CJ7 Bushing

8/7/2019 CJ7 Bushing

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80-86 JEEP CJ 7 / 8 1 LIFT URE-THANE BUSHING INSTALLATIONINSTRUCTIONS-KIT #19012

WARNING

Installation of a Performance Accessories body lift willchange the center of gravity and the handling charac-teristics of the vehicle. Because of the higher center ofgravity and larger tires, the vehicle will handle andreact differently both on and off road. You must drive itsafely! Extreme care must be taken to prevent vehiclerollover or loss of control, which could result in seriousinjury or death. Avoid sudden sharp turns or abruptmaneuvers and always make sure all vehicle occu-pants have their seat belts fastened.

WARNING

Read and understand all instructions, warnings, cau-tions, and notes in this sheet and in your owners man-ual before you begin the installation of this body lift kit.

CAUTION

Proper installation of a Performance Accessories bodylift kit requires knowledge of the factory recommendedprocedures for disassembly and assembly of originalequipment components. We recommend that the fac-tory shop manual and any special tools necessary toyour vehicle be on hand during the installation. Instal-lation of this body lift kit without proper knowledge ofthe factory recommended procedures may affect theperformance of these components and the safety ofyour vehicle. We strongly recommend that a certifiedmechanic familiar with the installation of similar com-ponents install this body lift kit.

WARNING

This body lift kit should only be installed on vehicles ingood working condition. Before installation, the vehi-cle should be thoroughly inspected for evidence of cor-rosion or deformation of the sheet metal around thefactory body mounts. This body lift kit should not beinstalled on any vehicle that is suspected to have beenin a collision or misused. Off road use of your vehicle

with this body lift installed may increase the stressapplied to the factory body mounts. We do not recom-mend that any vehicle with a body lift installed beinvolved in any extreme off road maneuvers such as

jumping. Failure to observe this warning may result inserious personal injury and/or severe damage to yourvehicle.

WARNING

Performance Accessories strongly discourages theuse of a suspension lift kit or any other lift device inaddition to a body lift kit. A vehicle that uses a combi-nation of lift devices not originally engineered to be

used together may result in unexpected and unsafehandling characteristics. Many states now have lawsrestricting bumper heights and vehicle lifts. Local lawsshould be consulted to determine if the changes youintend to make to your vehicle comply with state laws.

WARNING

The installation of larger wheel and tire combinationsmay reduce the effectiveness of the Anti-lock BrakingSystem.

WARNING

We will not warranty any damage to the a/c system.

WARNING

Always wear eye protection when operating powertools.

WARNING

Ensure that your vehicle tires are properly blocked andsecured before you begin installation of this lift kit.

WARNING

To ensure the Supplemental Restraint System (SRS,

or air bag) is not accidentally deployed during lift kitinstallation, always ground yourself and the vehicle.Do not use power or pneumatic tools. Exerciseextreme caution while working near SRS sensors andwiring. Do not allow anyone near air bags during lift kitinstallation. Accidental deployment can result in seri-ous personal injury or death.

NOTE

Performance Accessories recommends using the Loc-tite supplied in the kit on all hardware unless noted inthe instructions.

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A. Before you start.

1. Read all warnings and instructions completely andcarefully before you begin.

2. Check to make sure the kit is complete (refer to theParts List, section E).

3. Only install this kit on the vehicle for which it isintended. If anytime during the installation youencounter something different from what is outlinedin the instructions, call technical support at (520)

636-0979.

4. Park the vehicle on a clean, dry, flat, level surfaceand block the tires so the vehicle cannot roll in eitherdirection.

5. Disconnect both battery cables. Disconnect the neg-ative cable (1) first, then the positive cable (2) fromthe battery (3).

B. Get ready to install the kit.

1. Air Intake.

a. Loosen two clamps (4) and remove air intake

duct (5) from core support (6).

