JKS JKSOGS960 User manual

JKSOGS960 /JKSOGS962JKS Steering Brace System Installation Page 1
INSTALLATION
INSTRUCTIONS
Product: Steering Brace System™
Part Number: JKSOGS960 - JKSOGS962
Applications: Jeep® Cherokee XJ, 1984-01
Welcome
CONGRATULATIONS on purchasing a new Steering
Brace System from JKS Manufacturing. We are committed
to providing you with the best products available and your
satisfaction is our rst priority.
READ INSTRUCTIONS THOROUGHLY to familiarize
yourself with the required skills and tools BEFORE at-
tempting installation.
Important
INSTALLATION REQUIRES WELDING to the unibody
chassis by a qualied welder or metal fabricator. A
bolt-on installation is not possible for this product.
CHECK STEERING GEAR TORQUE SPECS on a regu-
lar basis.
Tools Required
Metric/Standard Socket Wrench Set
Torque Wrench
Die Grinder with Sanding/Grinding Wheels
(or similar tool for cleaning chassis)
5/8” Drill Bit, or preferably a Uni-bit
(for enlarging holes in chassis)
Carbide Cutting Tool *
(for enlarging holes in chassis)
3/4” Drill Bit (for new tow hook holes)
C-clamp or Locking Pliers
Hammer *
Factory Service Manual (recommended)
Welding Equipment
Satin Black Spray Paint
* Asterisk denotes tools that are not required for some applica-
tions. Thoroughly read instructions rst to determine which tools
will be required for your application.
Parts
Description QTY
AOuter Chassis Plate (3/16”) 1
BInner Chassis Plate (1/8”) 1
CSupport Sleeves 3
DSteering Gear Mounting Bolts 3
EFlat Washers 3
FInstallation Spacers 3
GTow Hook Support Bracket 1
H3/4” Solid Rod 1
ATTENTION INSTALLER
Review front bumper re-installation
section on page 5 BEFORE installing
product.
517-278-1226 • [e-mail] • www.jksmfg.com
491 W. Gareld Avenue, Coldwater, MI 49036

JKSOGS960 /JKSOGS962 JKS Steering Brace System Installation
2 Page
ATTENTION INSTALLER
IMPORTANT NOTE REGARDING
DUAL STEERING BRACE SYSTEM
The following instructions refer to installation of a
single Steering Brace System (PN OGS960) on the
driver-side chassis rail only. For a dual Steering Brace
System (PN OGS962), the additional parts should be
installed on the passenger-side chassis rail using the
same procedures.
NOTE: Some vehicles are factory equipped with
steering gear mounting holes on both chassis rails.
Otherwise, it will be necessary to drill new holes on
the passenger-side chassis rail to accommodate the
supplied Support Sleeves.
Installation
1. PREPARE DRIVER-SIDE CHASSIS RAIL
ZThe following items must be removed from the
chassis rail, along with any other components that
prevent the Chassis Plates (A & B) from tting
ush against mounting surface. Refer to factory
service manual for specic instructions.
ÂTow Hook & Bracket
ÂLower Radiator Support Bracket
ÂFront Swaybar
ÂFront Bumper & Bracket
ZUnbolt the steering gear and adapter plate from
the chassis. Temporarily secure the steering gear
out of the way – it should not be necessary to
disconnect uid lines or steering shaft. Discard
steering gear adapter plate.
ZTest t the Inner and Outer Chassis Plates (A & B)
to the chassis rail. Mark an outline of each plate
onto chassis surface.
ZCompletely remove all paint/primer, weld slag/
spatter, or other debris from chassis surface
(inboard and outboard side) until bare metal is
exposed.
HINT: A die grinder with sanding wheel, disc
sander, or similar tool is useful for cleaning chas-
sis surface.
ZTest t the Inner and Outer Chassis Plates (A &
B) again to check for ush tment against chassis
surface, and to ensure all debris has been re-
moved from the necessary areas.
2. ENLARGE STEERING GEAR MOUNTING
HOLES IN CHASSIS
ZLocate the three (3) steering gear mounting holes
on the inboard and outboard side of chassis rail.
ZEnlarge the inboard and outboard mounting holes
to approximately 5/8” – or until narrow end of Sup-
port Sleeves (C) can be inserted.
HINT: A uni-bit (step-drill bit) is useful for enlarging
holes to 5/8” – and more eective on the unibody
chassis than standard drill bits. A pneumatic die
grinder or dremel tool with carbide cutting attach-
ment (shown) is also eective, particularly where
clearance is limited.

