A novice installs AEV DualSport RT Suspension Kit - DIY writeup w/ photos

[AmosMoses01]

Well I survived the install. The torquing was rough! Had no issues and followed the tips I found on here. One other tip I came up with was installing the front bump stop extenders simultaneously with the front coil. That allowed the extra 4 inches or so of clearance for the longer coil. Took me about 11 hours for the job including the steering wheel correction and headlight adjustment afterward. The 33's look just okay, so I can't wait to burn through those and get 35's.

Before pic I forgot to take until the last minute:

After pic: (bonus, received and installed the smart cap the next day!)

Looks great - glad you were able to knock it out!

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[OHJeeper]

To the OP: Awesome job! Looks great!

Couple of questions:

Did you re-adjust your headlamps? I ran a 2" lift + 37's for about a week before I realized all the "a-holes" that were flashing me were actually right and my headlamps were blinding them.

Also, when dropping the front axle: have you gone back and looked at the driveshaft mount on the transfer case side? Mine is almost oval-shaped now because I allowed the axle to drop far enough for the springs but didn't notice the driveshaft shroud (surrounding the boot) wasn't meant for that . Thankfully it doesn't hinder the driveshaft rotation when it's all put back together, but that could have been worse!

 

[AmosMoses01]

To the OP: Awesome job! Looks great!

Couple of questions:

Did you re-adjust your headlamps? I ran a 2" lift + 37's for about a week before I realized all the "a-holes" that were flashing me were actually right and my headlamps were blinding them.

Also, when dropping the front axle: have you gone back and looked at the driveshaft mount on the transfer case side? Mine is almost oval-shaped now because I allowed the axle to drop far enough for the springs but didn't notice the driveshaft shroud (surrounding the boot) wasn't meant for that . Thankfully it doesn't hinder the driveshaft rotation when it's all put back together, but that could have been worse!

I had adjusting the headlights on my to-do list upon completion - but found that I didn't have to. My heavy bumper and winch set up gives me enough rake that it wasn't necessary. I haven't had a single "flashing" complaint from oncoming traffic to confirm what I found. (I kinda wondered about the spring strength with the rake I have, but haven't measured it ... dang it, now I have another thing for the to-do list.)

Next - I am going to have to go look at the transfer case shroud; I was super paranoid about dropping too much, and didn't see any damage, but will have to go purposely put eyeballs on it to be sure. Thanks for the heads up!

 

[Sarge502]

I know this is a bit of a thread revival but I'm thinking of going with this kit now. Downloaded the instructions and if I do will most likely tackle this install myself.

OP seems weird you got a kit with different thread pitch on your track bar bolt. You'd think with all the work put into these, that would be figured out. Def wouldn't want to have to re tap any threads. Kind of makes me nervous now. I'm not knocking AEV by any means I'm so considering this kit opposed to the Mopar one I was initially dead set on. But I've literally followed every write up I've found on this forum for this kit and have seen a handful of people have more issues with missing parts, different thread pitched bolts, wrong torque specs in instructions which resulted in snapped bolts etc.

So overall it appears that there's more concern with actually receiving a 100% complete kit than the actual lifts function itself. With all the engineering put into the design you'd think they'd be able to have people put together a complete part list. That's the only thing that has me on edge. I know how to check for parts prior to install. But I mean if some things within the install require the mix/use of OEM hardware with given hardware, than who actually goes through and threads each nut onto each bolt on mixed hardware? You'd have to go through the instructions twice or more before doing the actual install. Talk about time consuming. I should have confidence bolts have the correct thread pattern.

Hopefully some of this has been rectified with up to date manufactured kits. I plan to maybe go right through AEV as opposed to Northridge, Quadratec, etc in "hopes" to maybe alleviate that.

 

[AmosMoses01]

But I mean if some things within the install require the mix/use of OEM hardware with given hardware, than who actually goes through and threads each nut onto each bolt on mixed hardware? You'd have to go through the instructions twice or more before doing the actual install. Talk about time consuming. I should have confidence bolts have the correct thread pattern.

