Q JK 2.5 LIFT 16400 0X4X QLIFT - Quadratec · the trusted source ® 3 important product safety tips quadratec® recommends professional installation of this product. 2.5” coil spring

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Quadratec® 2.5”Coil Suspension Lift Kit

TO REDUCE RISK OF SERIOUS INJURY OR PROPERTY DAMAGE:READ ALL SAFETY MESSAGES AND UNDERSTAND ALL INSTRUC-TIONS AND PROCEDURE NOTICES BEFORE ATTEMPTING TOINSTALL OR USE THIS PRODUCT. FOLLOW ALL INSTRUCTIONSAND WARNINGS WITH PRODUCT & VEHICLE OWNERS MANUAL.

THIS KIT INCLUDES A COCKPIT SAFETY WARNING STICKERREGARDING INCREASED ROLLOVER RISK. THIS STICKERMUST BE AFFIXED IN THE COCKPIT, VISIBLE TO ALL VEHICLEOCCUPANTS AT ALL TIMES.

RISK OF EYE INJURY! SAFETY GLASSES MUST BE WORN AT ALLTIMES WHILE INSTALLING OR MAINTAINING THIS PRODUCT.TORQUE AND RECHECK FASTENERS AFTER 250 MILES ANDFREQUENTLY THEREAFTER. DO NOT USE IF DAMAGED.

Installation Manual: for 2007-Current Wrangler (JK)#16400.0X4X

PARTS LIST:Front Coil Springs - QTY 2Rear Coil Springs - QTY 22” Front Bump Stop Spacers - QTY 22” Rear Bump Stop Spacers - QTY 2Rear Track Bar Bracket - QTY 1Brake Line Drop Brackets - QTY 4Front Shocks - QTY 2Rear Shocks - QTY 2Kit Hardware Listed Inside Booklet

Q_JK_2.5_LIFT_16400_0X4X_QLIFT 3/12/15 10:55 AM Page 1

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INSTALLATION OF THIS PRODUCT ON YOUR JEEP® WILL MODIFY AND EN-HANCE ITS SUSPENSION AND OFF-ROAD PERFORMANCE. IT MAY HANDLEDIFFERENTLY THAN AS FACTORY-EQUIPPED INCLUDING; INCREASED RIDE-HEIGHT; REDUCED LATERAL STABILITY; AND HIGHER RISK OF ROLL-OVEROR OTHER ACCIDENT. ALSO, OWNER’S CHOICE OF LARGER TIRE/WHEELCOMBINATIONS MAY REQUIRE ADDITIONAL PEDAL PRESSURE OR IN-CREASED DISTANCE TO STOP; CAUSE SPEEDOMETER TO READ SLOW ANDMAY REDUCE VISIBILITY AROUND THE VEHICLE. CHOICE OF TIRE/WHEELCOMBINATIONS OTHER THAN AS TESTED OR RECOMMENDED MAYCOMPROMISE FMVSS 126 COMPATIBILITY.

FAMILIARIZE YOURSELF WITH VEHICLE HANDLING AND REVIEW ALL VEHI-CLE MANUFACTURERS AND QUADRATEC® WARNINGS, INSTRUCTIONS ANDLIMITED WARRANTIES BEFORE DRIVING A MODIFIED SUSPENSION JEEP®.FOLLOW ALL RECOMMENDED MAINTENANCE PROCEDURES AND ROUTINELYINSPECT YOUR VEHICLE COMPONENTS FOR UNUSUAL WEAR OR OFF-ROADDAMAGE.

DO NOT DRIVE UNDER ANY SPEED OR MANEUVERING CONDITIONS WHICHMAY CAUSE THE VEHICLE TO TRIP, ROLL, LOSE TRACTION OR COMPROMISEYOUR ABILITY TO SAFELY BRAKE IN AN EMERGENCY. QUADRATEC® DOESNOT RECOMMEND COMBINED USE OF SUSPENSION KITS, BODY LIFTS,OTHER LIFTING DEVICES OR COMPONENTS ALTERING THE INTENDED RIDE-HEIGHT OR FUNCTION OF ITS PRODUCTS. MANY STATES HAVE LAWS RE-STRICTING THE EXTENT OF VEHICLE MODIFICATIONS. OWNER/DRIVER ISRESPONSIBLE FOR MODIFICATIONS CONSISTENT WITH STATE LAWS ANDGOOD SENSE.

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Before You Begin Installation: Congratulations on your purchase ofthe Quadratec 2.5” Coil Spring Lift Kitfor 2007-Current JK Wrangler Vehicles.When unpacking, check to make sure all

parts are included and not damaged dueto shipping. If any part is missing orbroken, please call Customer Serviceat 800-745-6037 as soon as possible.

a hazardous situation which, if not avoided, could result in death orserious injury. You CAN be KILLED or SERIOUSLY HURT if you don’tfollow instructions.

a hazardous situation which, if not avoided, could result in minor ormoderate injury. You CAN be moderately HURT and also may sufferproperty damage if you don’t follow instructions.

