Teraflex 1365000 User manual

Jeep JT 3.5” Spring Lift

www.TERAFLEX.com

Revision B 999376

Tools Needed:

- Metric Sockets and Open End Wrenches - Factory Service Manual

- Torque Wrench - General Mechanics Tools

Maintenance Note:

After the rst 300 miles and every 3,000 miles after that, re-torque all the suspension

components and bolts.

Important Notes:

Prior to beginning this install, or any installation, read the instructions thoroughly to familiarize yourself with

the required steps. Evaluate if you are experienced and capable to personally perform these modications.

A factory service manual should be used in conjunction with these installation instructions.

This product will change the highway handling characteristics of your vehicle, exercise caution. After

altering the suspension it is always advisable to have an alignment done by a competent 4 wheel drive

shop or by an alignment shop that is experienced with lifted 4 wheel drive vehicles.

Refer to the parts list to ensure that all necessary components and hardware has been included. If any

parts are missing please contact your local TeraFlex dealer for assistance.

# 1365000

# 2013000

# 2023000

# 2033000

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Description Item #

RT3 Alpine CT3 Sport ST3 Base Lift

Front Spring 02-21-401-400-1 2 2 2 2

Rear Spring 02-23-401-150-1 2 2 2 2

Front Bumpstops 12-01-109-200 - 2 2 2

Front Bumpstop Spacer 12-02-109-050 - 4 4 4

Rear Top Bumpstop

Spacers 1.5" 12-01-309-150 2 2 2 2

Rear Top Bumpstop

Spacer Rings .5" 12-01-309-050 2 2 2 2

Rear Bumpstop Spacers 12-02-309-050 4 4 4 2

Front Track Bar Bracket 1953250 1 1 1 1

Front Swaybar link 11.50" 21-01-001-115 - - - 2

Rear Swaybar Link 13.0" 21-01-001-130 - - - 2

M10 x 30mm OD

Flat Washer 45-10-003-003 4 4 4 4

M10 X 1.50 X 70mm

Hex Head Bolt 45-21-001-001 2 2 2 2

M10 x 1.5 Fuji Nut 23-07-03-001 2 2 2 2

M10 x 1.5 x 100mm

Flat Socket Cap Screw 45-04-003-001 - 2 2 2

M8 x 1.25mm

Yellow Zinc Fuji Nut 23-07-03-002 - 4 4 4

M8 x 1.25 x 30mm

Hex Flange Bolt 45-02-003-016 4 4 4 4

Rear Upper Bumpstop

Spacer 56-10-05-044-1-1 2 2 2 2

Nut Wrench Tool 600271 - 1 1 1

M14 x 1.5 x 80mm

Hex Cap Screw 45-01-005-002 1 1 1 1

M12 x 1.75 x 25mm

Hex Flange Bolt 45-02-005-003 2 2 2 2

M14 X 1.5 Flange

Top Lock Nut 45-08-004-005 1 1 1 1

M12 X 1.75 Flange

Top Lock Nut 45-08-004-006 1 1 1 1

M14 x 28mm OD

Flat Washer 45-10-005-004 1 1 1 1

Spring Box Components

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Revision B 999376

Description Item #

RT3 Alpine CT3 Sport ST3 Base Lift

Alpine Control Arm Kit 1417500 - 1 - -

Alpine IR Control Arm Kit 1417550 1 - - -

SpeedBump Kit 2" 1968352 1 - - -

Front Track Bar 1753420 1 1 - -

Rear Track Bar 1764420 1 - - -

Front Sway Bar

Quick Disconnect 1764000 1 1 1 -

Front Brake Line Anchor Kit 1101255 1 1 1 -

Rear Brake Line Anchor Kit 1101455 1 1 1 -

Rear Trail Rate Forged S/T

Swaybar Kit 1774700 1 1 1 -

Front Drop Bracket Kit 1938125 - - 1 -

Rear Control Arm Bracket Kit 1938225 1 1 1 -

Rear Track Bar Bracket 1963600 1 1 1 -

JT Driveline Spacer Kit 4801000 1 1 1 -

JT Extended Travel Accessory

Kit 4834100 1 1 1 -

JT Rear Upper / Lower Spring

Retainer Kit 4954000 1 1 1 -

Other Boxed Kits

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Revision B 999376

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*NOTES*

*FOR ALPINE & ALPINE IR CONTROL ARM KITS: Before continuing

refer to Instruction #999373

-CONTROL ARMS WITH ALPINE IR BUSHINGS can be torqued

with the Jeep raised in the air.

-CONTROL ARMS WITH ALPINE BUSHINGS Will need to leave

the control arms loose until the end of the installation.

