Q TJ SPACER LIFT 16400 0X41 QLIFT - Quadratec · the trusted source ® 3 important product safety tips quadratec® recommends professional installation of this product. park the vehicle

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Quadratec® 2”Coil Spacer 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 97-06 Wrangler (TJ & LJ)#16400.0X31

PARTS LIST:TJ 1 3⁄4” Coil Spacers - QTY 41” Bump Stop Extensions - QTY 410mm x 50mm Bolts - QTY 43⁄8” SAE Washers - QTY 4Front Shocks - QTY 2Rear Socks - QTY 2

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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” Lift Kit for 1997-2006TJ Wrangler Vehicles. When unpacking,check to make sure all parts are

included and not damaged due toshipping. 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 INSTALLATIONOF THIS PRODUCT.

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

PARTS LIST:TJ 1 3⁄4” Coil Spacers - QTY 41” Bump Stop Extensions - QTY 410mm x 50mm Bolts - QTY 43⁄8” SAE Washers - QTY 4Front Shocks - QTY 2Rear Shocks - QTY 2

REQUIRED TOOLS: Safety Glasses

REQUIRED TOOLS:13mm Open End Wrench15mm Open End Wrench18mm Open End WrenchT40 Torx SocketT55 Torx Socket13mm Deep Well Socket15mm Socket9/16” Socket17mm Socket18mm Socket

2.0” Coil Spacer Kit Installation: Front

Caution: Park the vehicle on flat, levelground and set emergency brake. Put onsafety glasses. Raise the front of the ve-hicle and support frame rails using jackstands. Do not lower the axle at thistime. Remove front tires/wheels.

Disconnect the front sway bar end linksusing a 18mm open end wrench andT55 Torx socket. Disconnect front trackbar using a 15mm socket.(see FIG 1 & 2)

Figure 1 Figure 2


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Disconnect the bottom end of the frontshocks using a 13mm deep well socketand open end wrench. (see FIG 3 & 4)

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Figure 4

Disconnect brake line bracket fromframe using a T40 Torx socket.(see FIG 5 & 6)

Figure 5 Figure 6Figure 5


Figure 3Figure 3


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Gently lower axle housing towards theground and remove original coil springs.(see FIG 7)

Remove original bump stop by pullingdownward and twisting. (see FIG 8).

Figure 7Figure 7 Figure 8Figure 8

Remove bump stop cup using a 15mmsocket (see FIG 9)

Slide down original coil spring isolatorand install included coil spring spaceron top as shown (see FIG 10)

Figure 9 Figure 10

COIL SPRING MAY BE UNDER TENSION. REMOVE CAREFULLY.INSTALL COIL SPACERS EXACTLY AS SHOWN.

New CoilSpacer

OriginalSpringIsolator


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Re install coil spring and index onbottom mount as shown (see FIG 12)Locate upper shock mount stem and

remove using vise grips and 15mm openend wrench. (see FIG 13 & 14) Removeand discard old front shocks.

Re-attach original bump stop cup usingsupplied bump stop cup spacer, sup-plied 10mm bolt and washer using a

17mm socket. (see FIG 11) Press inbump stop as shown. (see FIG 11A)

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Figure 12

Figure 11 Figure 11A

INSTALL BUMP STOP SPACERS EXACTLY AS SHOWN.

Figure 14

Figure 13


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Locate and assemble front shocks asshown (see FIG 15 & 16). Install intooriginal opening at top mount andtorque to 20 ft lbs using a 9/16” socket.

Raise the axle using a floor jack sothe full weight of vehicle is on the coilsprings with newly installed coilspacers.

Re-Attach brake line bracket to frame.Re-Attach front sway bar end links toaxle housing and torque to 75 ft lbs.

Using factory hardware, re-attach thebottom end of the shock and torque to21 ft lbs. Install wheels/tires and torqueto 105 ft lbs.

Finally, remove jack stands and lowervehicle onto the ground. Re-attach trackbar using factory hardware and torqueto 55 ft lbs for 97-02 models and 40 ftlbs for 03-06 models.

Figure 15 Figure 16


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Raise rear end and properly supportframe rails using jack stands. Locaterear axle track bar mount and removedplastic cover (see FIG 17) and discard.

Disconnect the rear track bar from thebracket using a T55 torx socket. (seeFIG 18)

Figure 17Figure 17 Figure 18Figure 18

Remove rear lower shock bolts andsway bar end links using a 18mmsocket and 15mm open end wrench.(see FIG 19)

Locate rear upper shock mounting boltsand remove using 13mm socket (see FIG20). Discard rear shocks.

ALWAYS SUPPORT FRAME RAILS USING JACK STANDS.COIL SPRING MAY BE UNDER TENSION. REMOVE CAREFULLY.

Figure 19 Figure 20

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2.0” Coil Spacer Kit Installation: Rear

8


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Carefully lower axle housing and re-move coil springs (see FIG 21).

Remove original bump stop by pullingdownward and twisting. (see FIG 22). Remove bump stop cup using a 15mmsocket (see FIG 23)

Figure 23Figure 23Figure 22

Install included coil spring spacer secur-ing it with included bump stop cupspacer, original bump stop cup,10mmbolt and washer using a 17mm socket

(see FIG 24). Press in original bumpstop. Install coil spring as shown (seeFIG 25), rears springs are not indexed,so alignment is not critical.

INSTALL COIL SPRING AND BUMP STOP SPACERS EXACTLY AS SHOWN.

Figure 24 Figure 25Figure 24 Figure 25


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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.

Locate and assemble rear shocks asshown (see FIG 26 & 27). Install intotop mount using original hardware andtorque to 23 ft lbs.

Raise the axle using a floor jack sothe full weight of vehicle is on the coilsprings with new installed coil spacers.

Re-attach rear lower shock to axle usingfactory hardware and torque to 74 ftlbs. Install wheels/tires and torque to105 ft lbs. Finally, remove jack standsand lower vehicle onto the ground.Then, re-attach track bar using factoryhardware and torque to 74 ft lbs.

Figure 26 Figure 27


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


02272015104121

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Applications for YJ and TJ Wrangler Vehicles:

For ’88-’95 Wrangler w/Upper Doors & Clear Windows #11000.00XX

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A Colors: 09 . 15 . 17

For ’97-’06 Wrangler w/Clear Windows #11000.02XX

For ’97-’06 Wrangler w/Tinted Windows #11000.03XX

For ’97-’06 Wrangler w/Upper Doors & Clear Windows #11000.04XX

For ’97-’06 Wrangler w/Upper Doors & Tinted Windows #11000.05XX

A Colors: 15 . 17. 33 . 35

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33-DarkTan DenimFabric

35-BlackDiamondFabric

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Due to the limitations ofprinting, all color samplesshown in this catalog areclose approximations only.

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11

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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 #12999.9035


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Q TJ SPACER LIFT 16400 0X41 QLIFT - Quadratec · the trusted source ® 3 important product safety tips quadratec® recommends professional installation of this product. park the vehicle