BARNES4WD XJ Front 3 Link Long Arm Suspension Kit Installation Guide

Installation Guide for BARNES4WD models including: B4WK12787, B4WK12788, B4WK12789, XJ Front 3 Link, XJ Front 3 Link Long Arm Suspension Kit, Long Arm Suspension Kit, Arm Suspension Kit, Suspension Kit, Kit

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XJ Front 3 Link Installation Instructions ?v=1684236718

XJ Front 3 Link Installation Instructions
Thank you for purchasing our XJ Front 3 Link!
Installation Notes:
· This product is designed to fit Jeep Cherokees 2 door or 4 doors 1984-2001 with an AW4 automatic transmission.
· The transfer case skid is designed to fit a NP231. · This kit requires welding, automotive mechanical knowledge, and general fabrication skills, it
should only be installed by qualified individuals. · This kit requires a minimum of 4" of lift with 3" of bump stop extensions. · If a front axle has been swapped using our swap kit the left upper control arm mount will need
to be drilled out to accept a 9/16" bolt. · The factory lower frame control arm mounts and the left side frame front upper control arm
mount will need to be removed. · The components of this kit will need to be painted or powder coated during installation. · This kit includes stainless steel hardware on some components. We recommend using a quality
anti-seize compound on any stainless hardware during installation.
Tools required:
· Drill · 17/32" Drill Bit *if you do not have frame stiffeners installed · 8.5mm Drill Bit · R Drill Bit *only if you have frame stiffeners installed · M10x1.5 Tap · Various Hand Tools · Jack · Jack Stands · Welding machine with the capability to weld at least ¼" thick steel · Cutting torch, plasma cutter, or other appropriate cutting tool
AJM 5/4/23

Possible Kit Combinations
Use the charts below to determine which combination of boxes you will receive for your make and model of Jeep. Each box should have a barcode with the kit part number listed on it.

Qty

Kit Part Number

Kit Description

B4WK12787

XJ Front 3 Link Bracket Kit

B4WK12788

XJ Front 3 Link Lowers Pre-Pack

B4WK12789

XJ Front 3 Link Upper Pre-Pack

B4WK12790

XJ Front 3 Link Kit Transfer Case Skid Pre-Pack

Contents of each box

Bill Of Materials for B4WK12787

QTY

Part Number

Etch Number

Description

B4W188980

980 B

XJ Front 3 Link Driver Gusset

B4W250958

958 B

XJ Front 3 Link Crossmember Frame Bracket Driver

B4W250961

961 B

XJ Front 3 Link Kit Upper Bracket

B4W250960

960 B

XJ Front 3 Link Lower Bracket Driver

B4W250956

956 B

XJ Front 3 Link Crossmember Main

B4W250959

959 B

XJ Front 3 Link Crossmember Frame Bracket

Passenger

B4W188981

981 B

XJ Front 3 Link Passenger Gusset

B4W250971

971 B

XJ Front 3 Link Lower Bracket Passenger

B4WK12786

957

XJ Front 3 Link Crossmember Bottom Assembly

37C125HC8Y

3/8"-16X1-1/4" Hex Bolt Grade 8 Yellow

37NWSAFY

3/8 SAE Washer Yellow Zinc

FPCALFST616150

3/8-16 Rivet Nut Insert .027-.150

43CNNE0Y/GC

7/16-14 NYLOCK

43C125HCS8Y

7/16-14 x 1.25

43NWSAFY

7/16 SAE Washer Yellow

6 .100C350BHF0Y/6921

M10-1.5 x 35mm Hex Flange Bolt Yellow Zinc

43CNFH8Y

7/16-14 Nut

37C125HTR0Z

3/8"-16 x 1-1/4" Hex Washer Thread Forming Screw

AJM 5/4/23

Bill Of Materials for B4WK12788

QTY Part Number Etch Number

Description

2 56C400HCS8Y

9/16-12x4 GRADE 8 BOLT

2 56CNNE0Y/GC

9/16-12 NYLOCK

2 DOM201536

DOM 2"X1.5"X36"

2 JN125012LH

LH 1-1/4"-12 Jam Nut

2 JN125012RH

RH 1-1/4"-12 Jam Nut

125HWRH

Heavy Wall Tube Insert (1 1/4"-12) For 1 1/2" I.D. Tubing

125HWLH

Heavy Wall Tube Insert (1 1/4"-12) For 1 1/2" I.D. Tubing

HMS169ZP

Hi Mis-Alignment Spacer Pair

XM16-CR

Heat Treated Chromoly 1 1/4-12 X 1 RH Long Shank

XM16-CL

Heat Treated Chromoly 1 1/4-12 X 1 LH Long Shank

Bill Of Materials for B4WK12789

QTY Part Number Etch Number

Description

56C400HCS8Y

9/16-12x4 GRADE 8 BOLT

56CNNE0Y/GC

9/16-12 NYLOCK

56C325HCS8Y

9/16-12 X 3 1/4" Grade 8 Bolt

B4WXJLAFUL

XJ Front Long Arm Upper Link

TJFAUCAB9

TJ Front Axle UCA Bushing 9/16"