*FOR SPEEDBUMP KITS: Before continuing refer to Instruction

#999370

*FOR FRONT TRACK BAR: Refer to Instruction #999340

*FOR FRONT TRACK BAR BRACKET: Refer to Instruction #999341

*FOR REAR TRACK BAR: Refer to Instruction #999384

*FOR FRONT QUICK DISCONNECTS: Refer to Instruction #999372

*FOR FRONT BRAKE LINE ANCHORS: Refer to Instruction #999267

*FOR REAR BRAKE LINE ANCHORS: Refer to Instruction #999396

*FOR REAR TRAIL RATE FORGED S/T SWAYBAR: Refer to

Instruction #999404

*FOR FRONT DROP BRACKETS: Before continuing refer to

Instruction #999309

*FOR REAR CONTROL ARM BRACKET: Before continuing refer to

Instruction #999398

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Revision B 999376

LIFT AND SUPPORT AT FRAME

REMOVE FRONT TIRES

1 2

FRONT INSTALLATION

*NOTES*

*FOR REAR TRACK BAR BRACKETS: Refer to Instruction #999391

*FOR JT DRIVELINE SPACER KIT: Refer to Instruction #999401

*FOR JT EXTENDED TRAVEL ACCESSORY KIT: Refer to

Instruction #999402

*FOR JT REAR UPPER & LOWER SPRING RETAINERS: Before

continuing refer to Instruction #999389

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Revision B 999376

REMOVE PASSENGER SWAY BAR LINK & REMOVE TRACK BAR BOLT AT THE AXLE

REMOVE DRIVER SWAY BAR LINK

REMO

NUT 18

REMOVE

NUT 18mm

REMOVE

BOLT 18mm

REMOVE

& DISCARD

STUD 6mm

NUT 18mm

BOLT

18mm

REMOVE &

DISCARD

BOLT

18mm

STUD 6mm HEX REMOVE &

DISCARD

BOLT

18mm

REMOVE

NUT 18mm

REMOVE

NUT 18mm

SUPPORT THE FRONT AXLE

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Revision B 999376

REMOVE AND DISCARD BRAKE LINE BRACKETS FROM LOWER CONTROL ARMS

DISCONNECT ACTUATORS AND VENT HOSE AT THE FRONT AXLE

LOOSEN FRONT CONTROL ARM BOLTS

NOTE: DO NOT REMOVE THE CONTROL ARM BOLTS

PRY OPEN

REMOVE

NUT 15MM

LOOSEN

BOLT & NUT

18mm

LOOSEN

BOLT 21mm

NUT 24mm

NOTE: IF INSTALLING

ALPINE ARMS, REFER TO

INSTRUCTION #999373

NOTE: IF INSTALLING

FRONT DROP

BRACKETS, REFER TO

INSTRUCTION #999309

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Revision B 999376

LOWER AXLE AND REMOVE FRONT SPRINGS

NOTE: REMOVE ANY

PLASTIC RETAINERS

FROM WIRING OR

HOSES AS NEEDED.

9BOLT &

NUT 18mm

BOLT

18mm

REMOVE FRONT SHOCKS

INSTALL FRONT SPRINGS AND LOWER BUMPSTOPS

NOTE: REFER TO PAGE 16 FOR BUMPSTOP AMOUNT

NOTE: IF INSTALLING SPEEDBUMP KIT,

REFER TO INSTRUCTION #999370

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Revision B 999376

TORQUE

12 FT-LBS

RAISE AXLE & INSTALL NEW SHOCKS

FOR INSTALLING FALCON SHOCKS

(REFER TO QUICK START GUIDE INSIDE

FALCON SHOCK BOX)

NOTE: IF INSTALLING CONTROL ARMS WITH ALPINE BUSHINGS, LOWER THE

JEEP TO THE GROUND BEFORE TORQUING THE CONTROL ARM BOLTS.

NOTE: IF INSTALLING CONTROL ARMS WITH ALPINE IR BUSHINGS THE

CONTROL ARM BOLTS CAN BE TORQUED WITH THE JEEP RAISED.

REFER TO PAGE 15 FOR TORQUE SETTINGS

MAKE SURE SPRING

IS FULLY SEATED ON

PERCH

INSTALL THE BUMPSTOP ONTO THE AXLE AND FULLY SEAT THE SPRINGS INTO THE

LOWER SPRING PERCH

NOTE: IF INSTALLING FRONT

BRAKE LINE ANCHORS, REFER

TO THE INSTRUCTIONS ON THE

BACK OF THE BOX.

