How to Install Zone Offroad Front Adjustable Track Bar for 1-3.5 in. Lift (97-06 Wrangler TJ) on your Jeep Wrangler

CONGRATULATIONS on purchasing a new Adjustable 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.

Important

NOT COMPATIBLE WITH right hand drive vehicles.

CHECK TORQUE SPECIFICATIONS regularly.

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 9/16” drill bit, enlarge the tapered mounting hole in the chassis rail bracket located on the driver-side of the vehicle.

Locate the Chassis End (D) of Adjustable Trackbar and insert the 9/16” x 4-1/2” Bolt (E) through the spherical bushing.

Place the Tapered Split Cone (K) over the bolt threads with the narrow end facing away from the trackbar.

Apply anti-seize lubricant to bolt threads.

Mount chassis end of Adjustable Trackbar to chassis rail bracket by inserting the

9/16” x 4-1/2” Bolt (E) upwards into enlarged hole. Secure with 9/16” Flat Washer – only if required – () and 9/16” Ovalok Nut (M).

IMPORTANT: Flat Washers are supplied for use with 1984-01 Cherokee XJ and 1993-1998 Grand Cherokee ZJ models ONLY. Do NOT use Flat Washer on Wrangler TJ models.

HINT: Tapered Split Cone (K) should be located between flange of spherical bushing (G) and mounting surface of chassis rail bracket, with the narrow end of tapered cone facing up towards chassis.

Tighten 9/16” x 4-1/2” bolt (E) to 110 ft-lb. using a torque wrench.

IMPORTANT: The upper flange of spherical bushing must fit flush against the chassis rail bracket. If any gap exists, it will be necessary to file the bottom edge of the Tapered Split Cone until completely flush with bottom of 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

IMPORTANT: The length of the Adjustable Trackbar must be set with the 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 rubber bushing aligns with the mounting holes on the axle bracket.

Install Axle End (B) of Adjustable Trackbar to the axle bracket by securing with the original mounting bolt and flag nut. Apply anti-seize lubricant to bolt threads.

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

Check the Chassis End (D) 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 (C).

Tighten original mounting bolt on axle bracket to 50 ft-lb. using a torque wrench.

5. LUBRICATE ADJUSTABLE TRACKBAR

Lubricate the the chassis end of Adjustable Trackbar through the side grease fitting using a non-petroleum based gease.

Maintenance

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 polyurethane bushing which is both greaseable and rebuildable. Lubricate the bushing via the grease fitting on the side of the housing regularly as part of vehicle maintenance schedule.

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