NOTE

As you read through this procedure, note that eachpart referenced has the same callout number through-out. Also, the part number in the text matches the cor-responding part number in the art. Kit parts areprefaced by the word kit in italics.

NOTE

You will find it easier to keep track of hardware ifimmediately after removal you put the fasteners foreach subassembly in a paper lunch bag and write onthe bag where they go.


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2. Radiator.

a. Remove four radiator mounting bolts (7), vent

hose (8), fan shroud (9), and radiator (10) fromcore support (6).

b. Remove and discard four clip nuts (11).

3. Steering column.

a. Using 1/8 drill, remove plastic pins (12) from

two sides of steering column (13) so column canextend while truck is being lifted. Do not drillthrough steering column.

4. Manual transmission/transfer case.

a. Loosen locknut (14) and remove transmissionshift knob (15) from shift lever (16).

b. Loosen locknut (17) and remove 4 wheel driveshift knob (18) from shift lever (19).

c. Remove eight screws (20) from floorboard (21).

d. Remove outer shift boot (22) and inner shift boot(23) (if present) from shift levers (16 and 19).

NOTE

On models equipped with power steering it may benecessary to remove the power steering reservoir fromthe core support.

NOTE

You may want to wait to do steps B.4.a. through d. untilyou see if your manual transmission and transfer caseshifters engage all positions. If not, you can performthese steps in conjunction with Installation steps C. 7.

j. through k.


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e. Remove wire keeper (24, washer (25), and clutchrod (26) from clutch pedal linkage (27).

f. Remove cotter pin (28) and washer (29) fromclutch rod (26). Remove clutch rod from clutch pivotlinkage (30) and vehicle.

g. Remove two nuts (31) and clutch pivot bracket(32) from firewall (33).

h. Remove wire keeper (34) and clutch pivot linkage(30) from clutch pivot bracket (32) and clutch pivotbracket from vehicle.

5. Automatic transmission.

a. Remove shift linkage rod (35) from steering col-umn lever (36).

b. Remove shift linkage rod (35) from transmissionlinkage pivot assembly (37).

c. Remove two bolts (38) and transmission linkage

pivot assembly (37) from bracket (39), pivotbracket (40), and vehicle.


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C. Install the kit.

1. Lift body.

a. Loosen but do not remove eleven (thirteen /CJ8) body mounting bolts (41).

b. Remove core support body mounting bolt (41),washer (42), and bottom bushing (43) from coresupport frame mounting pad (44).

c. Remove five body mounting bolts (41), washers(42), bolt (45), brace (46), and five bottom bush-ings (43) from passenger side frame mountingpads (47).

d. Using a hydraulic jack and a wooden block,slowly lift the body (48) passenger side just high

enough to remove top bushings (49) from framemounting pads (47).

WARNING

Failure to replace the OEM mounting hardware(except mounting bolts in the kit) in the stock locations

could result in serious personal injury or damage to thevehicle.

CAUTION

Be sure to constantly check for any wires, hoses,cables, etc. that may be binding.


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2. Core support bushings.

a. Remove spacer (50) (if present) and top bushing(49) from core support frame mounting pad (44).Remove steel insert (51) from top bushing.

b. Press kit 11/16 x 1 crush tube (52) and steelinsert (51) in kit top bushing (53).

c. Position kit top bushing (53) and spacer (50) (if

removed) on core support frame mounting pad(44) and install kit 7/16 x 3 1/2 mounting bolt

(54). Do not tighten.


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3. Passenger side bushings.

a. Remove five top bushings (49) (six / CJ8) one ata time as shown in *step C. 1. c. from framemounting pads (47). Remove five (six / CJ8)

steel inserts (51) from top bushings.

b. Press five (six / CJ8) steel inserts (51) and four(five / CJ8) kit7/8 x 1 crush tubes (55) in five kit

top bushings (56) as shown. Kit 7/8 x 1 crushtubes are installed in two rear kit top bushings in*step C. 6 b. below.

c. Position five (six / CJ8) kit top bushings (56) onframe mounting pads (47) and install kit3/8 x 4

mounting bolt (57), three (five / CJ8) kit 3/8 x 31/2 mounting bolts (58), and kit 7/16 x 3 1/2

mounting bolt (54). Do not tighten.

d. If steel collar of kit top bushing (56) wont fit inframe mounting pad (47) hole, file hole out

slightly.

