American Expedition Vehicles AEV-Nth JK Suspension Systems - Manual (Page 5)

IJKS0100R (JK RHD Suspensions).doc Released: 12-Jan-10 page 5 of 14
Step 7: Install Driver’s (Right Side) Front Axle Bracket. For premium systems, find the smallest of the
three brackets; for standard systems use one of the two identical brackets you received. This bracket is
used solely to provide a higher attachment point for the stabilizer end link. Install the bracket to the
inboard side of the stock axle tab as shown in figure 7-1. Secure the bracket using a supplied ½” x 1.0”L
bolt, nut, and washer.
For standard +3.5” systems, repeat this with the second bracket on the passenger-side axle tab,
again making sure the bracket is inboard of the tab. Note that the direction of the bent flange on the front
of the bracket is irrelevant and does not need to be a ‘mirror image’ of the driver’s-side bracket.
Step 8: Install Left (Passenger-Side) Front Axle Brackets (Premium Systems only). Refer to figures 8-1
& 8-2 (pictures) and 8-3 & 8-4 (CAD views) for illustration of this step when completed. On RHD models
the track bar attaches to the axle near the differential, so the new brackets you will install depend on a
‘ring’ that attaches to the differential cover bolts to provide the needed bracing for the higher mounting
location. Your kit includes two rings – one for Dana 30 axles found in all non-Rubicon JKs, and a larger
one for the Dana 44 in Rubicons. Both rings are intended to be mounted over the stock cover without
the need to remove it – just remove the bolts and reinstall with the ring with the 10 longer bolts supplied
in the hardware pack, making sure the extra mounting holes on the ring are at the top-outboard position
as shown. NOTE: when installing the ring over the stock cover, take great care not to disturb the RTV
silicone that seals the cover to the axle housing. While there’s little risk of the cover falling off and
showing you with gear lube, slight disturbance can result in a ‘seeping’ cover that will later require
removal to replace the RTV (or better – a gasket such as those made by LubeLocker).
8-1 8-2
If you have an aftermarket cast or otherwise ‘thicker than stock’ cover, you may also mount the
ring under the cover. This of course requires draining the axle and removing the cover, and will entail
two sealing surfaces (both sides of the ring), but will otherwise work the same.
Now locate the smaller ‘nearly flat’ bracket of your remaining HighSteer parts and twist off the
attached spacer which is identical to the one you may have removed from the Dana 30 ring. Insert the
plate into the original trackbar bracket along with the spacer tube from the hardware pack and
temporarily fit the supplied 9/16” bolt through the original trackbar holes to hold things in place. Now
align the two adjacent holes with the two available holes on the differential cover ring and add spacers as
needed: For Dana 30 axles use one spacer if the ring is over the stock cover, and use both spacers if
you put the ring under/behind the cover; for Dana 44s, use no spacers if the ring is over the stock cover,
or one spacer if the ring is under the cover. Once you have the correct stack-up, attach the plates and
spacers together with the supplied ½” bolts and nuts and tighten them – the figures above show a Dana
30 with the ring over the stock cover (one spacer).