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Topic: How To: Rusty's 2" spacers/AAL install

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How To: Rusty's 2" spacers/AAL install

So forever I've been paranoid about getting a lift.  I've always wanted one, but scared of the driveline vibes and stuff I've debated within myself :touche: and finally one day, I decided to get an alignment.  They said my trackbar was no good.   I could get a factory type one put in for about $200, or I could get a JKS adjustable tracbar (for 2-4" of lift if I remember right) for a little more.

I order that, and while thinking about a Rubicon Express 2" bb since I talked to a guy who had one and he really liked it, I found a Rusty's kit here I got for $95 shipped.

Later I found that I had leaky axle seals in the Dana 35, so it was good that I put the lift on when I did, despite my dad's supportive "you don't need a lift, leave it alone, it'll be unstable" words.  If I had taken that advice, I would probably not know that the axle seals were leaky, and chances are would think that the sucky brakes is just because it's a little truck, and they're a far cry from the Grand Am and Saturn SC2 (the sporty ones, the '1' cars are slow) I had before.  Enjoy.

Pics 1 and 2: It feels like Christmas!



Inside the box from the fellow forum member (he sold his XJ before installation)


Inside the JKS box (if you lose instructions, they are available at their website)

...at my girlfriend's house... I put the coil compressors (rent them from import zone:devbug: ) on before lifting the Jeep.  This saves a lot of time.  It helps to have the wheels turned one way, and then the other for each spring compressor.  A 3/4 inch wrench turned those bolts, and it takes a long time.  Good bicep builder though.


I couldn't get these bolts out for the life of me... yup I did the 1 week dailly wd40 soak.



So I dropped the shocks from the upper mounts!  The shocks dropped right out with the swaybar disconnected, and I put my girlfriend to use guiding the shocks back into place while I jacked the axle up (Jeep supported by jackstands) and reinstalled bolt, bushing, and washers.  I left the swaybar undone until the other side was finished.



I disconnected the swaybar for more flex, the torx bolt looks retarded and when I get something to get that stupid thing out, I'm going to lengthen the swaybar links and do a manual quick disconnect setup with hitch pins and stuff.  You can tell that they're a bit short at 2" of lift!  I have new bushings but I'm not using them until the aforementioned things are finally done.


This is at full droop, make sure you install the pucks with the little u-shape down so the spring sits up in there nicely.  Before removing the coils, there's a little clip and a bolt that was a pain to get undone.  Make sure you wd40 soak that too!

The coil retainer clip is a little above the wd40 soaked lower shock bolts.


I repeated everything for the other side of the Jeep, and got started on the rear.  It started to rain right as I was starting on it, so I cleaned up really quick and decided to finish the rest at home.  Besides, the gf wanted me inside, so all the signs seemed to say "go inside".:)

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1996 XJ "Snowball"- 3.5" lift, bunch of little mods.  I hate pegleg rear axles!
1974 AMC Javelin "Jade Grenade"- 360v8, 4sp, green inside and out. Underfunded Project.
2009 Kawsaki Vulan 900 "Rocket III"- Summer DD

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...at home... with dad's help so he could get his 'outdoor-phobic' cute-ute in the garage.:idmo:
Support the rear of the Jeep on jackstands, and I supported the axle with just the jack. The ubolts were a PAIN to get off, if I knew how hard it would be, I would have gotten new ones and cut off the old. Stock size ubolts work for the Rusty's AAL, not sure about others. To get the shocks off, support the axle and remove the single nut on the lower part, and work it off from there. To reinstall, jack axle to same height as the hole in the shock, and slide it on. Using a rubber hammer or other 'soft' means to get the shock in place helps a lot. I left the main spring in place and the rest of the pack dropped right out after removing the old bands (I hacked away with a chisel and hammer, use a cutoff wheel instead, it'll go a lot quicker). I installed the AALs according to overall length, as per instructions. I've read someplace that they got rid of the littlest leaf, but I kept it. The big hammer was used to try to tap the stud out of the leafs, I ended up using a punch with a smaller hammer. Tapping with a sledge is really difficult. After reinstalling the leaf pack, use c-clamps to hold the whole thing together, and use a hammer to get everything aligned, then bend (I used a hammer and a vise grip) to put the new bands on. For the driver's side I didn't let the axle droop all the way since we have these things called brake lines. I used a prybar to hold the main spring up while a helper set the rest of the pack in place.

Stock leaf pack about to come out... ubolts out and axle dropped... shock still in place.


AAL and rest of spring pack with old stud (just for pics)


Afterwards I had the tracbar installed plus an alignment and balancing, which came to about $102.00:) Final pics, on stock size rubber.

before lift...

after lift...



I have a little vibrations every so often, nothing to worry about, and nothing my gf complained about. Except when going about 65mph it vibes just right so that something, somewhere (maybe the junk in the glovebox) rattles horribly. It smoothes out by 70, but I don't really like to take it over 65... it's a truck, which reacts a lot differently than a car. The blisten shocks that are of unknown age work great, and the ride is just a tad firmer out back, and it's stock up front. Maybe with a 3" AAL it would ride like a Radio Flyer on a dirt road, but not with the 2". I'm happy with it, and wonder if wedges would help with the vibes at highway speeds.

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My Fleet
1996 XJ "Snowball"- 3.5" lift, bunch of little mods.  I hate pegleg rear axles!
1974 AMC Javelin "Jade Grenade"- 360v8, 4sp, green inside and out. Underfunded Project.
2009 Kawsaki Vulan 900 "Rocket III"- Summer DD

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RE: How To: Rusty's 2" spacers/AAL install

Looks good Matt!

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looks great man, nice of you to join us in the lifted club!

oh and i also wanted to add what a nice job you did with the writeup and pics! keep up the great work and look forward to you next mod

-- Edited by lazarus at 02:04, 2007-06-17

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How To: Rusty's 2" spacers/AAL install

Thanks! I'd like to put it all together into a book someday, along the lines of the High-performance XJ builder's guide that's out there (I have a copy too), but put more emphasis budget strokers, cooling system mods (electric fans, tranny coolers...) It'll probably be a while though.

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My Fleet
1996 XJ "Snowball"- 3.5" lift, bunch of little mods.  I hate pegleg rear axles!
1974 AMC Javelin "Jade Grenade"- 360v8, 4sp, green inside and out. Underfunded Project.
2009 Kawsaki Vulan 900 "Rocket III"- Summer DD

 
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