B4W188660

660 B

TJ Suspension Kit Front Upper Link Axle Bracket

JN125012RH

RH 1-1/4"-12 Jam Nut

HMS169ZP

Hi Mis-Alignment Spacer Pair

XM16-CR

Heat Treated Chromoly 1 1/4-12 X 1 RH Long Shank

1 1251215175RHMS

Tube Insert 1.25-12RH 1.5ID 1.75OD

Bill Of Materials for B4WK12790

QTY Part Number Etch Number

Description

B4W250963

963 B

XJ 3 Link Tcase Skid Bracket

B4W250962

962 CB

XJ 3 Link Tcase Skid

37C100KFCS

3/8-16 x 1 Counter sunk SS bolt

3 37C125HCS8Y

3/8"-16X1-1/4" Hex Bolt Grade 8 Yellow

1 FPCALFST616150

3/8-16 Rivet Nut Insert .027-.150

37NWSAFY

3/8 SAE Washer Yellow Zinc

2 37CNNE0Y/GC

3/8-16 Nylock Yellow

AJM 5/4/23

Step 1:
Park vehicle on a level surface. Support the transmission and remove the factory crossmember.
Step 2:
Drill out the forward most hole in the unibody with an 8.5mm drill bit and tap to a M10X1.5 thread.
Step 3:
Remove crossmember studs from the unibody threading two nuts together onto the stud. Tighten the nuts together and turn the top nut to remove the stud.
AJM 5/4/23

Step 4:
Assemble the crossmember as shown below making sure it is assembled in the correct orientation. Weld the bottom to the main crossmember.
Step 5:
Assemble the driver and passenger side control arm brackets as shown below. Once assembled in the correct orientation weld the assembly together.
AJM 5/4/23

Step 6:
Install the driver and passenger side bracket assembly, and gusset onto the vehicle as shown below. Mark the 3 holes in the gussets on each side of the unibody. Remove the bracket
assembly. Drill a 7/32" hole if you do not have frame stiffeners and move to step 7. If you do have frame stiffeners drills a R size hole and move to step 8
Step 7:
Using one of the 3/8" bolts, two 3/8" washers, and the provided 7/16" nut, as shown below, install the six rivet nuts. Push the rivet nut into drilled in step 6. With a 11/16" wrench, hold the
7/16" nut and using a 9/16" wrench or socket, tighten the bolt until the rivet nut is fully installed. The bolt will become very tight and there should be no wiggle or twist to the rivet nut.
AJM 5/4/23

Step 8:
Reinstall the driver and passenger side bracket assembly and gusset to the unibody. Using 3/8" thread forming screws for frame stiffener installation and standard 3/8" hardware for nonstiffener installation. Leave hardware loose until crossmember has been installed.
Step 9:
Install the crossmember as shown below and tighten all the hardware.
Step 10:
With the Jeep sitting at ride height measure the bolt hole center distances from each bracket on the crossmember to the accompanying bracket on the axle and record these measurements in the table
below. The measurements taken here will be used to build the new control arms.
Right Lower Left Lower
Upper Step 11:
The provided front axle right side control arm bushing now needs to be installed in the front axle. Remove the front left upper control arm from the Jeep. Take a measurement from the side of the casting to the end of the bushing and record this measurement. The old bushing now needs to be removed. This can be accomplished with multiple methods, however using a pneumatic air hammer to drive the old bushing out is the most effective method. The new bushing will now need to be installed to the same dimension as recorded above. A ball joint press or other appropriate tool can be used to press
the new bushing in.
AJM 5/4/23

Step 12:
Assemble the lowers, the provided tubing will need to be cut to length and the threaded inserts welded into each end. Referencing the images below for component placement, assemble each heim joint, tube insert and jam nut with 1" of thread showing between the end of the jam nut and the end of the threads
on the heim. This will allow for some adjustment after installation if needed. Place the assembled components on a table or other flat surface and arrange them based on the bolt hole center
measurements taken in step 10. Measure the distance between the tube inserts and cut the tubing to this length. Remove the heim joints from the threaded inserts, install the inserts in the tubing, and weld
in place for each link.
AJM 5/4/23

Step 13:
Assemble the upper link as follows. The provided tubing will not need to be cut for the upper. Install the threaded insert and weld in place. Lay the tube flat on a level surface across the short bent and. Center B4W188660 on the tube, the top should measure 90° from the level surface. Weld the bracket together
and to the tubing.
AJM 5/4/23

Step 14:
The unibody front left upper control arm mount and both the unibody lower control arm mounting brackets will need to be cut off from the unibody. This can be done all at the same time or one at a time. If only removing one link and unibody bracket at a time, the new link can be then installed in its place. This is a useful method if installing this kit without the use of a vehicle lift. Hardware has been provided for all the frame brackets and the uppers at the axle, the factory bolts for the lowers at the axle will be reused. The remaining upper control arm brackets on the unibody and axle brackets can be removed if desired or left in place. Tighten all 9/16" hardware to 110 Ft-lbs.
Congratulations! You have finished the installation of the Barnes4wd XJ Front 3 Link Kit.
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AJM 5/4/23

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