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Old 07-15-2019, 11:25 PM
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EVO Long Arms Issue

I have been using the EVO long arm kit for a few months now.
Recently it started developing some serious rattles and noises.
Inspecting the ends I noticed that the arms are not locked to the Johnny Joints and turn freely around the joints with very light effort.
Those arms were designed to adjust without removing them from the Jeep by using a threaded sleeve that is running between the ending and the arm. The sleeve can be turned to extend/shorten the arm length and there's a pinch bolt that is supposed to lock the arm to the sleeve and the ending after adjustment. The Large Hex nut in the photo below is a part of the sleeve not a jam nut (I wish it was a jam nut...).
This mechanism is completely failing on all 4 corners of my rig and no matter how I set the sleeves and tighten the pinch bolt the arms just do not lock and the endings are loose and rattling. I can only assume the threads are getting destroyed quickly without being tightened.
I have contacted both EVO and Mel (I installed it at Off Road Evolution) and the solutions offered were to align the sleeves correctly before tightening (didn't work) or to thread-lock the whole thing (which I find insufficient to hold the endings to my arms together.. it's like using glue.. LOL).
I have spent many hours trying to resolve the issue with no success and I'm still getting a lot of movement and clunking from the arms which is ridiculous for a kit at this price point.

Before giving up and replacing the EVO arms with something that can lock I wanted to post my problem here first to see if there's anybody else who's using the EVO adjustable arms with the same issue that actually managed to get them to lock properly.



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2017 JKU on 40" Cooper STT Pros
EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
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Rock Krawler Aluminum tie-rod and drag-link
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Old 07-16-2019, 05:13 PM   #2
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EVO Long Arms Issue

Do you have the slits lined up? What did you torque the pinch nut to?

Also, they look pretty beat up for only being a few months old

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Old 07-16-2019, 05:17 PM   #3
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They also look like they are a short as they can go. I see no threads at all


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Old 07-16-2019, 07:08 PM   #4
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Are the ends turning, or is the johnny joint itself loose? I have the adjustable synergy arms with the similar clamp, but have rubber joints. They do not turn and I even have anti-seize on the threads. Correct torque?
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Old 07-17-2019, 01:38 AM
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Originally Posted by wheatbackdigger View Post
Do you have the slits lined up? What did you torque the pinch nut to?
Also, they look pretty beat up for only being a few months old
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Yes, slits aligned and I took the JJ's out about 3/8" and torqed the pinch to 50ftlb.
The JJ's didn't lock...
I tightened the sleeve back to at least have some partial locking for now.

Beat up? Absolutely. I actually use my rig on the AZ rocks...
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2017 JKU on 40" Cooper STT Pros
EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
Dynatrac XD60 front XD80 rear 72.5" wide
Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 07-17-2019, 01:41 AM
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They also look like they are a short as they can go. I see no threads at all


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This is how they were installed by Off Road Evolition. As mentioned above, I did try to pull them a little longer but no cigar
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EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
Dynatrac XD60 front XD80 rear 72.5" wide
Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 07-17-2019, 01:48 AM
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Originally Posted by deepbluerubi View Post
Are the ends turning, or is the johnny joint itself loose? I have the adjustable synergy arms with the similar clamp, but have rubber joints. They do not turn and I even have anti-seize on the threads. Correct torque?
The JJs are completely loose with considerable play. Driver/front sleeve is loose as well.
I envy you (-;
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EVO high clearance long arms
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Rock Krawler Aluminum tie-rod and drag-link
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Old 07-17-2019, 06:57 AM   #8
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Yes, slits aligned and I took the JJ's out about 3/8" and torqed the pinch to 50ftlb.
The JJ's didn't lock...
I tightened the sleeve back to at least have some partial locking for now.

Beat up? Absolutely. I actually use my rig on the AZ rocks...


I have the Evo enforcer front lower adjustable arms, not the long arms. I have the pinch bolt torqued to 80ftlbs. Couldnít find what the actual value should be in the instructions. Synergyís arms are similar and thatís what they called for torque. 50ftlbs honestly donít seem like enough.


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Old 07-17-2019, 07:01 AM   #9
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I have the Evo enforcer front lower adjustable arms, not the long arms. I have the pinch bolt torqued to 80ftlbs. Couldnít find what the actual value in the instructions. Synergyís arms are similar and thatís what they called for torque. 50ftlbs honestly donít seem like enough. I think you should have an even amount of threads showing with the joints and the sleeve.


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Old 07-17-2019, 08:21 AM
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Originally Posted by wheatbackdigger View Post
Quote:
Originally Posted by preeb View Post
Yes, slits aligned and I took the JJ's out about 3/8" and torqed the pinch to 50ftlb.
The JJ's didn't lock...
I tightened the sleeve back to at least have some partial locking for now.

Beat up? Absolutely. I actually use my rig on the AZ rocks...


I have the Evo enforcer front lower adjustable arms, not the long arms. I have the pinch bolt torqued to 80ftlbs. Couldn’t find what the actual value should be in the instructions. Synergy’s arms are similar and that’s what they called for torque. 50ftlbs honestly don’t seem like enough.


