How to Install Tuff Country 2 In. Suspension Lift Kit, EZ-Ride on your 1987-1995 Wrangler

Special Note: This box kit includes the front and rear U-bolts, transfer case drop kit and necessary hardware. The front and rear springs need to be ordered as separate part number. If you have not already ordered your front and rear springs please contact Tuff Country or your local Tuff Country dealer and order (2) TCIY..12F (Front Springs) and (2) TCIYJ2R (Rear Springs).

Congratulations on your selection to purchase a Tuff Country 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.

*Important Notes: Please read before beginning installation. OEM Manual should be used as a reference.

TUFF COUNTRY SUSPENSION highly recommends a qualified and or certified mechanic to perform this installation.

Check off parts to be sure that all parts are on hand. If any parts are missing, Please call us @ (800) 288-2190

Use locktite on all bolts associated with this installation.

Product safety label must be installed inside the cab in plain view of all occupants.

WARNING
If you desire to return vehicle to stock make sure to save all stock components

IMPORTANT CUSTOMER INFORMATION

This vehicle's 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 or 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 customer's responsibility to make sure a re-torque is performed on all hardware associated with this suspension system after the first 100 miles of installation. It is also the customer's responsibility to do a complete re-torque after every 1000 miles or after every off road use.

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

IMPORTANT NOTICE

DO NOT install a body lift in combination with a suspension system. If a body lift is used in conjunction with any Tuff Country Suspension product, your Tuff Country WARRANTY WILL BE VOID.

NOTICE

It is the responsibility of the customer or the mechanic to wear safety glasses at all times when working with air tools.

Please Follow Instruction Carefully

Before installation begins, drive and check to make sure there are not any uncommon sounds and or frame damage. Also at this time measure from the center of the hub to the bottom of 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. 

Driver Side Front ______________________________
Passenger Side Front __________________________
Driver Side Rear ______________________________
Passenger Side Rear __________________________

Front Eng 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 jack stands. Place jack stands on both the driver and the passenger side. Next remove the wheels and tires from both sides. 

2. Working on the driver side, remove the stock hardware from the upper stern mount on the stock shock, discard hardware. Next, remove the tower stock hardware and save hardware for later re-installation. Discard stock shocks. Repeat procedure on passenger side. Longer shocks will be needed after installation is completed. (Shocks not included) 

3. Working on the driver side, remove the stock sway bar end link from the stock location and save for later re-installation. Repeat procedure on passenger side. 

4. Place a hydraulic floor jack under the front axle and raise up until the jack makes contact with the axle. Remove the stock front track bar from the passenger side location and save hardware for later re-installation. 

5. Working on the driver side front spring, remove the stock U-bolts and discard. Next, remove the front and rear spring eye bolts and save for later re-installation. Stock spring may be discarded. 

6. Locate (1) TCW.J2F front leaf spring, install new front spring into stock location and secure using stock hardware. Tighten the spring hanger bolt to 95 ft. lbs, at this point do not tighten the spring shackle bolt, this will be performed once the vehicle is on the ground. Special Note: Before installation of spring, the sleeve and two piece bushings from each end of the spring needs to be removed. (The small spring eyelet does not have a sleeve). Make sure to use a lithium or moly grease prior to inserting bushings back into springs. This will increase the life of the bushing, prevent squeaking, allow springs to flex and give the spring the best ride possible. If lithium base or mole grease is not used problems will occur In the ride of the spring. 

7. Lower down on hydraulic jack until front axle perch seats properly with newly installed spring.. Locate (1) 1/2" x 2 1/2"  x 7" round U-bolt, (1) 1/2" x 3" x 7 1/2" round U-bolt, (4) 112" U-bolt high nuts and (4) 1/2" U-bolt washers. Install new U-bolts into stock location and secure using new high nuts and washers. Torque to 85 ft lbs. Repeat steps 5 -7 on the passenger side. 

8. Install the stock track bar back into the stock location and secure using stock hardware. Torque to 70 ft lbs. Special Note: The stock track bar may not line up with the stock hole. If this is the case the stock track bar may need to be installed when the weight of the vehicle is on the ground. 

9. Install new shocks, shock boots (not included in kit), tires and wheels, Safely lower vehicle to the ground. If the stock track bar was not able to line up to the stock location Perform step # 8 at this point. Also tighten the front spring shackle to 17 ft lbs. If the spring shackle is torqued to tight it will not allow the spring to flex, which will cause ride problems. 

Front End Complete:

Rear End Installation:

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

11. Remove the stock shocks and save hardware for later re-installation. Stock shocks may be discarded. Longer shocks will be needed after installation is completed. (Shocks not included) 

12. Place a hydraulic floor jack under the rear axle and raise up until the jack makes contact with the axle, Remove the stock rear track bar from the passenger side location and save hardware for later re-installation. 

13. Working on the driver side rear spring, remove the stock U-bolts and discard. Next, remove the front and rear sprim eye bolts and save for later re-installation. Stock spring may be discarded.

14. Locate (1) TCIYJ2R rear leaf spring, install new rear spring into stock location and secure using stock hardware Tighten the spring hanger bolt to 95 ft. lbs, at this point do not tighten the spring shackle bolt, this will be performed once the vehicle is on the ground. Special Note: Before Installation of spring, the sleeve and two piece bushings from each end of the spring needs to be removed. (The small spring eyelet does not have a sleeve). Make sure to use a lithium or moly grease prior to inserting bushings back into springs. This will increase the life of the bushing, prevent squeaking, allow springs to flex and give the spring the best ride possible. If lithium base or mole grease is not used problems will occur in the ride of the spring..

15. Lower down on hydraulic jack until rear axle perch seats properly with newly installed spring. Locate (2)1/2' x 2112"  x 7" round U-bolt, (4) 1/2" U-bolt high nuts and (4) 1/2' U-bolt washers. Install new U-bolts into stock location and secure using new high nuts and washers. Torque to 85 ft lbs. Repeat steps 13 - 15 on the passenger side. 

16. Install stock track bar back into the passenger side location and secure using stock hardware. Torque to 70 ft lbs. Special Note: The stock track bar may not line up with the stock hole. If this is the case the stock track bar may need to be installed when the weight of the vehicle is on the ground.

17. Install new shocks, shock boots (not included in kit), tires and wheels. Safely lower vehicle to the ground. If the stock track bar was not able to line up in the stock location in step # 16. Perform step # 16 at this point. Also tighten the rear spring shackle to 17 ft lbs. If the spring shackle is torqued to tight it will not allow the spring to flex which will cause ride problems.

Rear End Complete:

Transfer Case Lowering Kit Installation:

18. Place a jack stand under the transfer case crossmember and remove the six stock bolts that secures the skid plate to the frame. (Three on each side of the skid plate). Stock bolts may be discarded. Ease down on jack so that the skid plate cross member lowers about 1".

19. Locate (6) transfer case sleeves and (6) 1/2" x 3" hex head bolts. Install the new transfer case sleeves between the transfer case crossmember and frame. Secure transfer case crossmember to frame using the 1/2" x 3" hex head bolts and torque to 85 ft lbs. Make sure to use lock tight on the new transfer case bolts and it is highly recommended that a air ratchet is used. If a air gun is used the new bolts may strip. 

See Illustration 1

Congratulations Installation Complete