Black Diamond X2 Jeep Suspension Kit - 4Wheel & Off-Road Magazine

Black Diamond X2 Jeep Suspension Kit - Leaves To Coilovers black Diamond X2 Jeep Kit jeep Front View Photo 9616269

Most hard-core Jeepers know about the Black Diamond XCL (Xtreme Coil Link), a Warn-engineered kit that redefined rockcrawling in 1996. Black Diamond created this production coil-conversion kitso that YJ and later-model CJ owners (and inexperienced shops) didn't have to fumble through a custom longer-travel suspension project.

Superlift acquired Black Diamond and spent the past five years R&D-ing a successor to the XCL (which is still available). Two priorities emerged: simplifying installation and creating a kit that was more street and trail friendly. Controlling weight transfer-especially at pavement speeds-is what sets the X2 apart

The X2 kit differs from XCL in four main areas. The X2's long-arm front suspension is four-link (compared to XCL's three-link), and the rear is leaf-spring-over-axle (SOA) as opposed to the previous triangulated four-link with coilovers.

For YJ applications, the X2 kit includes progressive-rate front coilovers and axle bracketry for the front link arms. Single-spring coilovers (optional for TJ applications) got the nod because of quieter operation than dual-coil designs. The coils are coupled to 10-inch-travel monotube gas shocks with remote reservoirs.

To address the factory stability issues under torque load, both YJ and TJ systems use rear SOA leaves that are designed specifically for the kit. The packs have nine thin, shot-peened leaves with tapered ends, antifriction pads, military-wrap main leaves with OE-type rubber bushings and bolt-type spring clips. Their U-bolt plates have integral bumpstop extensions, and boomerang-style shackles clear the bumper during suspension travel. Black Diamond SS rear monotube shocks by Bilstein provide damping and enough length to accommodate additional suspension travel.

Up front, the X2 uses Superlift Rockrunner link arms, which have threaded ends that won't bind, unlike Heim-style joints. The arms are made from 0.188-inch-wall DOM tubing (1.5-inch OD uppers, 2.0-inch OD lowers), and they're contoured to allow full lock-to-lock steering and maximum ground clearance. The longer the arm, the less the operating angles during suspension cycling, so more movement is possible before the arms bind within their mounts.

These extended arms attach to the frame at the X2's skidpan assembly. Two side rails serve as rear mounts for the link arms. The rails also support the 3/16-inch-thick inner pan, which functions as a transmission crossmember.

Steering correction is also addressed. The kit includes a dropped pitman arm, an adjustable track bar with bracket, and a lateral brace. These components are compatible with the OE under-knuckle tie-rod or a "flipped" high-steer arrangement.

PhotosView Slideshow The existing suspension and axles must be removed. A reciprocating saw amputated the exhaust system, which needs to be rerouted around the Black Diamond long-arms and over the skidpan. This YJ already has a required slip-yoke eliminator kit on its NP231J transfer case. On YJ applications, the rear pair of the front spring hangers and track-bar frame mount must be removed. Also, the stock shock towers need to be cut flush with the frame to clear the kit's coilover hoops. The e-brake tensioner bracket must also be trimmed. The system's skidpan side rails catch some of the factory holes. Additional frame-hole locations are marked with the correct-size transfer punch, then a stepped bit is used for drilling. Each hole houses a crush sleeve to reinforce the Jeep's frame. The inner pan serves as a transmission crossmember. It's contoured for easy access to serviceable parts and fill/drain plugs. After the shock towers are trimmed, the kit's YJ coilover hoops are installed. Two factory holes are used, and a third is drilled for each rear leg. All new holes take sleeves since these hoops support the vehicle's weight. Bumpstop lowering brackets are already installed. The coilover hoops accommodate brackets for a lateral brace on the new track-bar bracket, which adds rigidity. The driver-side hoop assembly also contains the upper attachment point for the track bar.

The X2's marquee upgrade is Superlift's Torque Fork traction bar. Similar in design to the XCL's three-link front arms, the Torque Fork uses two shackles to control spring wrap throughout suspension cycling.

Other options are extended Rockrunner link-arm ends for up to 3 inches of wheelbase stretch as well as the eXtreme Clearance flat skidpan, which requires floorboard modifications. Front-axle weld-on link-arm brackets are available that essentially emulate the OE TJ arrangement are available for popular frontend swaps, as are spring pads for common rear axle swaps.

The X2 installation also provided an opportunity to try Pro Comp's new Xtreme MTs. Since the X2 fits up to 37-inch-tall tires, we chose the 37x12.50-17, one of a handful of fitments available at press time. A trade-off is a D load range-stiff for a short-wheelbase Jeep.

One compromise with production alloy 17s is limited widths and backspacings. Since this YJ is a daily-driver, we stuck to aluminum wheels to minimize rolling mass. Pro Comp series 1023 got the nod because the 17x9 size has 4.5 inches of backspacing.

