JEEP WRANGLER TJ UNLIMITED TJL RUBICON MODELS BODY

Jeep Wrangler Tj Unlimited Tjl Rubicon Models Body-Free PDF

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A Before you start,As you read through this procedure note that each. part 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 are,prefaced by the word kit in italics. 1 Read all warnings and instructions completely and. carefully before you begin, 2 Check to make sure the kit is complete refer to the. Parts List at the end of this document, 3 Only install this kit on the vehicle for which it is. intended If anytime during the installation you, encounter something different from what is outlined.
in the instructions call technical support at 928, 4 Park vehicle on a clean dry flat level surface and. block the tires so vehicle cannot roll in either direc. 5 Disconnect both battery cables Disconnect the neg. ative cable 1 first then the positive cable 2 from. the battery 3,6 Open glove box 4 remove strap 5 from glove. box Remove glove box from dash 6 and vehicle, Fuse locations may vary Check fuse chart in owners. 7 Remove airbag fuse 7 from fuse panel 8 See,owners manual for fuse location. 2 97 06 TJ TJL Rubicon Kit 972 973,B Get ready to install the kit.
1 Jeep front bumper cover,a Remove four bolts 9 and plastic cover 10. from frame 11 and front bumper 12,2 Headlights,a Remove six screws 13 and two headlight. bezels 14 from core support 15 and vehicle,b If equipped with a second set of headlights on. front bumper remove two push clips 16 and,wiring harness 17 from fenders 18. 3 Under the hood radiator,a Remove overflow hose 19 and overflow bottle.
20 from fan shroud 21 radiator 22 and,3 97 06 TJ TJL Rubicon Kit 972 973. Skip step B 3 b if vehicle is not equipped with A C. b Remove four fan shroud mounting bolts 23,from fan shroud 21 and radiator 22. c Remove six radiator mounting bolts 24 and,radiator 22 from core support 15 Let fan. shroud and radiator rest against fan,4 Under the hood air intake. a Remove vacuum hose 25 from air intake 26,b Remove two clamps 27 and air intake 26 from.
air filter box 28 throttle body 29 and vehicle,5 2004 models Under the hood wire harness. Wire Harness, a Remove three wire harness connectors from Connectors. center firewall mounting bracket,6 Under the hood steering carrier bearing. a Remove two bolts with captive washers 30 and,steering carrier bearing bracket 31 from frame. Skip the following section if your vehicle is equipped. with an automatic transmission,7 Manual transmission console.
a Remove shift pattern display cap 32 from,transmission shift knob 33. b Remove locknut 34 and transmission shift,knob 33 from transmission shift lever 35. 4 97 06 TJ TJL Rubicon Kit 972 973,c Remove shift lever cover 36 from shift lever. console 37 and transmission shift lever 35,d Remove cup holder 38 from shift lever console. e Remove two screws 39 from shift lever console,8 2003 2006 Models Manual transmission lever.
a Remove two screws 39 from shift lever console,b Remove bolt 40 and transmission shift lever. 35 from transmission 41 and vehicle,c If equipped with passenger side air bag switch. 42 lift shift lever console 37 and remove four,clips 43 and passenger side air bag switch. panel 44 from shift lever console,d Remove shift lever console 37 from 4wd shift. lever 45 and vehicle,e Remove four bolts 46 and inner shift boot 47.
from body 48,5 97 06 TJ TJL Rubicon Kit 972 973,9 1997 2002 Models Manual transmission lever. a Squeeze and remove manual shift lever cover,from shift lever console and transmission shift. lever assembly,Shift Lever Cover,Shift Lever,b Remove cup holder from shift lever console. Cup Holder,Shift Lever,c Remove two screws from shift lever console. d Lift shift lever console and remove four clips and. passenger side air bag switch panel from shift,lever console.
e Remove shift lever console from transmission,shift lever assembly 4wd shift lever and vehicle. Switch Panel,6 97 06 TJ TJL Rubicon Kit 972 973,f Remove four bolts from inner shift boot and. g Lift transmission shift lever boot from transmis. Inner Shift,Transmission,Shift Boot,h 6 Cylinder Models Remove four screws and. 6 Cylinder,transmission spring plate from transmission. i Remove transmission shift lever assembly from,Spring Plate.