JKSOGS960 /JKSOGS962JKS Steering Brace System Installation Page 3
3. WELD SUPPORT SLEEVES & CHASSIS
PLATES TO FRAME
ZPosition Inner Chassis Plate (B) against inboard
side of chassis.
ZInsert Support Sleeves (C) into steering gear
mounting holes from inboard side of chassis. Once
inserted, shoulder of Support Sleeves will hold
Inner Chassis Plate (B) in place. HINT: A hammer
may be needed to tap Support Sleeves into mount-
ing holes.
ZInsert the 3/4” Solid Rod (H) into large hole in
chassis rail. Refer to Hole Identication Diagram
on page 1 for assistance. HINT: The 3/4” Solid
Rod lls a factory tow hook support bracket hole
and ties the Inner and Outer Chassis Plates to-
gether during the welding portion of installation.
ZPosition and align the Outer Chassis Plate (A)
against the outboard side of chassis. HI NT: Sup-
port Sleeves (C) should protrude through large
holes in Outer Chassis Plate (A), but need not
be in perfect alignment as any voids surrounding
holes will be lled when welded.
ZPlace the supplied Installation Spacers (F) on the
Steering Gear Mounting Bolts (D) and temporar-
ily insert bolts into Support Sleeves (C) from the
outboard side of chassis. HINT: Recessed side of
Installation Spacer (F) should face Outer Chassis
Plate (A).
ZPosition steering gear against the inboard side of
chassis and align with mounting holes.
ZThread Steering Gear Mounting Bolts (D) into
steering gear and lightly snug bolts. Make sure
both Chassis Plates (A & B) remain aligned and
ush with chassis surface.

JKSOGS960 /JKSOGS962 JKS Steering Brace System Installation
4 Page
ZTack-weld all three (3) Support Sleeves (C) to the
Outer Chassis Plate (A).
ZWorking with one mounting hole at a time, remove
a Steering Gear Mounting Bolt (D) and nish weld-
ing the Support Sleeve (C) to the Outer Chassis
Plate (A), making sure any voids are completely
lled.
ZAfter Support Sleeves (C) have been welded to the
Outer Chassis Plate (A), secure the steering gear
out of the way to gain access to the Inner Chassis
Plate (B).
ZWeld the shoulder of all three (3) Support Sleeves
(C) to the Inner Chassis Plate (B).
ZRosette weld Inner and Outer Plates (A & B) to
chassis at each slotted hole. Although not neces-
sary, Chassis Plates may also be stitch-welded
along edges for additional support. HINT: For
cleanest appearance, slotted holes can be lled
completely and sanded smooth.
ZRosette weld the 3/4" Solid Rod (H) to Inner and
Outer Chassis Plates (A & B).
ZOnce welding is complete, grind any protruding
portion of the Support Sleeves (C) on outboard
side of chassis until completely ush with Outer
Chassis Plate (A).
ZRemove any other protrusions from surface of In-
ner and Outer Chassis Plates (A & B) until smooth
and completely at. HI NT: A power sanding/grind-
ing wheel or similar tool is useful for smoothing
chassis.
4. MOUNT TOW HOOK BRACKET
ZPosition the Tow Hook Support Bracket (G) against
the underside of chassis rail with the slotted holes
facing up. Clamp the non-slotted side of bracket to
the Outer Chassis Plate (A).

