I am currently swapping all the CA's on my '08 JKUR which is equipped with a Rancho 2" BB.

1) the instructions call for certain measurements on the adjustable control arms. But, when I install them they are too short. Can I just let them out a bit? Will this not keep it as it was with the stock control arms? I'm only running a Rancho BB right now. Just swapping the control arms for future upgrades. I'm doing the install on the floor. So no release of tension or flex on the suspension.

2) The front upper instructions called for the bolt on the frame end of the passengers side CA to be cut off, which I did. Then a bolt is provided for install, but it doesn't fit the factory but. Any ideal what size but I need to buy so I can finish install?

 

Most likely your axle shifted when you removed the stock control arms. Use the measurements provided then pull the axle into position with a ratchet strap or if the tires are still installed just roll one side by hand. They'll move pretty easily.

Don't forget to forget to Loc-tite the control arm jam nut, use a slugging wrench to help torque it. You can do it on the vehicle but I've found it easier to do in a workbench vice. You want the joint to be straight once installed (like the bottom one in the pic below).

 

Got it! Thanks!

One more question that is probably obvious but, the end of the CA with the articulate joint goes to the frame and the fixed to the axel? Correct?

 

The opposite.