6 Cylinder,j 4 Cylinder Models Push down on cap and turn. counter clockwise to release cap from transmis,k Remove boot cap spring and transmission. shift lever assembly from transmission,4 Cylinder,7 97 06 TJ TJL Rubicon Kit 972 973. Skip the following section if your vehicle is equipped. with a manual transmission,10 Inside cab automatic transmission. Automatic transmission models come equipped with a. cable shifting mechanism Care should be taken to, make sure the cable shifting mechanism remains flexi.
ble and loose during the lifting process,a Remove shift lever cover 36 from shift lever. console 37,b Remove cup holder 38 from shift lever console. c Remove two screws 39 from shift lever console,8 97 06 TJ TJL Rubicon Kit 972 973. 11 Manual 4wd,a Remove two bolts 49 from 4wd shift lever pivot. 50 and bracket 51,b Remove transfer case upper shift linkage 52.
from 4wd shift lever pivot 50 and 4wd shift,c Lift driver side carpet 53 as shown and remove. four bolts with captive washers 54 from body,48 and bracket 51. d Remove bracket 51 from body 48 and 4wd,shift lever pivot 50. 12 Remove fuel filler,a Remove fuel cap 55 from fuel filler assembly. b Remove four screws 57 and fuel filler assembly,56 from fuel filler surround 58.
c Remove four screws 59 and fuel filler surround,58 from body 48. 13 Remove EPA canister,9 97 06 TJ TJL Rubicon Kit 972 973. a Remove seven push clips 60 two locator tabs,61 and inner rear fender 62 from body 48. passenger side,b Remove three bolts 63 and EPA canister cover. plate 64 from body 48,c Remove clamp 65 from hose 66 and EPA.
canister bracket 67,10 97 06 TJ TJL Rubicon Kit 972 973. C Install the kit,1 Prepare to lift body from frame. Failure to install the OEM cab mounting bushings in. the stock locations could result in serious personal. injury or damage to the vehicle,a Loosen but do not remove eleven body bolts. 68 from core support mounting pad 69 and,frame mounting pads 70 core support 15. and body 48,Use extreme caution when lifting body from frame.
Ensure lifting device is securely placed Keep hands. out from between frame and body or serious personal. injury could result, Continually check hoses wires lines etc to be sure. that everything is flexing properly and not binding or. damage to the vehicle could result Be especially care. ful of the a c hoses at the firewall the belt pulley and at. the core support Ensure brake lines stretch while lift. ing Bending the lines to gain ample slack may be nec. essary Be extremely careful not to kink the lines, Ensure stock spacers and cab mounting pads stay on. vehicle unless otherwise specified in these instruc. tions Kit spacer blocks are installed in addition to the. stock spacers and cab mounting pads,b Remove bolt 68 and lower bushing 71 from. core support mounting pad 69,c Remove five bolts 68 and lower bushings 71. from frame mounting pads 70 and body 48,passenger side.
11 97 06 TJ TJL Rubicon Kit 972 973, 2 Lift body and install passenger side spacer blocks. Wait to install kit spacer block under the core support. until the passenger side of the body is lifted and the. driver side of the body is being lifted,a Using a hydraulic jack and a wooden block. slowly lift the body 48 passenger side just high,enough to position the five kit spacer blocks 72. and 73 between the body and top body bush,b Install kit 1 2 x 6 1 2 1 2 x 5 1 2 for 2 bolt. 75 through kit 1 2 SAE washer 76 lower,body bushing 71 frame mounting pad 70 top.
body bushing 74 kit 3 x 3 2 x 3 for 2,spacer block 72 and body 48. c Install kit 1 2 x 6 1 2 1 2 x 5 1 2 for 2 bolt,75 through kit 1 2 SAE washer 76 lower. body bushing 71 frame mounting pad 70 top,body bushing 74 kit 3 x 2 2 x 2 for 2. spacer block 73 and body 48,d Install kit 1 2 x 6 1 2 1 2 x 5 1 2 for 2 bolt. 75 through kit 1 2 SAE washer 76 lower,body bushing 71 frame mounting pad 70 top.