PhotosView Slideshow The spring mounts on the Dana 30 front axle are shaved to accommodate the new suspension brackets. These brackets sandwich the OE mounts and set all of the necessary suspension and caster angles. The instruction sheet details the procedures for popular swapped-in axles. For the YJ Dana 30, the passenger-side four-link brackets attach to the axle at the vacuum-disconnect area. The disconnect's flange and a boss on the factory track-bar mount must both be trimmed to accommodate the bolt-on brackets. As with the passenger side, the driver-side YJ Dana 30 brackets use a U-bolt to secure upper and lower mounts to the axle. Longer bolts are included for securing the bracket to the axlehousing through the diff cover. The front axle is rolled back under the Jeep. Then the link arms, which were previously connected to the frame, are bolted to the axle on the kit's brackets. The coilover shocks install on the kit's hoops and axle mounts. The coilovers' remote reservoirs can then be clamped to the hoops. Once the rearend is removed from the vehicle, its housing can be prepped. Spring pads and shock mounts are cut off.

For mechanically skilled Jeep owners, the photos here show highlights of a YJ job, the most involved X2 installation. (Superlift highly recommends professional installation.) YJs require axle and shock brackets that replicate the OE TJ approach. Also, the '88 YJ used here had a Ford 8.8 rearend and a Vortec V-8 swap. Installation highlights:

* Although the job could conceivably be done at home using floor jacks and jackstands, a hydraulic lift is invaluable for lifting the Jeep on and off the axles. Even with a hydraulic lift, this installation/instruction-sheet session at 4Wheel Parts took the better part of three full work days.

* Using a plasma cutter produces more precise cuts than an acetylene torch or reciprocating saw, minimizing the grinder work.

* Errant cuts into the frame should be patched by welding on plates.

* Black Diamond front axle kits for Dana 44 and Dana 60 applications use weld-on brackets.

* A transfer-punch kit helps center the numerous holes that are drilled through the frame.

* Always check inside the frame for wires and lines before drilling through from the outside.

* After drilling pilot holes, a stepped uni-bit hogs through the frame faster than using a series of single-size drill bits.

* The unibit creates tight tolerances for the frame sleeves. Losing a sleeve inside the frame can result in a time-consuming fishing expedition.

* Button-up details include leveling the front end with the coilover adjusters, re-aiming the headlights, recalibrating the speedometer, retorquing all fasteners, greasing all zerks, bleeding the brakes, routing and securing brake hoses and breather tubes, rerouting the exhaust around the link arms, obtaining a longer rear driveshaft, and an alignment job that includes setting the caster in addition to the toe.

* If retaining the OE NP231J transfer case, a slip-yoke eliminator (SYE) kit is required. A "super short" kit provides more than 2 additional driveshaft inches but requires an electrical speed-sensor setup.

Although the X2 appears to have slightly less overall rear travel than some four-coil 6-inch long-arm TJ kits, the leaves control lateral weight transfer better than coils. This allows the X2's frontend to "stick" when a rear tire comes off the ground. Our test YJ had front and rear ARB Air Lockers, so any two tires simultaneously in contact with the ground were able to claw the Jeep out of ruts that swallowed a TJ with a 6-inch long-arm kit and dual Air Lockers.

Road ride is a bit stiffer than stock, particularly with the new D-load-range Pro Comp Xtreme M/Ts running 22 psi on the street. A competent alignment job that dials in caster is crucial for eliminating wander, and the optional steering stabilizer absorbs some road shake. Also, the Torque Fork works as intended-off-the-line launch is smooth, even under enthusiastic V-8 acceleration.

The X2 appears to achieve Superlift's goals. The kit isn't cheap (no long-arm systems are), and installation is a multi-day proposition. However, the result is a Wrangler that can keep up with many trailered trail rigs, outwheel some, and handle predictably enough to be driven home on the highway.

PhotosView Slideshow The rear axle must be centered under the vehicle. Plumb bobs and a tape measure are used here to center the kit's spring pads in line with the frame. Once the pinion angle is determined, the pads can be tacked into place. Then the rear axle is removed so that the pads can be fully welded, taking care not to warp the housing. The rear monotube shocks attach to the factory upper mounts. With the axle almost at full droop, the kit's lower mounts can be positioned. Then they're welded to the axlehousing. The full-width main skidpan sits in approximately the same location as the stock pan but provides drivetrain protection. It installs with recessed button-head bolts to maximize ground clearance. The pan is made from 1/4-inch-thick plate, so a transmission jack helps support it during installation. Due to the direction of engine rotation, the Torque Fork installs on the passenger side to control squat upon acceleration. It controls spring wrap by attaching to the axle at a bracket that's welded to the housing. Shackles at the axle and skidpan allow slight movement before redirecting energy, as does the Torque Fork's internal swivel. A Heim joint threads into the track-bar tubing to center the frontend. Superlift brake hoses and air locker lines were routed and secured during button-up.