Rusty's 4.5" TJ Long Travel Suspension Kit is based on our proven 5.5" kit but has a few key changes that enable it to work at a lower ride height and still maintain impressive amounts of suspension flex. Like the taller kit, it takes you places other vehicles can't go; over logs, big boulders, or just about anything else on the trail. We have applied race technology and years of research and development to deliver a suspension system with enough articulation to keep your rig firmly planted even over the most radical terrain. This system is the answer for those who demand nothing less than bulletproof off-road performance!
The system starts with Rusty's 4.5" front and rear coil springs, which have recently been released to address the needs of those that want a little more lift to clear 35s, yet don't want the height that our 5.5" system offers. It also includes heavy-duty adjustable front and rear track bars, brake lines, sway bar links, shocks, and other related components (see the component list below). The real fun begins with new radius-style control arms that are completely adjustable, both the long lower arm as well as the upper link. The arms utilize Clevite factory rubber control arm bushings at one end to ensure that no noise or vibrations are transmitted through the frame and at the other end Rusty's rebuildable Flex Joints for superior flex and articulation. The arms are constructed of 2" diameter D.O.M. tubing, so go ahead and bash them against rocks and ledges because they can take the abuse and keep right on going!
The front radius-style control arms and the rear control arms bolt to completely new 1/4" thick steel brackets that have been laser-cut and CNC formed for a precision fit. These brackets sandwich the frame and are secured with additional hardware positioned through the frame for additional strength. To top things off and provide protection as well as additional ground clearance, the weak stamped steel factory crossmember is replaced with Rusty's 1/4" inch thick steel "skinny up" belly pan. The belly pan provides total protection to the transfer case while tying the long arm suspension mounting points together as one solid assembly. The complete kit comes in a durable black powder coated finish.
Note: Rusty recommends installing a Slip Yoke Eliminator Kit and CV Driveshaft Combo Kit to prevent driveline vibrations with this suspension system. This kit provides additional driveshaft length along with provisions to run a CV (Constant Velocity) joint at the transfer case. These kits are available for the NP231 transfer case that comes standard on non-Rubicon TJs.
For Rubicon models, we offer a Tom Woods 1310 Series Rear CV Driveshaft to replace the factory rear driveshaft and smooth out the driveline by replacing the driveshaft with one that utilizes a double cardan to reduce the operating angles on the factory u-joints.
Note: Exhaust modifications may be required if using the stock muffler with this suspension system. A popular muffler replacement is the Flowmaster HP2 Muffler Series or similar muffler options.