At some point, during my travels through Kentucky back in April, I thought long and hard about the off-road capability of my Jeep. The Wrangler Rubicon is extraordinarily capable off of the showroom floor. However, since my Jeep is so heavily-laden with cargo and equipment, ground clearance is lower than normal. This is potentially problematic as I frequently explore unmaintained, primitive roads while on my journey.

I felt it was important, if not imperative, to upgrade my suspension with one that offers increased ground clearance and preserves (or even improves upon) all-around performance. In theory, this would help handle my payload, and it would also help me safely negotiate a wider selection of technical terrain.

This was going to be a challenging endeavor - maybe even a little crazy - since I was already on the road, well on my way across the country!

What could go wrong?

American Expedition Vehicles

My suspension of choice is the 3.5” AEV DualSport Suspension.

I chose this suspension system for two primary reasons:

First, is familiarity. I have a number of friends who run this suspension. I’ve seen it perform on technical terrain in person, and I’ve had ample seat-time in AEV-equipped vehicles.

Second is trust. I trust AEV as a brand. Their suspensions are labeled “dual sport” because they place emphasis on maximizing off-pavement performance while preserving the factory driving characteristics. Given their reputation and the high quality of their products, I trust this pitch. Furthermore, AEV is directly supported by numerous Jeep dealers across the country, which, in my opinion, is a ringing endorsement.

AEV components come in at a higher price point than many alternatives. It is important to note that there isn’t one right answer when it comes to vehicle modifications. Do your research. Support the brand that suits your needs, but do not base your decision primarily on price. Skimping on something as critical as a suspension is a good way to reduce the comfort and capability of your vehicle, and that’s the last thing you want to do - especially if you’re living overland.

Jeepin Outfitters

Okay, so I know what suspension I want, but that’s not the hard part. I’m on the road. How and where do I get it installed?

I reached out to my friend Jason West, who lives with his family in Lewisville, Texas. Jason and I met online almost two decades ago. We both attended Camp Jeep 1998, but unfortunately, we didn’t cross paths at the event. That didn’t stop us from forging a close friendship over the years.

Jason lives and breathes Jeeps like none other. He is extremely passionate, knowledgeable, and hands-on, so I gave him a shout.

“Hey, can we lift my Jeep in your driveway in a few weeks?”

He thought I was kidding at first. I’ll admit, it was an unusual request coming from an Internet-friend who lived a thousand miles away. As soon as he realized that I was serious, he agreed without hesitation!

I contacted AEV for the suspension, and had it shipped to Jason’s residence, where I later met him to perform the install.

Turning Wrenches

Early on Saturday morning, Jason printed out the latest version of the installation instructions from AEV’s website. We then put the Jeep on jack stands and started tearing the front end apart.

The front consisted of springs, shocks, steering linkage, and relocation brackets to optimize the geometry for the taller ride height. Our pace was slow and careful, and it took most of the day to complete the front suspension to our satisfaction. However, we encountered no notable obstacles. All of AEV’s holes lined up.

On Sunday morning we resumed with the rear suspension. This was straightforward as we didn’t have to worry about any steering components, just springs, shocks, end-links, and another relocation bracket.

For the rear, aside from AEV’s components, we added a pair of 1” Teraflex coil spacers to give the back of the Jeep an additional boost to compensate for heavy loads.

We also had to install a set of 1.25” wheel spacers from Teraflex to space out the stock Rubicon wheels. Jeep wheels traditionally have a very deep backspacing which makes oversized tires prone to rubbing on control arms and fender wells, and can also interfere with the extended swaybar linkage required by many lift kits.

After another full day, the rear suspension was complete.

The Gotcha

One item remained.

When installing a suspension lift on a Jeep Wrangler JK, it might be necessary to make an exhaust modification. Since the front driveshaft is now allowed to descend further than normal, it becomes prone to contacting an exhaust pipe that passes below it perpendicularly.

For instance, if the front axle is allowed to droop freely, the front driveshaft will also descend and  impact the front crossover pipe. This could be catastrophic if allowed to occur in a real-world scenario, so it needs to be addressed.

Since exhaust setups and tolerances vary so greatly, AEV does not include a solution as a part of their kit. We opted to purchase an exhaust spacer kit from Teraflex, which is a simple pair of tubes that adjust the tolerances of the exhaust route just enough to remedy the issue.

We attempted this ourselves, but there was rust. A lot of it. The first bolt broke as we tried to loosen a flange, and we immediately stopped what we were doing. Jason wasn’t equipped for driveway exhaust work that would likely require fire. We agreed that I should take it to an exhaust shop to have them finish the job.

The following morning, I found an exhaust shop that was willing to take it on without an appointment, and they did so quickly and expertly… for a couple hundred bucks.

The Parting of Ways

On Monday, I parted ways with Jason and his family, who had been phenomenal hosts throughout the weekend. I am in their debt! Jason is a great friend and a voracious four-wheel drive enthusiast, so please look him up on Instagram at @jeepinoutfitters

My initial impression was that the suspension felt softer and more comfortable than stock as I hit the dips and bumps on the road. This was very satisfying as reduced ride quality used to be commonplace for suspension upgrades.

I will talk more about the performance of the AEV suspension as my journey continues. For now, my trust in AEV seems to have been well-placed. It was time to start thinking about tires.

There is nothing quite like the feeling of hitting the highway with a brand new suspension and no intention of going home. All you can do is cross your fingers and hope that everything is sufficiently torqued!