How to Install a JKS Front Adjustable HD Trackbar on your 1997-2006 Jeep Wrangler TJ

CONGRATULATIONS on purchasing a new Adjustable HD Trackbar from JKS Manufacturing. We are committed to providing you with the best products available and your satisfaction is our first priority.

PLEASE READ these Installation Instructions carefully, and save them for future reference, as they contain important installation and maintenance information.

NOT COMPATIBLE WITH right hand drive vehicles.

RE-TORQUE ALL FASTENERS after driving 150 miles.

CHECK TORQUE SPECIFICATIONS as part of normal vehicle maintenance.

1. REMOVE ORIGINAL EQUIPMENT (OE) FRONT TRACK BAR

 Remove front track bar and mounting hardware per the factory service manual instructions for your vehicle. HINT: If difficult to remove, use universal puller tool to separate OE track bar ball stud from chassis rail bracket.

2. MOUNT ADJUSTABLE TRACKBAR TO CHASSIS BRACKET

 Using a 5/8” drill bit, enlarge the tapered mounting hole in the chassis rail bracket located on the driver-side of the vehicle.

 Locate Chassis End (A) of Adjustable Trackbar and insert the 5/8” x 4-1/2” Bolt (H) through the Flex Joint Ball (K).

 Apply anti-seize lubricant to bolt threads.

 Mount chassis end of Adjustable Trackbar to chassis rail bracket by inserting the 5/8” x 4-1/2” Bolt (H) upwards into enlarged hole. Secure with 5/8” Locking Nut (M).

Tighten the 5/8” x 4-1/2” Bolt (H) to 135 ft-lb. using a torque wrench.

IMPORTANT: Upper flange of spherical bushing must fit flush against the chassis rail bracket.

3. CENTER FRONT AXLE HOUSING

The front axle housing must be in perfect lateral alignment with vehicle chassis before Adjustable Trackbar installation can be completed.

 Before you center the axle housing, make sure the vehicle is at normal ride height, on level ground, with the suspension supporting the full vehicle weight.

 Determine if the axle housing is centered by measuring the distance between the tire and chassis, using the exact same points on each side of the vehicle to ensure accuracy.

HINT: For example, measure from the edge of a tire tread lug to the outboard side of the chassis, then repeat the measurement on the other side of vehicle using the exact same points.

If the two measurements are equal, the axle is centered. If the measurements vary, divide the difference in half to determine the amount of adjustment required. HINT: If the axle housing is not centered, the chassis can be laterally shifted using either of the following methods.

Ratchet Strap (preferred)

 Attach a heavy duty ratchet strap to the chassis on one side of the vehicle, and to the axle housing on the other side.

 Tighten the strap in small increments to pull the chassis in alignment with the axle.

 Take measurements after each adjustment until centered.

Steering Wheel

 Have a partner turn the steering wheel in small increments to shift the vehicle chassis side-to-side.

 After each adjustment, have your partner hold the steering wheel steady while you take measurements.

4. SET ADJUSTABLE TRACKBAR LENGTH AND MOUNT TO AXLE 

 Using a 1/2” drill bit, enlarge the original mounting hole on the factory axle bracket.

IMPORTANT: Length of Adjustable Trackbar must be set with axle housing perfectly centered and the vehicle at normal ride height.

 With the axle housing centered beneath the chassis, adjust the length of Adjustable Trackbar by rotating the axle end until the bushing aligns with the mounting holes on the axle bracket.

 Apply anti-seize lubricant to threads of 1/2” x 2-1/2” Bolt (D). 

 Install Axle End (C) of Adjustable Trackbar to the axle bracket and secure with 1/2” x 2-1/2” Bolt (D) and 1/2” Flanged Locking Nut (G).

 Take measurements again to ensure axle housing is perfectly centered and make any final adjustments if necessary.

 Check the Chassis End (A) of Adjustable Trackbar to ensure it is aligned with the chassis rail bracket. If necessary, rotate fore/aft until the space between the trackbar and chassis rail bracket is even.

IMPORTANT: The Chassis End of Adjustable Trackbar must be in the “neutral” position (as illustrated above) before the Jam Nut is tightened.

 Once all adjustments are complete, fully tighten the Jam Nut (B) to prevent Adjustable Trackbar length from changing. HINT: It may be easier to tighten Jam Nut with the Adjustable Trackbar removed from the vehicle.

 Tighten the 1/2” x 2-1/2” Bolt (D) on axle bracket to 65 ft-lb. using a torque wrench.

5. LUBRICATE ADJUSTABLE TRACKBAR

 Lubricate the Grease Zerk (N) at the chassis end of Adjustable Trackbar using common wheel bearing grease or equivalent.

Re-torque fasteners after driving 150 miles. Continue to check torque specifications as part of regular vehicle maintenance routine.

The chassis end of the Adjustable Trackbar features a spherical Nylatron bushing which is greaseable, adjustable and rebuildable.

Lubrication

Lubricate the bushing via the Grease Zerk (N) regularly as part of vehicle maintenance schedule. Use common wheel bearing grease or equivalent.

Bushing Preload

The spherical Flex Joint is factory preloaded to 15 ft-lbs. and no adjustments are necessary at time of installation. In the unlikely occurrence that the bushing begins to loosen up over time, the user can tighten the Preload Ring (I) to eliminate any slop.

To adjust bushing preload, first remove the Set Screw (O) to unlock the Preload Ring (I). Then tighten the Preload Ring to 15 ft-lbs. using a torque wrench. Re-install the Set Screw to lock the Preload Ring.

JKS strongly recommends the use of Flex Joint Tool # SM-FJL-TOOL to adjust the Preload Ring (I). This special spanner socket is available directly from Summit Machine by calling (801) 576-8424.

Replacement Parts Flex Joints are designed for maximum longevity and it is extremely unlikely that any parts will wear out. Just in case, all replacement parts are available directly from JKS Manufacturing on our website at www.jksmfg.com.

Cleaning

Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability. Always lubricate afterwards to evacuate any moisture.