2002 TJ - OME lift install

[ThePhantum]

This writeup will cover the installation of an OME 2.5" lift (springs & shocks), front & rear extended bumpstops, front & rear adjustable trackbars, JKS "quicker" disconnects and a 1" t-case drop on a '02 TJ Sport. This installation was performed on Feb 28th, 2004. It was straightforward, but time consuming....and quite tiring I might add. Luckily, we had an awesome day for it... it was absolutley gorgeous outside!

Component List:
2.5" Lift OME coil springs & Shocks
OME 1" transfer case drop kit
JKS Front adjustable trackbar
JKS "Quicker" disconnects
RE Rear adjustable trackbar
2" front bumpstop extensions
1.5" rear bumpstop housing extensions
15"x8" Crager 352's (with simulated bead locks) wrapped with 32"x11.5" Goodyear MTR's

All of the components were purchased from Dirk at DPG Offroad, with the exception of the wheels and tires. The wheels were purchased from Quadratec and the tires from Tirerack.

Tools used:
Instructions that came with each of the components
Factory Service Manual
Floor jack and 4 Jack Stands
1/2" drive Torque Wrench (ft/lbs)
3/8" drive Torque wrench (in/lbs & ft/lbs)
3/8" and 1/2" drive ratchets, breakbars and sockets (metric and imperial sizes)
Open end and box wrenches (metric and imperial sizes)
Allen keys
Drill with 5/16" and 9/16" bits
Circlip pliers
Torx bits
Ball joint separator (a.k.a. forkbar or pickle fork)
BFH - 3lb
Spring Compressor
3/8" Thread tap

I could call him a tool (which he is) but I also had Dale, a.k.a. majikxms, helping me out with this install…which also made the whole thing go quicker.

Shock Assembly
The day before the install, I put the Jeep up on jack stands, removed the wheels and sprayed every bolt that I planned to put a wrench to with PB Blaster to let them soak over night. I then proceeded to assemble the shocks. They use a T-bar mounting system that uses two washers to contain the poly bushing, which keeps the t-bar centered. The circlip holds the whole thing together and adds a slight preload to the bushing.

Now although the directions say to use a vise or a press to assemble it, I was too lazy to go out to the garage (it was 1AM at the time). So in tradition with my trademark for redneck engineering, I simply slid the washer over the t-bar, used a little dishsoap to lubricate the eye of the bushing and used a pair of channel locks to push the t-bar through. Then I just installed the other washer and followed it up with the circlip. Viola…the trick, she is done!



Front Springs & Shocks
Now onto the fun stuff…we started with the front suspension. First we disconnected the front sway bar links. We took off the nuts and, to my surprise, needed the forkbar and BFH to break the bar away from the links. We just beat and bashed on them until they broke loose. Then we removed the link from the axle by removing the nut and bolt (the bolt is torx). Then, after supporting the axle with the floor jack, we removed the shocks and the LCA bolts (at the frame). There were no spring retaining bolts, so we noted where the spring pigtailed in on the perch and dropped the axle enough to remove both springs.

Before installing the new spring we installed the bumpstop extensions. These particular extensions install on the spring perch itself and are secured by 3/8" bolts. So, we drilled 5/16" holes, tapped out threads for a 3/8" bolt and installed the stops. You can kinda see the bumpstops installed in this pic...



Now onto the spring install. One spring is slightly taller than the other. The taller one is intended to be (and was) installed on the drivers side. Fairly simple, we just used the spring compressor to scrunch the spring down until it would go on the perch, then removed the compressor, while making sure that the spring pigtailed into the perch correctly. Then, jacking and jostling the axle, we lined up the LCA's, reinstalled and torqued the bolts (I reversed the bolts so that the threads face inward, to facilitate the future installation of an engine skid) and installed the shocks.






JKS Disco install
Next, the discos were installed. We started by bolting the pin (bottom of the image) into the axle. Then we installed the U-bracket (at the top) on the sway bar. A bolt and bushing attach the upper eye of the disco to the bracket…using loctite on the threads to make sure it does not back out. After the entire lift install was done and the Jeep was sitting on level ground, we adjusted the length of the disco's ensuing that the sway bar was in a level position, connected them at the bottom and greased the hell out of them.



Here's a pic of the passenger disco in place. I really llike this pic...


Front Track Bar

Onto the front track bar…First, we removed the bolt at the axle. Then took out the cotter pin and removed the nut at the frame. Then Dale and I just took turns beating the hell out of it with the forkbar and BFH until it finally broke loose. Now to install the new track bar we had to drill out the frame side hole to 9/16". It's only the top potion of the hole that needed to be drilled so it took no time at all. Once that was done we hung the trackbar on the frame side and got the bolt godzilla tight. Now I was not to worried about getting the axle perfectly centered, as I had 4wdSpecialty dial both trackbars in and align it…but I wanted to get it fairly close. So Jen got in, turned on the jeep and we stood in front while she turned the steering wheel fully to the right side, then left, back and forth a few times. We then had her slowly turn the wheel and eyeballed the axle to center. After which, we installed the axle side of the tbar and torqued it all up…close enough for gubment work….


