If you haven't heard of the TeraFlex suspension system for Jeep TJs by now, you'd better seek professional help. Since the new Wrangler debuted, hard-core Jeep buffs have been crowing their praises for Tera Manufacturing's premier offering. A definite improvement over the stock TJ suspension system (which says a lot since the out-of-the-box TJ is already an off-road champ), the TeraFlex outfit provides optimum ground-hugging performance without the bone-jarring, white-knuckling ride quality so typically associated with heavy-hitting, ultra-performing lift kits.
Here is the TER3 suspension...
Here is the TER3 suspension kit's primary components.
"The System," as the company refers to its TJ suspension kit, includes front and rear springs rated at 175 lb-in (compared to the stock 165-lb-in units) capable of serious off-highway workouts while keeping the wheels on the ground where they're supposed to be. The system is available in 2- to 3-inch and 3- to 4-inch lift configurations. Two-inch lifts allow for 32-inch tires, while 3-inch lifts allow for up to 35-inch tires.
Three different kits are available. The TER2 provides 2 to 3 inches of lift (depending on engine size), and includes front and rear springs, a bumpstop extension kit, a drop pitman arm, and a rear sway-bar extension kit (shocks are not included). The TER3 offers 3 to 4 inches of lift and comes with front and rear springs, a bumpstop extension kit, a drop pitman arm, a rear sway-bar extension kit, a rear-track-arm bracket, and a transfer case lowering kit (again, shocks are not included). For the all-out TeraFlex TJ suspension, you'll want the TER3S. This kit is the same as the TER3, but includes TeraFlex's own front and rear lower Flexarms, front quick disconnect sway-bar links, a steering box skidplate, and four Explorer Pro Comp ES3000 shocks and shock boots.
Place the Jeep safely on jackstands,...
Place the Jeep safely on jackstands, and remove the wheels, the shocks, and the front sway-bar end links. Remove and save the front coil lower retaining clips. Note: We have found that the factory does not install this clip on the passenger side. If you don't have a clip on that side, go to your local dealer and purchase one (PN 52005917).
To give TJ owners a better look at this awesome system, and to show you how simple it is to install, we set up our TJ with the TER3S lift kit, featuring the new optional upper control arms. The tools required for this procedure include T50 and T55 Torx bits, a pitman arm puller, drill motor and 5/16 and 13/32 drill bits, jackstands and a floor jack, and standard hand tools. Understand that this how-to is presented in a somewhat abbreviated form. The instructions supplied with the kits are more detailed and are easy to follow-even the beginner weekend wrencher can perform this swap given the proper tools.
Note: If you are installing the TER3 or TER3S, you may want to wait to install the transfer case lowering kit if you are working on a 2.5L four-cylinder. Tera Manufacturing reports that most 2.5L applications do not experience driveshaft vibration. If there is driveshaft vibration, the spacer kit can be installed later.
Although the TeraFlex suspension is a definite improvement, a little insurance never hurts. That's where the Rock Crawler II front and rear bumpers come in. Manufactured by Currie Enterprises for the TJ Wrangler, the Rock Crawler bumpers are hard-core, Moab-tested units that should take an extra slice of worry off of your plate.
Loosen the lower control arms...
Loosen the lower control arms and track bar to allow the stock coils to be removed, then remove the stock front lower control arms.
The rear bumper is designed for a high-departure angle. It's made of 1/4-inch plate steel, and features a 2-inch receiver hitch, although it is not rated for towing. The bumper is offered in black powdercoat or chrome, and all of the installation hardware is included. The Rock Crawler II front bumper is similarly designed, except that it is made of a 3/16-inch steel plate. Again, the options are black powdercoat or chrome, and the front bumper uses the TJ's original mounting hardware.
Following the supplied instructions,...
Following the supplied instructions, turn the new TeraFlex flex arms to the proper length.
Drill out the lower coil spring...
Drill out the lower coil spring mount so you can install the bumpstop spacers after the new springs are installed.
Remove the track arm, then...
Remove the track arm, then measure and drill the new relocation hole according to the instructions.
Remove the tie-rod end, and...
Remove the tie-rod end, and pull the stock pitman arm with a quality puller.
Install the new TeraFlex arms,...
Install the new TeraFlex arms, then make sure the coils fit in the stock detent, and install the stock retaining clips.
Install the new TeraFlex quick-release...
Install the new TeraFlex quick-release sway-bar disconnects on the bar and axle housing.
Use a come-a-long, and put...
Use a come-a-long, and put the track bar back into position. Install the track arm, and release the come-a-long.
Install the drop pitman arm...
Install the drop pitman arm and tie-rod end. Then install the new steering stabilizer.
Install the new steering-box...
Install the new steering-box skidplate under the front bumper. Then go in between the coils and install the new bumpstops. Finally, attach brake-line extension brackets, and install the shocks.
Lower the transfer case, and...
Lower the transfer case, and install the spacers to relieve driveshaft bind.
Remove the rear track arm...
Remove the rear track arm at the axle housing.
Remove the rear sway-bar end...
Remove the rear sway-bar end links and shocks, and loosen the lower arms.
The rear coils will slip out...
The rear coils will slip out easily.
Install the new coils. Connect...
Install the new coils. Connect the track bar and the new sway-bar end links. Install the shocks to complete the TeraFlex upgrade.
To install the optional rear...
To install the optional rear upper arms, unbolt the brake line from the stock arm, and unbolt the arm.
Remove one arm at a time,...
Remove one arm at a time, and replace them with a Teraflex arm. The TeraFlex arms are preset to factory length. Install the brake line, then repeat for the other side.
For the front arm swap, simply...
For the front arm swap, simply remove one stock upper arm and replace with the new Teraflex arm.
The 3-inch lift provided by...
The 3-inch lift provided by the TeraFlex kit not only offers optimum articulation without compromising highway ride qualities, it also looks pretty darn good.
Rock Crawler II Bumper Install...
Rock Crawler II Bumper Install
Remove the stock bumper by first removing the top bolts. Next, remove the lower mounting bolts, so the stock bumper can now be removed from the frame.
The Rock Crawler II simply...
The Rock Crawler II simply bolts into the original bumper position. This is a good time to add a set of factory tow hooks.
The Currie units are much...
The Currie units are much more trim in design and size, allowing for maximum departure angle clearance. You can expect to spend about 30 minutes to complete the swap.
On the rear bumper, remove...
On the rear bumper, remove the factory bolts that secure the bumper to the frame, and remove the stock bumper.
Using the supplied reinforcement...
Using the supplied reinforcement plates, install the Rock Crawler II in the original mounting positions.
As with the front bumper,...
As with the front bumper, the rear piece provides a more trim appearance and optimizes ground clearance. Expect to spend 30 minutes to complete this swap, too.