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Revision B 999376

RECONNECT CONNECTIONS TO FRONT AXLE

RECONNECT PLASTIC RETAINERS FROM

WIRING OR HOSES AS NEEDED.

INSTALL NEW SWAY BAR LINKS

NOTE: IF ONLY FRONT OF JEEP WAS LIFTED, REINSTALL TIRES AND LOWER JEEP

BACK TO THE GROUND BEFORE LIFTING THE REAR

TORQUE

59 FT-LBS

BOLT 18mm

TORQUE

66 FT-LBS

NUT 18mm

STUD 6mm

HEX KEY

*TORQUE THE FRONT TIRES TO 130 FT LBS*

NOTE: IF INSTALLING QUICK

DISCONNECTS, REFER TO

INSTRUCTIONS #999372

NOTE: IT IS EASIEST TO REINSTALL TRACK

BAR AFTER JEEP IS BACK ON THE GROUND

NOTE: IF INSTALLING FRONT TRACK BAR,

REFER TO INSTRUCTION #999340

NOTE: FOR INSTALLING FRONT TRACK BAR

BRACKET, REFER TO INSTRUCTION #999341

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Revision B 999376

REMOVE REAR TIRES

REAR INSTALLATION

SUPPORT REAR AXLE

LIFT AND SUPPORT AT FRAME

REMOVE SWAY BAR LINKS

BOLT 19mm

BOLT 18mm

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Revision B 999376

REMOVE THE TRACK BAR FROM THE AXLE

BOLT 21mm

LOOSEN REAR CONTROL ARM BOLTS

NOTE: DO NOT REMOVE CONTROL ARM BOLTS

LOOSEN

BOLT 21mm

NUT 24mm

REMOVE THE REAR SHOCKS

BOLT & NUT 21mm BOLT 21mm

BOLT 10mm

TEMPORARILY REMOVE BRAKE LINE BRACKETS FROM BOTH SIDES OF THE FRAME

NOTE: IF INSTALLING

ALPINE ARMS, REFER TO

INSTRUCTION #999373

NOTE: IF INSTALLING

REAR CONTROL ARM

BRACKETS, REFER TO

INSTRUCTION #999398

NOTE: IF INSTALLING

EXTENDED TRAVEL

ACCESSORY KIT, REFER

TO INSTRUCTION #999402

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Revision B 999376

LOWER AXLE TO REMOVE REAR SPRINGS

NOTE: REMOVE ANY PLASTIC RETAINERS

FROM WIRING OR HOSES AS NEEDED.

INSTALL THE NEW REAR SPRINGS

MAKE SURE

SPRING

IS FULLY

SEATED ON THE

UPPER PERCH

RAISE THE REAR AXLE AND INSTALL NEW SHOCKS

INSTALLING FALCON SHOCKS

(REFER TO QUICK START GUIDE INSIDE

FALCON SHOCK BOX)

NOTE: IF INSTALLING CONTROL ARMS WITH ALPINE BUSHINGS, AND THE

JEEP WAS RAISED FOR INSTALLATION, LOWER THE JEEP TO THE GROUND

AND FINISH INSTALLATION BY TORQUING THE CONTROL ARM BOLTS.

NOTE: IF INSTALLING CONTROL ARMS WITH ALPINE IR BUSHINGS THE

CONTROL ARMS CAN BE TORQUED WITH THE JEEP RAISED IN THE AIR.

REFER TO PAGE 15 FOR TORQUE SETTINGS

NOTE: IF INSTALLING SPRING

RETAINERS, REFER TO

INSTRUCTIONS #999389

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Revision B 999376

INSTALL THE NEW REAR SWAY BAR ENDLINKS

INSTALL THE REAR BUMPSTOPS

NOTE: REFER TO PAGE 16 FOR BUMPSTOP AMOUNT

TORQUE

70 FT-LBS

NUT 19mm

STUD 6mm

HEX KEY

TORQUE

81 FT-LBS

BOLT 18mm

TORQUE

15 FT-LBS

BOLT 13mm

NUT 12mm

32 33

INSTALL UPPER BUMPSTOP SPACER

NOTE: REFER TO PAGE 16 FOR SPACER AMOUNT

TWIST AND

PULL DOWN

TO REMOVE

BUMPSTOP

FROM FRAME

TWIST AND

PUSH UP

TO INSTALL

BUMPSTOP

INTO SPACER

TORQUE

40 FT-LBS

BOLT 15mm

NUT 14mm

REINSTALL THE BRAKE LINE

BRACKETS TO THE FRAME

TORQUE 6 FT LBS

BOLT 10mm

NOTE: IF INSTALLING REAR

BRAKE LINE ANCHORS, REFER TO

INSTRUCTION #999396

NOTE: IF INSTALLING REAR

TRAIL RATE SWAYBAR, REFER TO

INSTRUCTION #999404

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Revision B 999376

REINSTALL TIRES AND LOWER TO

THE GROUND

TORQUE TO 130 FT LBS

REINSTALL FRONT TRACK BARS AT THE AXLE

REINSTALL REAR TRACK BARS AT THE AXLE

34 35

37 38

TORQUE FRONT

BOLT 18mm

52 Ft Lbs + 155°

(REF: 230-250 Ft Lbs)