JKSOGS960 /JKSOGS962JKS Steering Brace System Installation Page 5
ZWeld edges and bottom seam of Tow Hook Sup-
port Bracket (G) to Outer Chassis Plate (A).
ZRosette weld slotted holes of Tow Hook Support
Bracket (G) to underside of chassis rail.
ZOnce all welding and nal sanding/grinding is com-
plete, any bare metal must be painted to prevent
corrosion. There should be no exposed metal vis-
ible when painted properly.
5. MOUNT STEERING GEAR TO CHASSIS
ZPlace a Flat Washer (E) on each Steering Gear
Mounting Bolt (D) and insert bolts into Support
Sleeves (C) from the outboard side of chassis.
ZPosition steering gear against the inboard side of
chassis and align with mounting holes.
ZThread bolts into steering gear and tighten to 55-
60 ft-lb. using a torque wrench.
6. RE-INSTALL RELATED COMPONENTS
ZRe-install radiator support bracket to original
mounting location. Enlarge the upper mounting
holes of support bracket if they don’t line up.
ZRe-install front swaybar to original location.
ZInstall original tow hook on vertical surface of Tow
Hook Support Bracket (G) where welded to the
Outer Chassis Plate (A). Drill new mounting holes
using a 3/4” drill bit and install tow hook using
original mounting hardware.
ATTENTION INSTALLER
READ BEFORE INSTALLING
Additional modications may be necessary
to re-install the front bumper to the reinforced
chassis. Once installed, the Chassis Plates
(A & B) increase the overall width of the
chassis rail, which may prevent the bumper
mounting brackets from tting as intended.
ZReview each of the following options BEFORE
determining the best conguration for your applica-
tion.
ZTRIAL FIT the parts to familiarize yourself with any
installation complications.
ZOPTION 3 requires pre-installation modications
to the Outer Chassis Plate, and is only suggested
if OPTIONS 1 & 2 are not possible.

JKSOGS960 /JKSOGS962 JKS Steering Brace System Installation
6 Page
7. INSTALL FRONT BUMPER
The following steps are general tment suggestions only.
The actual installation procedure will depend on the
bumper-to-chassis mounting conguration.
Fabrication is required for most applications, and should
only be performed by a qualied metal fabricator or welder.
When installed correctly, the front bumper will be SE-
CURELY attached to the Outer Chassis Plate so that any
winch loading is transferred to the chassis rails and large
tubular support member that spans them.
OPTION 1
Bolt-On Mounting Bracket
Choose this option if the front bumper will t the rein-
forced chassis without interference.
Install the front bumper with the mounting bracket posi-
tioned outboard of the Outer Chassis Plate (A). Use the
new bumper mounting holes located at the front of the
chassis plate – see illustration below. If necessary, re-drill
any mounting holes or trim Chassis Plate to t.
OPTION 2
Modify Bumber Bracket
Choose this option if the front bumper will not t the
reinforced chassis.
Modify the bumper mounting bracket to accommodate the
additional 3/16” thickness of the Outer Chassis Plate (A).
Install the front bumper with the mounting bracket posi-
tioned outboard of the Outer Chassis Plate. Use the new
bumper mounting holes located at the front of the chas-
sis plate. If necessary, re-drill any mounting holes or trim
Chassis Plate to t.
OPTION 1
Bolt-On Mounting Bracket
Choose this option if modication of bumper mounting
bracket is not possible, or ine󰀨ective.
Before installing Outer Chassis Plate (A), cut in half as
indicated in the illustration and discard the front portion.
Install the rear portion of chassis plate as instructed. Mount
bumper to original mounting holes in chassis. If necessary,
re-drill any mounting holes or trim Chassis Plate to t.
Front Portion Rear Portion
Cut
Line
Maintenance
Check Steering Gear Mounting Bolt (D) torque specica-
tions regularly.
©2013 JKS Manufacturing, Inc & Aftermarketing, LLC
Revision Date 11/1/2013