901
Oak Ridge Turnpike
Oak Ridge, TN 37830
(865) 482-6912
"Still
Plays With Jeeps" Since 1978
Darrell Dumont's TJ Gets a Pair of Teraflex 60 CRDs
Written by Joey Yoakum
For our project install, we received a pair of 60 CRDs and an LCG long-arm kit from Tera Manufacturing. After opening all the boxes and checking all the parts , I found out that we had the wrong instructions for the kit. After a call to Tera, we got the right instructions.
First, everything came out of the TJ. Axle housings, skidplates, transfer case, and misc parts were thrown to one side of the garage, out of the way. I started next by cutting all of the lower control arm brackets from the Jeep and grinding all the excess welds. I put an Advanced Adapters short tailhousing kit in the NP231 transfer case, with a chain, bearing, and pump. In the process of reinstalling the 231 into the Jeep, Tera said we would need to use a belly-up skid pan. After trying to actually put this skid pan in the Jeep, I found that the transfer case lacked the clearance to make it functional. In other words, the transfer case hot the skid pan. After a call to Tera, I learned that I would have to modify the skid pan because they were built for 2000 and up model TJs, not 97-99 TJs. After cutting and welding a drop into the skid pan, it fit like a glove! As a service to those of you trying this modification on your 97-99 TJ, we took pictures of the modified skidplate and sent them to Tera so they might have a clue how to fix this problem in the future, or at least be able to speak intelligently about the subject.
The next project was installing all the frame brackets. After a few more calls to Tera to determine the correct spot on the frame to attach the upper rear link bars, I welded and installed them in the proper location. Next was the front upper link bar bracket, which went on relatively easy, compared to what we had been through so far. I bolted and welded it on, to make sure it didn't move.
After recruiting Mitchell and Adrienne to help, we tugged and cussed and finally got the housings situated under the TJ. Next, I attempted to set the link bar to Tera's center to center measurements. This is where the fun really began. The bottom links were right on the money, but the top links would not adjust to the proper length. Another call to Tera. After talking to their head research & development guy, we figured out that I had to cut 2 inches off the top link bars. Good to go. I put everything on the rear (springs, shocks, brake lines, etc.) and centered the housing in the Jeep. On to the front! When I started trying to hook up the front links, I found that the top link was too short to even begin to work. After another call to Tera, they sent me a longer top link which I installed along with the front housing, springs, shocks, and brake lines. The aluminum draglink and tie-rod had to be cut because they were too long, which meant that they also had to be tapped to allow for full adjustment of the steering. A little note here: a 7/8" - 18 tap is a good investment, no matter if you only use it once. It's better to have it when you need it than to have to try and track one down at every machine shop in town.
After we bled the brakes and adjusted the steering, we took it to R.T. Clapp, our friendly local alignment shop. Adrienne picked it up from the alignment shop and took it for a test drive. She said she didn't want to give it back to Mr. Dumont!
After looking back at the whole process, Tera has a few minor problems with this kit that they will need to address. If this kit was advertised as something a shadetree mechanic who's biggest project had been changing his oil or installing a body lift, then it was aimed at the wrong people. This was a long and drawn-out process, especially for the average person. The Jeep rides great and flexes really well, and I hope it will give Mr. Dumont lots of pleasure for a long time to come.
Pictures soming soon!!