nuts 2
1/4” x 3/4” Bolts 2
1/4” Flat Washers 4
1/4” Unitorque Nuts 2
1/2” x 3” Flat Head Bolt 6
Hardware Bag 44905NB Includes:
Description Quantity
12 MM x 55 MM Bolts 6
12 MM Flat Washers 6
12 MM Lock Washers 6
1/4” x 3/4” Bolts 2
1/4” Flat Washers 4
1/4” Unitorque Nuts 2
Description Quantity
Front Transfer Case Sleeve 2
Middle Transfer Case Sleeve 2
Rear Transfer Case Sleeve 2
.6875” x .558” x 1.50” Crush Sleeve 5
.625 x .500” x 1.250” Crush Sleeve 1
Hardware Bag 44905SL Includes:
Description Quantity
1.25” x .563” x 1” Crush Sleeve 6
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:__________________________
Please follow instructions carefully:
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 passenger side. Next, remove the tires and
wheels 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 top of the stock
shock from the stock location. The stock upper shock
hardware may be discarded. Remove the stock hardware
that connects the lower shock to the stock location. Save
the stock hardware for later re-installation. The stock
shock may be discarded. Special Note: New longer
front shocks are needed, if you have not already
ordered your front shocks, please contact Tuff
Country or your local Tuff Country dealer and order
the proper shocks. Tuff Country recommends using a
23” fully extended hydraulic shock. Repeat procedure
on the passenger side.
4. Working on the driver side, remove the stock brake
line bracket from the stock location on the frame rail and
save the stock hardware for later re-installation. Repeat
procedure on the passenger side.
5. Working on the driver side, remove the stock sway bar
end link from the stock sway bar and the lower stock
location. The stock sway bar end link may be discarded.
Remove the lower stock sway bar end link hardware and
discard. Repeat procedure on the passenger side.
6. Working on the passenger side, remove the stock
hardware that connects the stock front track bar to the
stock location. Save the stock hardware for later reinstallation.
7. Working on the passenger side, remove the stock
hardware that connect the stock stabilizer to the stock
location. Save the stock hardware for later re-installation.
Special Note: Leave the stock stabilizer attached to
the stock tie rod. Also, if you do not have a stock
stabilizer on the vehicle that you are working on, you
may skip this step.
8. Working on the driver side, remove the stock tie rod
end that connects to the stock pitman arm. Save the
stock hardware that connects the stock tie rod end to the
stock pitman arm for later re-installation. Special Note:
Take special care not to tear or rip the stock tie rod
Remove the stock hardware that connects the
boot.
stock pitman arm to the stock steering box. Save the
stock hardware for later re-installation. Using a pitman
arm puller, carefully remove the stock pitman arm from
the stock steering box. The stock pitman arm may be
discarded.
9. Working on the driver side lower control arm axle
mount, scribe a mark on the stock alignment cams and
reinforcement bracket. This mark will be used as a
reference when installing the new front EZ-Flex control
arms. Repeat procedure on the passenger side.
10. Working on the driver side, remove the stock lower
control arm from the stock front and rear location and
save the stock hardware for later re-installation. The
stock lower control arm may be discarded. Repeat
procedure on the passenger side.
11. Working on the driver side, remove the stock lower
coil spring clip and save the stock lower coil spring clip
and hardware for later re-installation. Repeat procedure
on the passenger side.
12. Carefully lower down on both hydraulic floor jacks at
the same time allowing enough room for the stock coil
springs to be removed and the new coil springs to be
installed.
13. Locate the new front coil springs. Working on the
driver side, install the new front coil springs into the stock
location.
Special Note: Make sure that the new coil
springs seat properly into the lower spring pocket.
Also, the stock bump stop may need to be removed
to make front coil spring installation easier. If you
remove the stock bump stop, make sure to re-install
the stock bump stop back into the stock location
once the new front coil spring has been installed.
Repeat procedure on the passenger side.
14. Locate the stock coil spring clips and hardware that
where removed from step # 11. Working on the driver
side, re-install the stock lower coil clips back into the
stock location. Special Note: Make sure to use thread locker or lock tite. Torque to 15 ft lbs.
15. Carefully raise up on both hydraulic floor jacks at the
same time until the new coil springs seat properly into the
stock upper coil spring bucket.
Special Note: Make sure
that the stock rubber spring isolator pads seat
properly with the stock upper coil spring bucket.
16. Locate (2) new front EZ-Flex control arms.
Special
Note: There is not a difference between the front and
rear EZ-Flex control arms. Remove the (2) half’s of the
front EZ-Flex control arms and pack both ends with a
good amount of moly or lithium base grease. Screw the
front EZ-flex control arms back together and set the
length at 16 1/2” from the center of one eyelet to the
center of the other eyelet.
See Photo # 1
17. Locate (4) 90 degree sert fittings and (2) straight sert
fittings from hardware bag 44905NB1. Carefully install
the sert fittings into the new front EZ Flex arms.
Special
Note: The 90 degree sert fittings need to be installed
in the outer holes and the straight sert fitting needs
to be installed in the middle hole.