Careful attention is required to this instruction or operation but doesgenerally not relate to personal injury. Damage to your Quadratec®

product or other property may result if you don’t follow instructions.

IMPORTANT PRODUCT SAFETY TIPS

A Few Words About Product Safety: Your Quadratec Suspension product isintended to enhance the utility andenjoyment of your off road capablevehicle. Before installation, pleasereview the following safety informationand installation recommendations.

Throughout these instructions impor-tant safety information is generallypreceded by one of three signal wordsindicating the relative risk of injury,property damage or adverse conse-quence. The signal words mean:


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IMPORTANT PRODUCT SAFETY TIPS

QUADRATEC® RECOMMENDS PROFESSIONAL INSTALLATION OF THISPRODUCT.

2.5” COIL SPRING KIT PARTS LIST:Front Coil Springs - QTY 2Rear Coil Springs - QTY 22” Front Bump Stop Spacers - QTY 210mm Button Head Bolts - QTY 23⁄8” SAE Washers - QTY 210mm Locknuts - QTY 22” Rear Bump Stop Spacers - QTY 25⁄16” x 1 Fine Thread Bolts - QTY 45⁄16” SAE Washers - QTY 85⁄16” Fine Thread Locknuts - QTY 4Rear Track Bar Bracket - QTY 1½” x 11⁄4” Fine Thread Bolt - QTY 1½” SAE Washer - QTY 1½” Fine Thread Locknut - QTY 19⁄16” x 3 Fine Thread Bolt - QTY 19⁄16” SAE Washers - QTY 29⁄16” Fine Thread Locknut - QTY 17⁄16” x 1 Fine Thread Bolt - QTY 17⁄16” SAE Washer - QTY 17⁄16” Fine Thread Locknut - QTY 1Crush Sleeve - QTY 1

Brake Line Drop Brackets - QTY 4¼” x 1 Fine Thread Bolts - QTY 4¼” SAE Washers - QTY 8¼” Fine Thread Locknuts - QTY 4Front Shocks - QTY 2Rear Shocks - QTY 2

REQUIRED TOOLS: Safety Glasses25⁄64” Drill Bit & Hand Drill15⁄32” Drill Bit7⁄32” Allen Wrench½” Socket10, 15, 16, 18, 19, 21mm Sockets½” Open End Wrench9⁄16” Open End Wrench5⁄8” Open End Wrench18mm Open End Wrench7⁄8” Open End WrenchLocking Pliers (I.E. Vise Grips)Diagonal Wire CuttersPaint Pen or Marker


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PARK THE VEHICLE ON FLAT, LEVEL GROUND AND SET EMERGENCYBRAKE. ALWAYS SUPPORT FRAME RAILS USING JACK STANDS.

2.5” Coil Spring Lift Kit Installation: Front

Caution: Park the vehicle on flat, levelground and set emergency brake. Puton safety glasses. Raise the front of thevehicle and support frame rails usingjack stands. Do not lower the axle at

this time. Remove front tires/wheels.Disconnect the front sway bar end linksusing a 18mm socket and open endwrench. Disconnect front track barusing a 21mm socket. (see FIG 1 & 2)

Figure 1Figure 1 Figure 2

Disconnect the bottom end of the frontshocks using an 18mm socket and openend wrench. (see FIG 3)

Disconnect brake line bracket fromframe using a 10mm socket. (see FIG 4)

Figure 3 Figure 4Figure 4


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Remove bracket using a 10mm socketand discard (see FIG 7).

Remove original equipment front shockabsorbers. Locate the shocks fastenersas shown.

On 2011 and newer models disconnectthe ABS lines from brake line bracket(see FIG 5)

Using locking pliers, separate thebracket from brake line (FIGS 6 & 7).

Figure 5 Figure 6

Figure 7Figure 7 Figure 8

Figure 5


Figure 8


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Disconnect axle vent line. (see FIG 11) Gently lower axle housing towards theground and remove original coil springs.(see FIG 12)

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Disconnect the top end of the frontshocks using two 5/8” open endwrenches. (see FIG 9)

Mark the front drive shaft position witha paint marker and remove 4 bolts usinga 15mm socket. (see FIG 10)

THE COIL SPRINGS MAY BE UNDER TENSION. REMOVE CAREFULLY.

Figure 9Figure 9 Figure 10Figure 10



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For ’07-’10 model years only: Using a7/16” open end wrench and socket,install brake line drop brackets andseparate ABS line from top of brake lineusing ¼” fine thread bolts, washers andlocknuts as shown. (see FIG 13)

Locate the new front bump stop in thekit. Using the bump stop as a template,mark the center of the bump stop padlocated on the front axle. Considerdrilling pilot holes. Carefully drill thebump stop pad using a 25/64” drill bit.(See FIG 14).