Agree for sure... it did teach me to never trust blindly, which is probably a good (if painfully annoying) lesson learned, which is why I shared here. I've definitely enjoyed the final product, and am very happy with it. One thing that I think AEV should do (really all lift manufacturers) is follow the best practices that folks like Teraflex do with well created installation videos. To be sure, it is challenging to make a video that will cover all model variations, but having at least one would be super useful for DIY folks. Northridge and Quadratec make good install videos, but they can't do so for all kits. The manufacturer would be best to create them in my humble opinion - full step by step installations not the "here's the unboxing - music plays / video pans out to a magically completed installation" type of videos that are out there.

 

[Lowlander]

Just finished spending an entire weekend installing this kit, and this thread was super helpful. My question is this - did either of you have any creaking or popping from the front suspension after install? I don't know if I installed something slightly off, didn't get my torques quite right, or if everything just needs a little time to settle in.

 

[Sarge502]

Can't wait to get this kit. Probably going to install myself too

 

[AmosMoses01]

Just finished spending an entire weekend installing this kit, and this thread was super helpful. My question is this - did either of you have any creaking or popping from the front suspension after install? I don't know if I installed something slightly off, didn't get my torques quite right, or if everything just needs a little time to settle in.

I'm glad the thread was helpful! Congrats on getting the kit installed!

On your question - sounds are so subjective, so can't say that I heard creaking per se, but after the first week or so of driving (about 200 miles or so) had a bit of what I'd call clunk/pop. I went back and re-checked everything for torque, and found that the control arms and one bolt on the geometry correction bracket on the passenger side needed to be torqued a bit back up to specs, and the sound went away. I'd say re-check everything is torqued down all the way. Those torque levels are kinda tough to hit, especially if you're tired after doing the whole lift.

Enjoy your ride!

 

[Lowlander]

Thanks for replying, and yeah that's what my plan was if the popping didn't go away after a couple weeks. Cheers!

 

[Supreme Nacho]

Some of my experience with this install. It took me 2 full days (jacks with jack stands) for install on my 21 Overland. First off, all the nuts AEV provides seemed to be bent which halted my install until I could make it to the hardware store. For me, the unforeseen hurdle was the front bump stop extension adapter thing. Had to be creative with my floor jack to get the rubber bump stop in the adapter.

 

[chorky]

I am
debating hard if i want to do mine myself or not. Just cant seem to decide.

 

[AmosMoses01]

I am
debating hard if i want to do mine myself or not. Just cant seem to decide.

In the end I am really glad I did it myself, because I had never tackled anything like it before and learned a ton. Biggest risks doing it solo are being without a vehicle if it takes you longer than anticipated as in my case, along with possibly needing to get some additional tools you don't already have, which is also a pro not a con. ?. Either way you choose, good luck and enjoy the results!

 

[chorky]

In the end I am really glad I did it myself, because I had never tackled anything like it before and learned a ton. Biggest risks doing it solo are being without a vehicle if it takes you longer than anticipated as in my case, along with possibly needing to get some additional tools you don't already have, which is also a pro not a con. ?. Either way you choose, good luck and enjoy the results!

Yeah I'm fully competent in doing it, but theres always hiccups, and a hiccup for me could be bad. No services really in my town and an hour away from a larger town. Getting a tow would be about $1,500 bucks.... Thats the debate lol

 

[Duece McCracken]

Some of my experience with this install. It took me 2 full days (jacks with jack stands) for install on my 21 Overland. First off, all the nuts AEV provides seemed to be bent which halted my install until I could make it to the hardware store. For me, the unforeseen hurdle was the front bump stop extension adapter thing. Had to be creative with my floor jack to get the rubber bump stop in the adapter.

Those nuts may just be a crimp style mechanical locking nut. If its round on the flange side and gets oval on the opposite side in a kinda taper, then its a locking fastener.

I'm most likely going this route, AEV. So Im reading up, lol

 

[Supreme Nacho]

Those nuts may just be a crimp style mechanical locking nut. If its round on the flange side and gets oval on the opposite side in a kinda taper, then its a locking fastener.

I'm most likely going this route, AEV. So Im reading up, lol

Didn’t know there was such a thing…. Would’ve saved my trip to the store if i would’ve known!!! lol

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