JKS BSE201 - Manual (Page 3)

JKSBSE201 JKS Hydraulic Bump Shocks Installation Page 3
 Remove Jounce Adapter (C) from upper spring
retainer and locate the weld location markings on
the adapter and upper spring retainer.
 Remove the zinc plating from the marked loca-
tions on the Jounce Adapter (C). Also remove the
factory paint from the corresponding locations on
the upper spring retainer. HINT: Emory cloth or a
suitable stripping tool is useful for removal of coat-
ings. Make sure bare metal is completely exposed
and free of contaminants to ensure proper weld
penetration.
‰ 4. INSTALL JOUNCE ADAPTER ON
PREPARED SPRING RETAINER
 With your welding equipment powered up and
ready to go, reposition the Jounce Adapter (C) on
the upper spring retainer, making sure the loca-
tions prepped for welding are in alignment.
 Hold or clamp the Jounce Adapter (C) in position
and tack weld the adapter to the spring retainer
at each location. Make sure the adapter has
remained fully seated against the spring retainer
before proceeding.
 Next, weld a 1/2” long bead over each tack weld
to ensure the Jounce Adapter (C) remains secured
to the upper spring retainer. HINT: As long as you
achieve proper weld penetration on the adapter
and spring retainer, it is not necessary to weld
around the entire perimeter.
 Allow the welded sections to cool and then drill a
3/8” hole through the upper spring retainer imme-
diately above one of the stitch welds. The purpose
of the hole is to facilitate the evacuation of any
moisture that may collect inside the retainer.
 To prevent corrosion, it will be necessary to paint
all exposed surfaces on the Jounce Adapter (C)
and spring retainer. Prepare for painting by thor-
oughly cleaning any dirt, debris or deposits from
the area. HINT: A clean piece of emory cloth or
equivalent is useful for preparing the area to be
painted.
 Completely cover the exterior of the Jounce
Adapter (C) and all exposed metal on the upper
spring retainer with satin black spray paint. Protect
inner threads of adapter from overspray.
‰ 5. INSTALL BUMP SHOCK ASSEMBLY
 Apply anti-seize lubricant to internal threads of
Jounce Adapter (C) and Bump Shock Nut (B).
 Completely thread the Bump Shock Nut (B) onto
Bump Shock Assembly (A).
 Thread Bump Shock Assembly (A) into Jounce
Adapter (C) as far as possible.