Tera Flex 3.25" Suspension System - - Jeep at Off-Road.com
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Tera Flex 3.25" Suspension System

Source: Jeep at Off-Road.com
Action shotWhen considering a suspension upgrade for the Grand Cherokee we all look for that ideal kit that retains our stock driving characteristics and allows us to traverse any imaginable terrain, anywhere, anytime, under any conditions. For this type of product to be developed you must employ a group of loyal Jeep enthusiasts that possess a naturally high mechanical aptitude along with a sincere love of Jeeps. The previous sentence would serve as an accurate description of the good folks at TeraFlex.

Action shotThere are many companies out there that can, and do, produce lifts for your Grand Cherokee but few compare to TeraFlex. These folks not only lift Jeeps and build kits, they drive Jeeps themselves. Keeping in touch with the 4x4 Jeep community allows them to remain on the cutting edge of suspension development. Try calling one of the big "lift all" companies and requesting specific info on lifting your Grand - no dice. Call Tera and you are likely to be talking to someone who owns a lifted ZJ themselves.

Action shotNow lets talk about the true performance of this lift. The days of lifting a vehicle and throwing its on road driving manners out the window are long gone when it comes to the Tera kit. This kit not only includes the finest springs available but all the necessary bump stop extensions, brackets, nuts and bolts to complete the install.

 

Parts Included:
  • two front springs
  • two rear springs
  • installation kit:
  • two rear sway bar links
  • four washers, flat 5/16" SAE
  • eight bushings, rubber
  • two spacers, 3"L x 1.25"W x 1.50"H (rear)
  • four bolts, 8mm x 60mm
  • four washers, flat 5/16"
  • four nuts, nyloc 5/16" NF
  • two spacers, 3" OD x 1.5" tall (aluminum)
  • two bolts, self tapping 2" x 3/8"
  • one bolt, 10mm x 75mm
  • one nut, 10mm x 1.5p hex
  • one bracket, rear track arm
  • one nut, 1/2" NC
  • one washer, flat 1/2"
  • one washer, lock 1/2"
  • one bolt, 3" x 1/2" NC
  • two bolts, 1" x 5/16" NF grade 8
  • two nuts, 5/16" NF
  • two washers, lock 5/16"
  • two washers, flat 5/16" SAE
  • one spacer, 1.62" x 1" OD x .5" ID
Tools Needed:
  • Torx bit T55
  • drill bits (5/16" & 13/32")
  • jack stands and jack
  • standard hand tools
  • external spring compressor recommended (sometimes called a strut compressor). These are commonly available at local auto stores as a "rental" tool for free use by customers.

 

The following is a step-by-step installation as per Tera instructions. The rear of the vehicle is always lifted first so that it is possible to lift the rear one evening and the front the next evening. If you can change your oil and rotate your tires - you can lift your Grand Cherokee. Full install takes an average of eight hours.

 