NOTE: IF INSTALLING REAR TRACK BAR,

REFER TO INSTRUCTION #999384

NOTE: IF INSTALLING REAR TRACK BAR

BRACKET, REFER TO INSTRUCTION #999391

TORQUE REAR

BOLT 21mm

100 Ft Lbs

TORQUE REAR CONTROL ARM TORQUE FRONT CONTROL ARMS

TORQUE

111 Ft Lbs + 95°

(REF: 240-260 Ft Lbs)

BOLTS 21mm

NUTS 24mm

TORQUE

111 Ft Lbs + 65°

(REF: 180-200 Ft Lbs)

TORQUE

111 Ft Lbs + 90°

(REF: 250-270 Ft Lbs)

TORQUE

111 Ft Lbs + 60°

(REF: 200-220 Ft Lbs)

TORQUE

103 Ft Lbs +145°

(REF: 230-250 Ft Lbs)

BOLT 21mm

NUT 24mm

TORQUE 18mm

37 Ft Lbs + 135°

(REF: 100-120 Ft Lbs)

TORQUE 18mm

41 Ft Lbs + 185°

(REF: 140-160 Ft Lbs)

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Revision B 999376

801.713.3314 • TERAFLEX.com

999368Rev C

JT Tire Clearance Guide for vehicles with FACTORY FENDER FLARES

33” TIRES 33” TIRES

35” TIRES

37” TIRES

39” TIRES

35” TIRES

37” TIRES

JT Rubicon

with Factory Fender Flares:with Factory Fender Flares:

*For vehicles with TERAFLEX Nomad Wheels, add 0.5” Bump Stop to the rear axle.

• When installed with a 1.5” Leveling Kit

- 1” Front & No Rear Bump Stop*

• When installed with a 1.5” Leveling Kit

- 1” Front & No Rear Bump Stop*

• No Front or Rear Bump Stop

JT Sport/Overland

• When installed with a 2.5”+ Lift Kit

- 2″ Front & 1″ Rear Bump Stops

• When installed with a 2.5”+ Lift Kit

- 2″ Front & 1″ Rear Bump Stops

• 2″ Front & 2.5″ Rear Bump Stops

• 4″ Front & 4″ Rear Bump Stops

• 4″ Front & 3.5″ Rear Bump Stops (2” Upper/1.5” Lower)

• 3″ Front & 2.5″ Rear Bump Stops

0.5"

1.5"

0.5"

1.5"

2.5"

**Additonal Bump Stops Required

Notes:

- Additional Front and Rear Bump Stop Strike Pads are available

for individual purchase.

- If installing on a Eco-Diesel Jeep, the jounce tubes are 1.375”

longer, so you should subtract 1.375” from the front bump stop

stack.

- A minimum of 2” bump stop is needed if 3.5”-4.5” Lift Falcon

Shocks are installed.

TeraFlex Bump Stop Strike Pad Extensions allow the use of larger

tires and factory fender ares by limiting suspension up travel.

JT Rubicon models feature high-clearance fenders that allow for

more up travel, while the lower-clearance fenders on JT Sport

and Overland restricts tire size due to fender rubbing.

In order to address these fender differences, TeraFlex designed a

proprietary modular bump stop system, which can be adapted to

t several different tire size congurations.

Additional 0.5″ shims can be added to ne tune bump stop height

and further limit suspension up travel.

IMPORTANT: Recommended Bump Stop conguration is based

on tested tires. Not all tires measure the same. Before driving,

cycle the suspension to check for rubbing or contact of the

shocks, springs, or suspension componets.