See Photo # 2
18. Locate the stock front lower control arm hardware
that was removed from step # 10. Working on the driver
side, install the new front EZ-Flex control arm into the
stock location and secure using the stock hardware.
Special Note: Make sure that when you install the
new EZ Flex control arms that the sert fittings are
pointing upwards. Slight prying of the stock lower
control arm mounts, raising the axle to ride height
and moving it slightly up and down will make for
easier installation. Also, refer the mark that was
scribed in step # 9 and set the stock cam alignment
bolt to the stock settings and torque the stock front
and rear hardware to 90 ft lbs. Repeat procedure on
the passenger side.
See Photo # 3 (Axle Mount)
See Photo # 4 (Frame Mount)
19. Locate the new front track bar relocation bracket.
Also, locate the stock front track bar hardware that was
removed from step # 6 and (1) .625 x .500” x 1.250” front
track bar crush sleeve from hardware 44900SL. Working
on the passenger side, install the new track bar
relocation bracket into the stock track bar pocket. Secure
the new track bar relocation bracket into the stock pocket
using the stock hardware and crush sleeve into the upper
hole of the new track bar relocation bracket.
Special
Note: Make sure to use thread locker or locktite.
Also, do not tighten at this point.
20. Working on the passenger side, make sure that the
new track bar relocation bracket is seating square with
the stock track bar location. Using the new track bar
relocation bracket as a guide, carefully drill a 3/8” hole
into the back side of the stock track bar bracket.
21. Locate (1) 3/8” x 1 1/4” bolt, (2) 3/8” flat washers and
(1) 3/8” unitorque nut from hardware bag 44900NB.
Working on the passenger side, secure the new track bar
relocation bracket to the stock track bar pocket using the
new 3/8” x 1 1/4” bolt and hardware into the previously
drilled hole.
Special Note: Make sure to use thread
locker or lock tite. Torque to 28 ft lbs.
22. Locate (1) 10 mm x 75 mm bolt, (1) 10 mm nylon lock
nut, (2) 3/8” flat washers and (1) 10 mm lock washer from
hardware bag 44900NB. Working on the passenger side,
install the stock front track bar into the new track bar
relocation bracket and secure using the new 10 mm bolt
and hardware. Special Note: Make sure to use thread locker or lock tite. Torque to 32 ft lbs. Once the stock
track bar is into the new passenger side track bar
relocation, the stock upper bolt can be torqued to
32 ft
lbs. Special Note: If you are not able to line up the
hole in the stock track bar and the new track bar
relocation bracket, you will have to perform this step
once the weight of the vehicle is on the ground.
See Photo # 5
23. Locate (2) new front brake line extension bracket
from hardware bag 44905NB1. Also, locate (2) 1/4” x 3/4”
bolts, (4) 1/4” flat washers and (2) 1/4” unitorque nuts
from hardware bag 44900NB. Working on the driver side,
install the new front brake line extension bracket to the
stock brake line bracket and secure using the new 1/4”
hardware. Special Note: Make sure to use thread locker or lock tite. Do not tighten at this point. Repeat
procedure on the passenger side.
24. Locate the stock brake line bracket hardware that
was removed in step # 4. Working on the driver side,
secure the new brake line extension bracket to the stock
brake line bracket location and secure using the stock
hardware. Special Note: Make sure to use thread locker or lock tite. Torque the stock hardware to 15 ft
and torque the 1/4” bolt that was installed in step # 23
lbs
to 15 ft lbs. Repeat procedure on the passenger side.
See Photo # 6
25. Locate (2) 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 front shocks. Tuff
Country EZ-Ride Suspension recommends using a
23” fully extended hydraulic shock. Also, locate (2)
front lower shock clevis mounts, (4) upper shock
grommets and (4) upper shock washers from hardware
bag 44905NB1. Install the new 5/8” lower shock bushing
into the lower eyelet of each shock. The new bushing
should be packaged with your new shocks. Next, install
the new lower clevis mount into the new 5/8” shock
bushing.
Special Note: to make the clevis mount
installation easier, it is highly recommended using a
moly or lithium base grease. Next, install the new
shock boot onto the new shocks and install the new
upper shock grommets and washers.
26. Locate the stock lower shock hardware that was
removed from step # 3. Working on the driver side, install
the new shock into the stock lower location and secure
the lower clevis mount to the stock lower location using
the stock hardware. Special Note: Make sure to use
thread locker or lock tite.
Torque to
15 ft lbs.
Install the
upper shock into the stock upper location and secure
using the stock nut that was supplied in the new shocks.
Torque to 15 ft lbs. Repeat procedure on the passenger
side.
See Photo # 7
(Passenger Side Shown)
27. Locate the stock stabilizer hardware that was
removed from step # 7. Working on the passenger side,
secure the stock stabilizer into the stock location and
secure using the stock hardware. Special Note: Make
sure to use thread locker or lock tite.
Torque to
65 ft
lbs.
28. Locate the new driver side sway bar quick
disconnect.