7

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With axle in drop position, place bumpstop in coil springs, and position thenew coil springs.

Attach bump stop to axle usingthe 10mm button head bolts and onewasher under the 10mm nut, as shown(see FIG 15&16). Perform this on bothsides of the vehicle.


DropBracket


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Press in the bottom end bushings asshown (see FIG 17). Install the top endof the new front shocks using a 9/16”open end wrench. Using factoryhardware, re-attach bottom endof shock and torque to 56 ft lbs.

Re-attach the driveshaft and torque to81 ft. lbs. Also re-attach the axle ventline at this time.

Finally, raise the axle using a floor jackso the full weight of vehicle is on thenew coil springs.

Re-attach sway bar end links to the axlehousing using factory hardware andtorque to 60 ft lbs. Install wheels/tiresand torque to 105 ft lbs.

Finally, remove jack stands and lowervehicle onto the ground. Re-attach trackbar using factory hardware and torqueto 111 ft lbs.

This completes the installation work onthe front end of the vehicle.

Assemble your new front shocks asshown in FIG 15, 16 &17. Install theshock boots and secure with zip-ties.Clip off zip-tie tail.

Assemble the shock top bushingsexactly as shown (see FIG 16).


Figure 17

Figure 19

Figure 18


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2.5” Coil Spring Lift Kit Installation: Rear

Moving to the rear of the vehicle: Raiserear end and properly support usingjack stands. Disconnect the rear trackbar bracket from axle using 21mmsocket, remove rear lower shock boltsand sway bar end links using a 18mmsocket and open end wrench (FIG 20).

Now disconnect the top end shock boltsshown above using a 16mm socket.(see FIG 21).

Disconnect ABS line from frame and dis-connect brake line from frame using a10mm socket. (see FIG 22)

Disconnect axle housing vent line. (see FIG 23)

Figure 20

Figure 22

Figure 21

Figure 23

ALWAYS SUPPORT FRAME RAILS USING JACK STANDS.


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Safely lower the rear axle in order toremove the original equipment rearsprings. Install the new coil springs inposition. Gently raise axle to hold newsprings in place. Install new bump stopswith 5/16” fine thread bolts, washersand locknuts as shown using ½” socket

and open end wrench. (see FIG 24)Install brake line drop brackets usingthe original bolt to the frame, and thesupplied ¼” fine thread bolts, washersand locknuts as shown with a 7/16”socket and open end wrench.(see FIG 25)

Place supplied rear track bar bracketover axle housing. Install OEM bolt andcrush sleeve, but do not tighten at thistime. Carefully drill a hole through thetrack bar bracket into axle housingbracket as shown using a 15/32” drill bit.Consider drilling pilot holes. (see FIG 26)

Install supplied 7/16” fine thread bolt,and washer into the hole you have justdrilled. Secure from the underside withthe supplied locknut, do not tighten atthis time. (see FIG 26b)

Figure 24

Figure 26

BoltSleeve

Figure 25

DropBracket

Figure 26b

7/16”Bolt


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Mark location on the center of the newbracket face with paint marker asshown (see FIG 27). Consider drilling apilot hole. It will be necessary to care-fully drill through the drivers side of thenew bracket and the axle housingmount using a 17/32” drill bit.

Install supplied ½” x 11/4” fine threadbolt, washer and locknut loosely atthis time. Tighten OEM track bar boltfollowed by the 7/16” and ½” bolts.

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1/2”Bolt

OEM Bolt


Figure 27 Figure 27b

Assemble your new rear shocks asshown in FIG 28, 29 & 30. Install theshock boots and secure with zip-ties.Clip off zip-tie tail. (see FIG 29).

Assemble the shock bottom bushingsexactly as shown (see FIG 30).

Figure 28 Figure 29


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Push the mounting plate with bushingthrough the top eyelet of the rear shocks(see FIG 30).

Install the top end of the new rearshocks using a 16mm socket.

Finally, raise the axle using a floor jackso the full weight of vehicle is on thenew coil springs.

Re-attach rear sway bar end links to theaxle housing using factory hardwareand torque to 60 ft lbs. Using factoryhardware, re-attach bottom end ofshocks and torque to 56 ft lbs. Installwheels/tires and torque to 105 ft lbs.Finally, remove jack stands and lowervehicle onto the ground.

Re-attach track bar using the included9/16” x 3” bolt, washer and locknut inlower mounting hole for 2.5” lifts andtorque to 111 ft lbs. (see FIG 32)

This completes the installation workon the rear end of the vehicle.