Compatable Lift Kit Heights: 1.5”

Compatable Lift Kit Heights: 1.5”-2.5”

Compatable Lift Kit Heights: 1.5”-4.5”

Compatable Lift Kit Heights: 2.5”-4.5”

Compatable Lift Kit Heights: 3.5”-4.5”

Compatable Lift Kit Heights: 4.5”

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Revision B 999376

2-3 Inch Shock Options

JT Falcon Adjustable PiggyBack Shocks

- 4 Door Series 3.3, 14-02-33-400-150 *Fast Adjust Knob

*High Flow Oil Channel

*O󰀨set Sleeve Design

*PiggyBack Reservoir

JT Falcon PiggyBack Shocks

- 4 Door Series 3.1, 14-02-31-400-150

JT Falcon Monotube Shocks

- 4 Door Series 2.1, 14-02-21-400-200

*Oil Gas Separator

*3/4” Chrome Shaft

*O󰀨set Sleeve Design

*JT Specic Shock

*Series 3.3 Upgradable

*High Flow Oil Channel

*O󰀨set Sleeve Design

*PiggyBack Reservoir

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Revision B 999376

PRODUCT INFORMATION

MAINTENANCE INFORMATION:

It is the buyer’s responsibility to have all suspension, drivetrain, steering, and other components checked for proper tightness and torque after the rst

100 miles and every 3000 miles after that.

NOTICE TO INSTALLER:

The enclosed “Warning to Driver” sticker must be installed in the vehicle in driver’s view. This sticker is to act as a constant safety reminder when oper-

ating the vehicle. It is your responsibility as the equipment installer to install the provided sticker and to forward the product instructions to the vehicle’s

owner for review. If a “Warning to Driver” sticker or product installation guide were not included in the kit, FREE replacement stickers and instructions

are available by request. It is the installer’s duty to ensure a safe and controllable vehicle after the modications have been performed.

WARNING:

Neither the seller nor the manufacturer will be liable for any loss, damage, or injury directly or indirectly arising from the use of or inability to determine

the use of these products. Before using, the user shall determine the suitability of the products for its intended use, and the user shall assume all re-

sponsibility and risk in connection therewith.

WARNING TO DRIVER:

This vehicle has been modied to enhance o󰀨 road performance and has unique handling characteristics. Use in harsh environments can cause ex-

treme stress on the components. Vehicle should be inspected after being o󰀨 road to make sure that all the components are in working order and safe to

travel on the highway. All fasteners should be checked so that they are at the correct torque specications as the vibration and stresses from o󰀨 roading

may cause critical fasteners to work loose. Extra care should be taken to inspect the critical components, steering, and brake systems. During each oil

change components such as arms, tie rod ends, etc should be greased and checked for excessive wear. Any worn components should be replaced.

When returning to the pavement always set or restore tire air pressure to the factory recommendation and connect or engage any disabled sway bar

mechanisms. Because of the higher center of gravity and larger tires, this vehicle handles and reacts di󰀨erently than many passenger cars, both on and

o󰀨 road. You must drive it safely! Extreme care should be taken to prevent vehicle rollover or loss of control, which can result in serious injury or death.

Avoid sudden sharp turns or abrupt maneuvers. Generally, braking performance and capabilities are decreased when signicantly larger/heavier tires

are used, especially when used in combination with transfer case low-range reduction kits. Take this into consideration while driving. Do not add, alter

or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the TeraFlex product purchased. Mixing component

brand is not recommended. TeraFlex Inc. will not be responsible for any altered product or any improper installation or use of our products. We will

be happy to answer any questions concerning the design, function, and correct use of our products. It is ultimately the buyer’s responsibility to have

all bolts/nuts checked for tightness after the rst 100 miles and then every 3000 miles. Wheel alignment, steering system, suspension and drive line

systems must be inspected by a qualied professional mechanic at least every 3000 miles.

TERAFLEX PRODUCT WARRANTY:

TeraFlex Inc. warrants TeraFlex Suspension products to the original retail purchaser to be free of defects in material and workmanship for as long as

the original purchaser owns the vehicle on which products were originally installed.

Failure to complete regular maintenance (grease every 3000 miles) on TeraFlex FlexArms will void this warranty. All other conditions of the standard

TeraFlex product warranty apply.

All TeraLow products are covered by the TeraFlex two (2) year warranty to be free of defects in material and workmanship for two years from date

purchased.

TeraFlex axles are covered by a 12-month warranty to be free of defects in materials and workmanship.

This warranty does not cover or include product nish, improperly installed or applied products, improperly maintained products, products or compo-

nents used for racing or competition or damage due to abuse or neglect, products that fail due to the use of larger tire and wheel combinations.

All returns must be accompanied by an original invoice. It is the customer’s responsibility to remove the product from the vehicle. Shipping charges are

the responsibility of the customer. TeraFlex Inc. will pay the return freight if the product meets the terms of warranty.

This warranty is for the replacement or repair of defective TeraFlex products only and does not include freight charges, labor charges for removal of

or installation of TeraFlex or related products or components, costs incurred due to down time of the vehicle, or lost prots due to vehicle down time.