Step 1

Step 5

Step 5

Step 6

Step 8

Step 9

Step 16

Step 17

Step 20

Step 24

Step 28

Step 30

Step 32

  1. Jack up the rear of the ZJ by the frame and secure it with jack stands. Make sure you get the tall 4x4 stands and not the short stands for normal vehicles.
  2. Remove the rear shocks.
  3. Remove the rear sway bar links.
  4. Remove the rear rubber bump stops by grasping the bump stop and pulling down with a side-to-side motion.
  5. Remove the bolts inside both bump stop cups.
  6. Remove the spring clamp and bolt. Remove the rear springs.
  7. With two new bolts (60mm x 8mm, 1.5 pitch) replace the bump stop cup placing the spacer (3"L x 1.25"W x 1.50" tall) between the bump stop cup and the frame.
  8. Remove the plastic dust shield that covers the bolt securing the rear track bar to the rear axle housing. You will no longer need this shield.
  9. Remove the Torx headed bolt size T55 and set it aside. (Note: It is easy to remove and replace the track bars front and rear with the Jeep on the ground.) Tie the track bar end up out of the way while you install the track bar extension bracket.
  10. Hold the rear track bracket extension over the axle bracket positioned as shown in the picture. Using one of the bolts (3" x .5" NC) and the spacer (1.62" x 1" OD x .5" ID) insert them in the hole vacated by the Torx headed bolt. Use the spacer to fill the spot the track bar once occupied. This will keep the bracket from collapsing when the new bolt is tightened.
  11. With the new track bracket in place you will see the smaller two holes in the bracket should line up close to the holes in the axle bracket vacated by the plastic one way fasteners you removed to get the plastic shield off.
  12. Using a 5/16" drill bit drill out the small holes upper and lower to make room for installing the (1" x 5/16") bolts, nuts, and washers all 5/16" NF. Install and tighten the nuts and bolts. (Note: Installing the top small bolt is kinda tricky but very necessary. You may find installation easier if you disconnect the drivers side upper control arm at the axle.)
  13. Line up the track bar with the upper holes in the new track bar bracket and use the Torx bolt and nut you removed in step #9 to secure the bar in place.
  14. Install the new TeraFlex rear springs.
  15. Install the new longer shocks you purchased along with the kit. The boot of the shock goes up unless the one you are using specifies differently.
  16. Install the new longer sway bar links.
  17. Lower the rear of the vehicle and jack up the front by the frame and set stands in place.
  18. Remove the front shocks. Save the lower bolts.
  19. Remove the bump stop cushions and the bolts in the bump stop cup. You will be putting these back after the new springs are in place.
  20. Remove the spring clamp and bolt, set aside.
  21. Remove the front sway bar links.
  22. Remove the springs, passenger side first.
  23. Using the 5/16" drill supplied locate the center of the front lower spring pad. You should see an impression in the center that works well as a guide. Drill a hole through the guide in the pad.
  24. Using the aluminum spacer (3" OD x 1.5" tall) as a guide, screw one of the self tapping bolts (2" x 3/8") into each hole to cut the new threads. Now remove the bolts and set aside.
  25. Install the TeraFlex front springs, passenger side first. Set the aluminum spacer (3" OD x 1.5" tall) inside the Teraflex spring as you put it up into place. Once the spring is in place rotate the spring so the bottom end of the spring butts up against the stop in the axle pad support.
  26. Replace the spring clamp and bolt taken out in step #20.
  27. With the aluminum spacer resting on the lower spring pad, center the spacer and install the self tapping bolt used to cut threads in step #24. Tighten the bolt.
  28. Replace the upper bump stop cup, bolt and cushion removed in step # 19.
  29. Install the new longer front shocks you purchased along with the kit.
  30. Re-attach the front anti-sway bar link. (Note: in picture below you will see that we have already installed TeraFlex quick disconnects in place of the stock links.)
  31. Re-check ALL bolts and make sure everything is tight.
  32. Now lets straighten out that steering wheel! (Note: Our goal is to find the "neutral" location for the front axle. If we do this the steering wheel will be very close to center.
  33. Make sure the Jeep is on flat level ground. Remove the passenger side of the front track bar. With the Jeep on the ground and steering wheel locked in its center position bounce the Jeep up and down. Use the front bumper to do this. After you have done this the front suspension and steering should be in a neutral position. Now without moving any other components raise the lower end of the track bar up into its mounting bracket. Using the track bar center hole as a guide mark the bracket. If you have room in the bracket so the hole does not overlap any edges go ahead and drill the new hole out. Make sure you are drilling at a right angle to the bracket when drilling through the rear half of the bracket. Use a 13/32" drill bit. If you drilled the hole in the correct location you should be able to just lift the bar up and insert the new 10mm x 70mm bolt. Torque bolt to 40ft/lbs.

 

Note: If you can't get enough area clear of the old hole to drill a clean hole then go ahead and reconnect the track bar. Drive the Jeep. If it feels OK then leave it.

A full alignment to factory specifications is recommended after every suspension modification.

Well, there you have it. The TeraFlex kit will give you the off-road prowess that will make even the seasoned Jeeper take notice as he watches you crawl and flex over seemingly impossible obstacles. When you leave the trail after a long hard day of off-roading it is sure nice to cruise home in the comfort of a TeraFlexed Grand Cherokee that handles as well on road as it does off road.

Look for the final segment next month when we install the TeraFlex "FlexArm" (with OEM rubber bushings!) lower control arms front and rear, along with the TeraFlex quick disconnects for the front anti-sway bar.

 

Tera Manufacturing
7241 South 620 West
Salt Lake City, UT 84047

801-256-9897
801-256-9879 fax

falkner@vii.com

TeraFlex kit installed at:

Grand Cherokee Connection
2514 Bird Drive
Erie, PA 16510

814-898-8381
814-899-5104 fax


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