4. Lower body (48) on kit top bushings (53 and 56).

5. Repeat step *C. 1 c., C. 1 d., and C. 3 a. throughC. 4. above for vehicle driver side.

6. Finish bushing installation.

a. Check body alignment. Remove eleven kitmounting bolts (54, 57 and 58) one at a time andapply Loctite to threads.

b. Install eleven kit bottom bushings (59, 60, and

61), four kit7/8 x 1 crush tubes (55), eight kit7/16 x 2 washers (62), three kit1/2 x 2 washers(63), three kit 7/16 x 3 1/2 mounting bolts (54),two kit3/8 x 4 mounting bolts (57), six kit3/8 x3 1/2 mounting bolts (58), brace (46), and bolt(45) in core support mounting pad (44) and

frame mounting pads (47). Tighten mountingbolts (54, 57 and 58) to 55 lb-ft.

NOTE

We recommend the use of Loctite on all mountinghardware.


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7. Manual transmission/transfer case.

a. To lengthen clutch rod (26), scribe a line and cutrod in half through scribed line as shown.

b. Position kit 1/2 x 1 extension pin (64) betweentwo halves of clutch rod (26), align scribed lines,and weld kit extension in place.

c. Install clutch pivot bracket (32) on kit clutchbracket (65) with two kit 5/16 nylock nuts (66).Do not tighten.

d. Mark clutch pivot bracket (32). Remove kitclutchbracket (65) and drill elongated hole with a 7/16drill in clutch pivot bracket (32) as shown.

e. Install clutch pivot bracket (32) on kit clutchbracket (65) with two kit 5/16 washers (67) and

two kit5/16 nylock nuts (68).

f. Install clutch bracket (65) on clutch pivot linkage(20) with wire keeper (34).

g. Install kitclutch bracket (65) on firewall (33) with

two nuts (31).

NOTE

We recommend that all welding be done by a certifiedwelder only.


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h. Position clutch rod (26) through firewall (33) andinstall on clutch pivot linkage (30) with washer(29) and cotter pin (28).

i. Install clutch rod (26) on clutch pedal linkage(27) with washer (25) and wire keeper (24).

j. Check engagement in all gears. If shift levers(16 and 19) do not fully engage in all gears, posi-tion outer shift boot (22) on shift levers andinstall eight screws (20) in floorboard (21).

LEAVE INNER SHIFT BOOT (23) OFF.

k. If levers still do not engage, it may be necessaryto heat and bend shift lever or notch floorboard

(21) to enable complete engagement. Install twoknobs (16 and 19) and tighten two locknuts (14and 17).

8. Automatic transmission.

a. To lengthen shift linkage rod (35), scribe a lineand cut rod in half through scribed line as

shown.

b. Position kit 3/8 x 1 extension pin (68) between

two halves of shift linkage rod (35), align scribedlines, and weld kit extension in place.

NOTE

We recommend that all welding be done by a certifiedwelder only.


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c. Install transmission linkage pivot assembly (37)in bracket (39).

d. Install kit transmission linkage pivot relocatingbracket (69) on pivot bracket (40) with two bolts(38).

e. Install transmission linkage pivot assembly (37)on kit transmission linkage pivot relocatingbracket (69) with two kit 1/4 x 1" bolts (70), fourkit1/4" washers (71) and two kit1/4" nylock nuts(72). Do not tighten.

f. Install shift linkage rod (35) on transmission link-age pivot assembly (37).

g. Install shift linkage rod (35) on steering column

shift lever (36).

h. Position shifter in low. If low does not fullyengage, adjust pivot assembly (37) by loosening

bolt (73) and pulling shift lever down until shift

lever fully engages low position. Tighten bolt andrun shifter though gears to ensure correct adjust-ment.


