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Old Man EMU 2.5" YJ to CJ Suspension Install

605K views 1K replies 179 participants last post by  80cj 
#1 ·
Hey gang,

I'll be tackling this install on my 1981 CJ7 258, today, and would appreciate any tips I can get. I got it from 4WD.com

It appears the rear end is pretty simple....space the brake line and bolt everything on.

The fronts are more involved, since I have to do some grinding to install new shackle hangers, but I've got a fair handle on that.

I'm most concerned about drivability issues, afterwards. I went with the 2.5" package because I wanted to avoid castor and driveshaft problems. I know shimming to create the correct angles isn't difficult, but it seems kinda band-aid-ish to me.

Anyway, I'd love to hear from any of you with experience with this kit.

Matt
 

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#186 ·
Now I'm done...at least with the suspension.

I had the Ol' Girl professionally aligned, today. As suspected, flipping the factory shims on the fronts gave me almost 3 degrees more castor, which put it within spec.

It's surprising that a few degrees makes a significant difference in handling. My old Jeep tracks and returns to center as well as my newish pickup, now.

With the new suspension, I can power over the washboard without the rear-end wanting to trade positions with the front. The wheel to road contact this setup allows is outstanding, especially for such a short wheelbased vehicle. I can confidently let go of the steering wheel on the straight away, which I've never been able to say.

She also brakes on a dead straight line.

The Ol' Girl will get her first big wheeling test when the elk-hunting season opens in a few weeks...I can't wait.

Matt
 

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#188 ·
Now I'm done...at least with the suspension.

I had the Ol' Girl professionally aligned, today. As suspected, flipping the factory shims on the fronts gave me almost 3 degrees more castor, which put it within spec.

It's surprising that a few degrees makes a significant difference in handling. My old Jeep tracks and returns to center as well as my newish pickup, now.

With the new suspension, I can power over the washboard without the rear-end wanting to trade positions with the front. The wheel to road contact this setup allows is outstanding, especially for such a short wheelbased vehicle. I can confidently let go of the steering wheel on the straight away, which I've never been able to say.

She also brakes on a dead straight line.

The Ol' Girl will get her first big wheeling test when the elk-hunting season opens in a few weeks...I can't wait.

Matt
Im curious to know how did you install that HiLIFT Jack in the stock spare tire carrier? if you could show a close up picture that will be great. thanks.
 
#195 ·
It never really ends with these old CJs, does it? ;)

My 13-year old tires still had good tread, but were showing some age-cracking. They also were never over about 30" tall even though they were labeled as 31s. That was all the excuse I needed to give the Ol' Girl a new set of shoes!!

I chose the BFG T/A KOs in 32"x 11.5 x 15. I think this is the perfect size for my rig with its new suspension. The tires are exactly flush with the outside of the fender flares, and they don't appear "stuffed" into the wheel wells.

I haven't flexed this setup to see if there's any rubbing, but I don't expect there will be much, if any.

Hey 85 Laredo, did you get your new rubber on, yet?

Matt
 

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#206 ·
Thanks for the pictures you posted about the highlift jack set up very nice. What size shackles are those in the front of your jeep? stock shackles are 3" bolt to bolt or 4.50" overall. Im trying to gain an extra 1/2" in the front of my jeep without throwing my caster angle off and im looking for shackle options to buy. thanks
 
#197 ·
I thought we already determined you are the guinea pig for finding the max flex of this setup? :)

My wheels are 15 x 8s. The backspacing appears to be in the middle. I could check for sure, if it's important.

I take it you had a shop do most of your suspension work, hence yours taking so long?

Matt
 
#198 ·
yep.......thats what happends when you have work, school, bagpipe commitments, 4 year old, wife, no patience, and it is 112 degrees out.....I had considered doing it myself, but just no time.

I picked up my stabilizer yesterday....the closest I could find to a Bilstein...in looks anyway...since they don't make one.

 
#201 ·
It's the compressed length you need to worry about, since that's what allows enough travel in the shock when you turn the wheel hard right.

Mine measures about 13" eyelet center to center fully compressed. It comes within 1/4" of hitting my pumpkin when I crank the wheel full right.

Matt
 
#204 ·
I've ran it over some moderately rough terrain here on my place without any rubbing.

The real test will be when I take it elk hunting in a few weeks, though. The trail into our spot was more than my Tundra wanted last year, mostly due to tight corners and high-centering, so I'm hoping the Jeep has an easier time of it.

Did anything happen on your rig, today?

Matt
 
#207 ·
So, here are a few pics of the Jeep. I couldn"t flex it out all the way because my HD tie rod was coming into contact with the sway bar bracket on the frame. I will have to remove those to get another 2-3" of up travel in the front, which will give me a little more droop in the rear. Other than that, I had to order some front extended shock mounts from Rocky Road to let the front Bilsteins use all of their travel. I will have those this Friday. So in other words, it still has more to go.. :)







 
#208 ·
Looks great, Tim!! But, when are you going to really flex that thing? :D

Post a few pics of the shock mount extensions, when your mechanic gets them on. I'm curious what they are all about.

I'm looking forward to your take on the ride. Have you taken her for a spin, even without front shocks?

When's the new rubber coming?

Matt
 
#210 ·
The longer mounts should be here Friday, and I will put them on maybe Sunday. The OE ones unbolt, and the new ones bolt on where the old ones are. I haven't bought tires yet. I haven't had time to get to the shop. If you want to see what the shock mounts look like, check out Rocky Road Outfitters website. Like I said, it still had room to go.....it just couldn't because of the tie rod hitting the sway bar mount.
 
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