Figure 30 Figure 31

Figure 32


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COMPLETE INSTALLATION BY CAREFULLY INSPECTING ANDCONFIRMING CLEARANCE OF CHOSEN TIRE/WHEELS THROUGHFULL STEERING SWEEP AND SUSPENSION TRAVEL. ASSUREBRAKE LINES CLEAR AND NOT RUBBING AGAINST ANY SUR-FACE, ABS FITTING AND OTHER FASTENERS SECURED. CHECKSPEEDOMETER READINGS AND IF NECESSARY RECALIBRATE.HAVE ALIGNMENT SETTINGS CHECKED AND IF INDICATED,RE-ALIGN AT SHOP WITH EQUIPMENT SUITED FOR MODIFIEDSUSPENSION JEEP VEHICLES.

INSTALL COCKPIT WARNING STICKER ON VISOR OR OTHERLOCATION VISIBLE TO ALL DRIVERS.


Install cockpit warning sticker on visoror other location visible to all driversand occupants.


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03122015105906

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Quadratec® ExclusiveLimited Lifetime Warranty

Your Quadratec® branded accessories arecovered by the following Limited Warrantyprovided exclusively by Quadratec, Inc.,1028 Saunders Lane, West Chester PA 19380.

This Limited Warranty is the only warranty madein connection with your purchase. Quadratecneither assumes nor authorizes any vendor, re-tailer or other person or entity to assume for it anyother obligation or liability in connection with thisproduct or Limited Warranty. This Limited War-ranty does not apply and is not cumulative toany accessory or part distributed by Quadratecfor which the Manufacturer provides a separatewritten warranty.

What is Covered: Subject to the terms, exclusionsand limitations herein and with respect only toQuadratec branded accessories first sold in theUnited States, Quadratec warrants to the initialretail purchaser only that your Quadratec acces-sory shall be free of defects in material and work-manship: for as long as the original purchaserowns the vehicle. The Warranty on bushings andother serviceable wear items (including shockabsorbers) is limited to 1 year from date of retailpurchase. This Limited Warranty is not assignableand shall terminate upon sale of the vehicle uponwhich the Quadratec accessory is installed orother transfer third persons.

All other warranties are hereby disclaimed, exceptto the extent prohibited by applicable law inwhich case any implied warranty of merchantabil-ity or fitness for a particular purpose on thislimited to for as long as the original purchaserowns the vehicle. Quadratec reserves the rights to:(a.) require invoice or other proof your accessoryis within the terms of this Limited Warranty asa condition of warranty service and, (b.) makefuture revisions to this product and LimitedWarranty without prior notice or obligationto upgrade your product.

What is Not Covered:Your Quadratec Limited Warranty does not coverproducts or parts Quadratec determines to havebeen damaged by or subjected to: (a.) installationdamage, alteration, modification, combinationwith other parts, failure to maintain or improperrepair or service, (b.) defects or use whichpre-dates installation of Quadratec® accessory

or suspension kit by authorized dealer or shop,(c.) normal wear & tear or gradual reduction inexpected performance of vehicle or components,(d.) emissions control or electronic stability sys-tems or components, (e.) cosmetic damage ordamage from moisture or water immersion,(f.) fleet, rental or commercial use, (g.) Acts ofGod, accidents, misuse, negligence, inadequatemounting or impact with vehicle(s), obstaclesor other aspects of the environment, (h.) theft,vandalism or other intentional damage.(i.) use in competition or racing.

Other Exclusions: Surface finish of exposedsuspension components is not covered underthis Limited Warranty.

Remedy Limited to Repair/Replacement:The exclusive remedy provided hereunder shall,upon Quadratec inspection and at Quadratec’soption, be either repair or replacement of productor parts (new or refurbished) covered under thisLimited Warranty. Customers requesting warrantyconsideration should first contact Quadratec toobtain a RGA number (610-701-3336). All labor,removal, shipping and installation costs arecustomer’s responsibility.

Other Limitations - Exclusion of Damages- Your Rights Under State Law:In consideration of the purchase price paid,neither Quadratec nor any independent Quadratec distributor/licensee are responsible for any timeloss, rental costs, or for any incidental, consequen-tial, punitive or other damages you may have orincur in connection with any part or productpurchased. Your exclusive remedy hereunder forcovered parts is repair/replacement as describedabove.

This Limited Warranty gives you specific rights.You may also have other rights that vary fromstate to state. For example, some states do notallow limitations of how long an implied warrantylasts and /or do not allow the exclusion or limita-tion of incidental or consequential damages, sothe limitations and exclusions herein may notapply to you.

©Quadratec, Inc. 2015. All Rights Reserved.2.27.15 LTR Version Part #12999.9032


03122015105907

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03122015105907

Documents

Q JK 2.5 LIFT 16400 0X4X QLIFT - Quadratec · the trusted source ® 3 important product safety tips quadratec® recommends professional installation of this product. 2.5” coil spring