Onto the rear….


Rear Springs, Shocks & Trackbar

We started by supporting the axle with a floor jack. Then we disconnected the rear sway bar, followed by removing the shocks, which was a PITA as the upper bolts are just in a tight place. After that we dropped the trackbar and lowered the axle until we could remove the springs.

Again, prior to installing the springs we installed the bumpstop extensions. These were a lot easier than the fronts. We pulled the bumpstops out of their housings, removed the bolts that hold the housings to the frame, installed the spacers using the longer bolts provided and pushed the bumpstops back in.

Just like the front springs, one is slightly taller than the other. The difference here is that the taller spring goes on the passenger side. To install the springs, we just used the compressor again. Next we installed the shocks…again a PITA because of the upper bolts. (The first image is about two seconds before Dale bonked his head off the drum. )




Then, we just bolted in the rear trackbar (again 4wdSpecialty dialed both of them in when they aligned it) and re-connected the rear swaybar.

Transfer Case drop

The t-case drop was a piece of cake…ok maybe not…but only because it was late and Dale and I were tired. As you can see from the directions that came with the kit, the install is pretty simple…support the skid plate with a floor jack and remove the six bolts that secure the pan to the frame. Then lower the jack until there is enough clearance to get the spacers between the frame and the plate, install the longer bolts with the tapered cone washers and tighten it all up to spec.




DONE! Whew...I'm tired just thinking about it now...

Since we had not gotten the new tires as yet, the old wheels had to go on temporarily. Then we took it for a test drive and aside from the aligment and t-bars being off there were no problems...it rode just fine. I then had it aligned and the tbars dialed in on Fri, March 5th. Which was followed by my hanging the tries on it that evening.

Here's a before, an interm and some after shots.

Before, bone stock:



After the lift with the old wheels:



After the new wheels:





That's it! They'll be more pics of "Red" shortly after the 20th of March....but those will be action pics of the lift gettin' broken in!

Rock On!

Steve
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97 XJ Sport with a bunch of stuff

[WhatWasIThinkin]

Great write up

This gives me a good idea where mine will be in about a month or so. We are in the beginning of mud season and my driveway wont be user freindly till April I have basically the same stuff going in mine with a few different items.

Nice Job
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Real Jeeps dont wear Bra's

[PAJeeper]

Excellent write up Steve, well done.

You get the PAJeeper write up of the week award.

[PAJeeper]

I forgot to ask. How does it ride? Better than before?

Now to keep it all yellow underneath you need the OME steering stabiliser.

[Black2001TJ]

Great writeup! You did an awesome job, folks should use this writeup for different lifts as a great resource when you get horrible destructions!
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Just damn happy to have my Jeep back, it's been a long time!

[ThePhantum]

Thanks for all the kudos! I'm getting better at documenting work with pictures...it's tough to stop when your on a roll. By the time I thought to grab the camera we were already halfway done.

All the pictures are now included, BTW.

Mike - To be honest, I only drove it a little. Since the axles weren't centered and the alignment was out, I drove it for the week back and forth to work (4 miles round trip...as compared to Jen's 130) until I could get it in to 4WD Specialty. From what I could tell it seemed smoother. After the tires were hung we both noticed the need to shift it a little differently...but that's to be expected. Jen's been driving it all over hell and creation since the tires were added...and she's liked it. She's put about 400 miles on it and most of that on the highway. I'll ask her to post her opinion to the thread.

Besides...I'm more interested in how it will wheel!

Rock On!

Steve
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97 XJ Sport with a bunch of stuff

[majikxms]

I agree, I'm a Turned out looking great, I like the GY's

We didn't use the compressor on the back springs though, remember they popped right in place, we just needed to push on the hub a little.
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AHHH PB Blaster

[ThePhantum]

[JaySea]

nice writeup...and the jeep looks great
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[YellowX]

AWESOME writeup!!!

TONS of great info and pictures!!!

[Jen2Goofy]

Red has been driving great with the new lift. I had to go on travel earlier this week and drove it the 2 and a half days I was gone (450 miles). Like Steve said, we lost some power with the bigger tires, but not too much. If and when we go with 33’’ we will defianly re-gear. Also I think it handles those little potholes and road bumps better now. The jeep doesn't throw you around as much.
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Some people are like slinkeys, they’re not of much use but they will still bring a smile to your face if someone pushes them down the stairs.

www.vajeepgirls.com

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[WhatWasIThinkin]

Where did you get the 2" bumpstop extensions?
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Real Jeeps dont wear Bra's

[ThePhantum]

[WhatWasIThinkin]

Thanks

Are they plastic or hard rubber?
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Real Jeeps dont wear Bra's

[ThePhantum]