3” Body Lift Install
(Before and After the 3” Body Lift)
Start off by laying out the contents to assure the kit is complete. (fig1.3). It is important that the Jeep is on flat even ground with the transmission in neutral for this installation. Use blocks at the tires to prevent it from rolling.
fig1.3 fig2.1
fig2.2
Disconnect the battery (negative first), vacuum line from the brake booster and everything else that you see that is going to be affected by raising the tub three inches (fig2.1). Remove the coolant reservoir (including the overflow hose), all six radiator mounting bolts, air bag fuse (located in the glove compartment), plastic jeep cover (fig2.2, 2.3) and the bolt that mounts the steering carrier bearing to the top of the frame. (15 mm socket)
fig2.3
fig3.1
fig3.2
This jeep has a manual transmission, skip this section for automatics. Remove the center console to access shifter boot and mount. Undo the four screws that hold the round shift boot to the floor pan. Do the same for the floor pan cover over the transmission and place it to the side (fig3.1). Disconnect the lower transfer case linkage from the pivot assembly. (This rod connects directly to the transfer case). Next the two bolts that mount the transfer case pivot assembly to the transmission and the bolts hold the t-case pivot assembly to the body (fig3.2). This will allow you to remove the assembly from the vehicle.
fig4.1
fig4.2
fig5.1
Take the gas cap off. Remove the four screws holding the spout in place (fig 4.1) and the four holding the plastic housing (fig4.2). Loosen the hose clamps and pull out the two hoses. These will need to be lengthened later on in the installation.
NOTE: The Gasoline tank is now
exposed & is extremely
flammable, use extreme caution when working near it.
fig5.2 fig5.3
fig5.4
Locate and loosen all eleven body mount bolts using the diagram below (fig10.5). Unbolt, the passenger side and slowly jack up the jeep. Keep an eye out for anything that may be still connected (fig5.2). Lift, just enough to slide in the 3" spacers and bolt them in (fig5.2, 5.3, 5.4). Do not tighten them yet. Lower the passenger side and repeat on the driver side.
fig6.1 fig6.2 fig6.3
Sure enough, a body mount bolt broke on the driver side and it’s trapped inside the floor of the tub. (fig6.1, 6.2, 6.3) Read the next section to see our solution.
fig6.4
fig6.5 fig6.6
Carefully cut a flap in the floor directly above the bolt location (fig6.4). Peel it back to access the bolt (fig6.5). Thread a nut on the end of the bolt that is protruding out of the body mount nut. (The idea here is to make another bolt head on the opposite side. This will allow you to unbolt it from our access flap.) Weld the nut to the bolt and grind a smooth surface where it broke off originally (fig6.6). Extract the broken bolt, fold down the flap and weld it shut. As a finishing touch, smooth out the weld and paint it to avoid rusting.
fig7.1
fig7.2
fig7.3
At this point, all the body mounts spacers should be installed except the one at the front end of the vehicle. This one is located under the radiator, which is held on with brackets, they will need to be modified to lower the radiator three inches. A template is included with the kit to make things easier. Make the appropriate cuts and bolt the radiator back into place (fig7.1, 7.2, 7.3, 7.4).
fig7.4
fig8.1
fig8.2
Mount the six radiator drop down brackets to the core support (fig8.1, 8.2). Adjust your fan to fan shroud clearance. Mount the vent hose to the top of the radiator mount. Tighten all of the bolts, remount the coolant recovery tank and reconnect the vacuum hose to the brake booster.
fig7.4 fig8.1
fig8.2
Install the relocating bracket to the stock pivot bracket using the original hardware (fig8.1.8.2) Reinstall the transfer case shift linkage and pivot assembly in the jeep. Attach the new relocating bracket using washers and nylon nuts (Do not tighten at this time). Place the floor pan back into position and fasten with all of the screws. At the end of the linkage rod you will find a nut, this nut is for adjusting your 4WD shift lever. You may need to unscrew the adjuster. This will give you more clearance for your lever to shift down into 4 LO. The same problem may occur with your Transmission shifter. You have the option of chopping off the lower part, and adding a spacer rod or heat may also be used to bend your shifter so it will not rub on your tub. I didn’t have a problem with my shifter, so we skipped this step. Once the shifters are working properly you can tighten up the fasteners on the linkage.
fig10.1 fig10.2 fig10.3
fig10.4
fig10.5
At this time you can install the steering carrier side support plate, it is basically just another relocating bracket for your steering rod.
You can now start on extending the fuel filler inlet hose. Cut the filler hose into two pieces in the straight area of the hose and install the extension piece. Next clamp your hose clamps at each end of the extensions and tighten securely (fig10.1). Replace the vent hose with the one given in the kit using hose clamps provided. Remount the plastic housing to the body. Remount the hoses to the tank as well as the plastic housing to the tub (fig10.2, 10.3).
Ok, on to the final steps, reconnect the plastic jeep cover onto the front bumper that covers your front sway bar (fig10.4) and reconnect your battery.
Now, that you are completed, be sure to check that everything is working properly. Gasoline leaks, shifter clearance, fan clearance, and any electrical problems.
Before
After:
Jeep Specs Retail Resources Body Lift Kit Information
1998 Jeep TJ Sport National4wd Daystar 3" TJ body lift
Engine: 4.0 Burlington, Ontario Complete Kit, ready to install
Driveline: Ax15 Manual / NP231 4122 South Service Road Part #
Axles: Dana 30/35 L7L 4X5
1 800 575-7500