body bushing 74 kit 3 x 2 2 x 2 for 2,spacer block 73 and body 48. e Install kit 7 16 x 5 1 2 7 16 x 4 1 2 for 2 bolt. 77 through kit 3 8 USS washer 78 lower,body bushing 71 frame mounting pad 70 top. body bushing 74 kit 3 x 2 2 x 2 for 2,spacer block 73 and body 48. Wait to install kit 7 16 x 5 1 2 bolt through body bush. ing rear bumper kit lift block and body until the pas. senger side of the body is lifted and the driver side of. the body is being lifted, f Install kit 7 16 x 5 1 2 7 16 x 4 1 2 for 2 bolt. 77 through kit 3 8 USS washer 78 lower,body bushing 71 frame mounting pad 70 top.
body bushing 74 kit 3 x 2 2 x 2 for 2,spacer block 73 and body 48. 12 97 06 TJ TJL Rubicon Kit 972 973,3 Passenger side bump stop head light bezel. a Remove urethane bumper 79 from core sup,port 15 passenger side. b Coat threads of kit 5 16 x 2 3 4 bolt 80 with, c Install kit 2 x 2 lift block for a 2 lift use a 1 x. 2 lift block 81 and kit bump stop 82 on core,support 15 with kit 5 16 USS washer 85 and.
kit 5 16 x 2 3 4 bolt for a 2 lift use a 5 16 x 1,3 4 bolt 80 Torque bolt to 10 lb ft DO NOT. overtighten,d Install head light bezel 14 on core support 15. with three screws 13,e Lower body 48 onto kit spacer blocks 72 and. 4 Install body driver side spacer blocks, a Repeat steps C 2 a through C 2 f for driver side. b Install kit 7 16 x 5 1 2 7 16 x 4 1 2 for 2 bolt. 77 through kit 3 8 USS washer 78 lower,body bushing 71 core support mounting pad.
69 top body bushing 74 kit 3 x 2 2 x 2 for,2 spacer block 73 and core support 15. c Repeat steps C 3 a through C 3 e for driver,side core support 15. 13 97 06 TJ TJL Rubicon Kit 972 973,5 Finish spacer block installation. a Remove five kit 7 16 x 5 1 2 7 16 x 4 1 2 for Rear Axle. 2 bolts 77 and six kit 1 2 x 6 1 2 1 2 x 5 1 Vent,2 for 2 bolts 75 one at a time from core sup. port body and frame mounting pads 15 48,and 70 coat threads with Loctite and reinstall.
b Adjust body 48 to frame alignment and tighten,bolts 75 to 50 lb ft and bolts 77 to 35 lb ft. 6 1997 2002 Models Fuel filler Fuel Filler, a If equipped with a rear axle vent line remove zip. tie from vent line and vent hose,Fuel Filler,b Remove two clamps fuel filler hose vent hose. and fuel filler assembly from fuel tank and vehi,c Cut vent hose and fuel hose in half as shown. Kit 28 Clamps,Kit Extension,Kit 10 Clamps,Kit Extension.
d Install kit vent hose extension on vent hose with. two kit 10 clamps, e Install kit fuel filler extension on fuel hose with. two kit 28 clamps,14 97 06 TJ TJL Rubicon Kit 972 973. f Install fuel filler assembly on fuel tank with two. Filler Hoses, g If equipped with a rear axle vent line install kit. zip tie on vent line and vent hose,Kit Zip Tie,Filler Hoses. h Install fuel filler surround on body with four, i Install fuel filler assembly on fuel filler surround.
with four screws,Fuel Filler, j Install fuel cap on fuel filler assembly Surround. 7 2003 2006 Models Fuel filler Fuel Filler,a If equipped with a rear axle vent line 84. remove zip tie 85 from vent line and vent hose,15 97 06 TJ TJL Rubicon Kit 972 973. JEEP WRANGLER TJ UNLIMITED TJL RUBICON MODELS BODY LIFT KIT INSTALLATION INSTRUCTIONS 1997 2006 2 KIT 972 3 KIT 973 WARNING Installation of a Performance Automotive Group body lift will change the center of gravity and the handling characteristics of the vehicle Because of the higher center of gravity and larger tires the vehicle will handle and react differently both on and

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