Special Note: To tell the driver side quick
disconnect from the passenger side quick
disconnect, once installed on the vehicle, the sert
fitting on the bottom of the quick disconnect will be
facing towards the front of the vehicle.
Install the new
driver side quick disconnect to the stock sway bar and
secure using the new hardware. Special Note: Make
sure to install the new tapered sleeve into the stock
sway bar.
Torque upper nut to
procedure on the passenger side.
32 ft lbs.
Repeat
29. Locate (2) lower sway bar mounting studs.
Special
Note: The lower sway bar mounting studs are the
bigger of the two that are in the hardware bag
44905NB1. Working on the driver side, secure the new
lower sway bar mounting studs into the stock lower sway
bar end links location. Torque to 85 ft lbs. Special Note:
When torqueing the lower sway bar mounting stud,
us the new pin for leverage. Repeat procedure on the passenger side.
See Photo # 8
30. Locate (2) large washers and (2) quick disconnect
pins from hardware bag 44904NB1. Working on the
driver side, attach the new sway bar quick disconnect to
the lower stud and secure using the new large washers
and quick disconnect pin. Special Note: To make
installation easier, use a lithium or moly base grease
on the inside of the lower bushing, this will help the
new quick disconnect slid over the lower stud.
Repeat procedure on the passenger side.
See Photo # 9
Follow Step # 31 — 34 to secure the new quick
disconnect out of the way when off roading.
31. Working on the driver side, disconnect the lower eye
let of the quick disconnect. Push the new quick
disconnect towards the front of the vehicle and hold it
against the stock frame rail. Scribe a mark on the side of
the stock frame rail in the center of the bushings.
32. Carefully drill a 5/16” hole in the side of the stock
frame where the mark was scribe in step # 31. Using a
tap wrench and a 3/8” tap, thread the hole in the side of
the frame rail. Special Note: Take special care that the
tap is perpendicular to the frame.
33. Locate (1) quick disconnect securing stud.
Special
Note: The securing stud is the smaller of the two
studs. Secure the securing stud into the side of the stock frame rail. Special Note: Make sure to use thread
locker or lock tite on the stub. Also for easier
installation, use the quick disconnect pin to help
tighten the quick disconnect stud to the side of the
frame rail.
See Photo # 10
34. Once the quick disconnect securing stud is in place,
you can attach the new sway bar end link up and out of
the way. Secure the new sway bar end link with the large
washer and quick disconnect pin to the quick disconnect
securing stud.
See Photo # 11
(Passenger Side Shown)
35. Repeat steps 31 — 34 on the passenger side.
36. Locate the new pitman arm, the stock pitman arm
hardware that was removed in step # 8. Install the new
pitman arm to the stock steering box and secure using
the stock hardware.
Special Note: Make sure to use
thread locker or locktite. Torque to 135 ft lbs.
See Photo # 12
37. Locate the stock tie rod hardware that was removed
form step # 8. Install the stock tie rod to the previously
installed pitman arm a secure using the stock hardware.
Torque to 75 ft lbs.
See Photo # 12
38. Carefully remove both hydraulic floor jacks from
under the front differential.
39. Check and double check to make sure that all steps
for the front end where performed properly. Install the
tires and wheels and carefully lower the vehicle to the
ground.
If you where not able to attach the front track bar to
the newly installed front track bar bracket in step #
22. Perform step # 22 now that the weight of the
vehicle in on the ground.
Congratulations, front end installation complete.
Rear end installation.
40. 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 tires and
wheels from both sides.
41. Place a pair of hydraulic floor jacks under the rear
differential. Place one on the driver side and one on the
passenger side.
42. Working on the driver side, remove the top of the
stock shock from the stock location and save the stock
upper shock hardware. Remove the stock hardware that
connects the lower shock to the stock location. 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 rear shocks, please contact Tuff Country or
your local Tuff Country dealer and order the proper
shocks. Tuff Country EZ-Ride Suspension
recommends using a 26” fully extended hydraulic
shock. Repeat procedure on the passenger side.
43. Working on the driver side, remove the stock sway
bar end link from the stock sway bar and the upper stock
location. The stock sway bar end link may be discarded.
Save the stock hardware for later re-installation.
44. Working on the driver side, remove the stock rear
track bar from the stock location and save the stock
hardware for later re-installation. The stock plastic piece
that wraps around the outer part of the stock track bar
bracket may be discarded.
45. Working on the driver side, remove the stock lower
control arm and save the stock front and rear mounting
hardware for later re-installation. Repeat procedure on
the passenger side.
46. Carefully lower down on both hydraulic floor jacks at
the same time allowing enough room for the stock coil
springs to be removed and the new coils springs to be reinstalled. Working on the driver side, remove the stock
coil spring. Repeat procedure on the passenger side.
47. Locate (2) new rear coil springs, working on the driver
side, install the new rear coil spring into the stock
location. Repeat procedure on the passenger side.
48. Carefully raise up on both hydraulic floor jacks at the
same time, until the new coil springs seat properly into
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