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9. Steering column.

a. Ensure steering column (13) has expanded.Using 1/8 drill, drill hole through steering col-umn halves in location of drilled plastic pins and

install kit1/8 x 1 roll pin (74).

10. Radiator.

a. Install four kit radiator brackets (75) on core sup-port (6) with four kit 1/4 washers (71) and four

kit1/4 nylock nuts (72). Do not tighten.

b. Install radiator (10), fan shroud (9), and venthose (8) on four kit radiator brackets (75) withfour kit1/4" washers (71) and four kit1/4 nylocknuts (72).

11. Air intake.

a. Install air intake duct (5) on core support (6) andtighten two clamps (4).

D. After installation is complete.

1. Connect both battery cables to the battery (3). Be

sure to reconnect the positive cable (2) first, then thenegative cable (1).


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E. Parts List

Quantity Description

10 Top bushing 19120 (12 / CJ8)

08 Bottom bushing 19105 (10 / CJ8

02 Bottom bushing 19103

01 Top bushing 19121

01 Bottom bushing 19104

2 3/8 x 4 bolts

6 3/8 x 3 1/2 bolts (8 / CJ8)

3 7/16 x 3 1/2 bolts

2 5/16 nylock nuts

8 1/4 nylock nuts

3 1/2 x 2 washers

8 7/16 x 2 washers (10 / CJ8)

2 5/16 washers

8 1/4 washers

10 Crush tubes 7/8 x 1 (12 / CJ8)

1 Crush tube 11/16 x 1

1 Clutch pivot bracket

1 1/2 clutch rod extension pin

1 3/8 auto shift rod extension pin

4 Radiator bracket

1 6ml bottle Loctite

1 Warning to driver sticker

1 Logo sticker

2. Stick kit warning sticker on the dash in plain sight ofall vehicle occupants.

3. Double check the vehicle.

a. Check all mounting hardware to ensure it is prop-erly tightened.

b. Check all wires, hoses, cables, etc. to ensurethey have been properly connected and there isample slack.

c. Check vehicle electrical system.

d. Start vehicle and check the steering in both direc-

tions to ensure that there is no bind. Check clutchoperation. Check the operation of the brake sys-tem and the parking brake. Check both shiftlevers operation. Ensure that there is properengagement in all gears and 4 wheel driveranges.

e. Test drive vehicle in all gears and 4 wheel drive

ranges. Pay close attention to all vehicle systems.Check all hardware again in 500 miles and as partof your regular maintenance schedule.

CAUTION

Retorque all fasteners after 500 miles and after offroad use. All lift components should be visuallyinspected and fasteners retorqued during routine vehi-

cle servicing.

CAUTION

Performance Accessories does not recommend anyparticular wheel and tire combinations for use with itslifts and cannot assume responsibility for the cus-tomers choice of wheels and tires. Reference yourowner's manual for recommended tire sizes and warn-ings related to the use of oversized tires. Larger wheeland tire combinations increase stress and wear onsteering and suspension components, which leads toincreased maintenance and higher risk for componentfailure. Larger wheel and tire combinations also alterspeedometer calibration, braking effectiveness, centerof gravity, and handling characteristics. Consult with

an experienced local off road shop to find what wheeland tire combinations work best with your vehicle.

NOTE

All warranty information, instruction sheets, and othedocuments regarding the installation of this producmust be retained by the vehicle owner. Informatiocontained in the instructions and on the warranty cardwill be required for any warranty claims. The vehicleowner needs to understand the modifications made tohis vehicle and how they affect vehicle handling andperformance. Failure to provide the customer with thisinformation can result in damage to the vehicle andsevere personal injury.

Documents

CJ7 Bushing