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EVO specs call for 45ftlb.
I'm currently at 50 but I have also tried to go much higher with no success.
Are your enforcer ends locked firmly when you try to turn the rods by hand?
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EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
Dynatrac XD60 front XD80 rear 72.5" wide
Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 07-17-2019, 07:07 PM   #11
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EVO specs call for 45ftlb.
I'm currently at 50 but I have also tried to go much higher with no success.
Are your enforcer ends locked firmly when you try to turn the rods by hand?


Canít budge them. To be honest, I only have a few hundred miles on them. I never could find in the instructions what to torque them to. The instructions stated to torque to factory spec. Never could find that, so I followed Synergyís installation video, which was 80ftlbs


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Old 07-17-2019, 07:26 PM   #12
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Can you show me where Evo specs state 45ftlbs in the installation directions? That just doesnít seem right. Maybe I have mine over torqued. It took a lot of turning on the wrench to get to 80ftlbs


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Old 07-18-2019, 09:28 AM
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Quote:
Originally Posted by wheatbackdigger View Post
Can you show me where Evo specs state 45ftlbs in the installation directions? That just doesn’t seem right. Maybe I have mine over torqued. It took a lot of turning on the wrench to get to 80ftlbs


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Unfortunately EVO instructions don't include specific torque values so I called both EVO MFG the manufacturer
and Off Road Evolution who did the install to get it.
On the driver's front lower arm I did experiment higher torque to see if it helps and it didn't.
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EVO high clearance long arms
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Old 07-18-2019, 09:34 AM
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Quote:
Originally Posted by wheatbackdigger View Post
Quote:
Originally Posted by preeb View Post
EVO specs call for 45ftlb.
I'm currently at 50 but I have also tried to go much higher with no success.
Are your enforcer ends locked firmly when you try to turn the rods by hand?


Can’t budge them. To be honest, I only have a few hundred miles on them. I never could find in the instructions what to torque them to. The instructions stated to torque to factory spec. Never could find that, so I followed Synergy’s installation video, which was 80ftlbs


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Can you please post a closeup photo of your lower arm at the JJ end?
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EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
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Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 07-18-2019, 11:01 PM   #15
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Can you please post a closeup photo of your lower arm at the JJ end?


Maybe Saturday, working around the clock the next couple days.


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Old 07-19-2019, 04:40 PM
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I had LetzRoll Offroad, my local shop, look at it and they found that it was needed to cut the slits wider and bring the torque up so high that the bolts got crooked. It was the only way to stop the JJ's from rattling and get them locked. They also found that the rear top arms brackets on the body side (frame) were cracked on both sides so I was lucky to catch this in time.
I made a decision to cut the arms shorter and weld a standard threaded end with a jam nut and call it the day. This will take care of that poor design issue.
As far as the brackets cracking, I will get rid of those and replace the two rear upper arms with a beefy single arm from the diff to a center bracket and do a 3 link instead of 4 as I don't see any other solution since those brackets will surely crack again as the fix was a temporary welding repair.
Kind of disappointed with the EVO high clearance long arm kit but I have to add that I ride hard once or twice a week and damages are always a part of the game... but with that said, EVO was always tough enough for me otherwise.

Thanks for the input everybody. I will post some photos of the changes here soon.
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EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
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4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 07-19-2019, 05:57 PM   #17
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Well that sucks to hear about. The JJ's on my lower arms rotate freely as well, but don't clunk. I also read about the mod to cut the slits longer so the bolts can pinch, but since the joints can only rotate a few degrees before the brackets hold them, I just let them stay crooked. When it's time for long arms, I might go a different direction if the brackets are cracking.
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Old 07-19-2019, 08:24 PM
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Well that sucks to hear about. The JJ's on my lower arms rotate freely as well, but don't clunk. I also read about the mod to cut the slits longer so the bolts can pinch, but since the joints can only rotate a few degrees before the brackets hold them, I just let them stay crooked. When it's time for long arms, I might go a different direction if the brackets are cracking.
They start by rotating freely but with time the threads get damaged and from there it's a straight road south...
I prefer strong and simple (-;
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EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
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Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 07-21-2019, 04:45 PM   #19
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I was off roading yesterday and I had a bunch of clunking. I pulled the driver's side arm and sure enough the JJ is wobbling all around in the threaded sleeve. I'm going to send a video to Evo to see what they say.

Do they make a JJ with threads big enough to just remove the sleeve and run a jam nut?
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Old 07-22-2019, 06:30 PM   #20
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Update: Evo emailed me back after seeing a video of the wobbling joint. They said it was obvious that the pinch bolt wasn't tight and the slot in the adjuster wasn't in line with the slot of the arm. Fair enough. I lined up the slots and torqued to 50 ft/lbs which really closed up the slot. It still didn't to anything for the loose Johny Joint. So the threads are probably trashed. New adjusters and JJ's are $200 plus shipping. Instead I bought a new set of Core 4x4 tier 4 arms with JJ's for $349 shipped. I don't think it's worth putting $200 into a set of arms with 35,000 miles on them when I can get all new arms with real jam nuts for a little bit more.

I'm glad I'm only running front lowers, replacing all 8 would be a tough pill to swallow.
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Old 07-22-2019, 08:15 PM   #21
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35,000 miles??? I thought they were only a few months old. 50ftlb isnít much more than 45. Iíve got mine torqued at 80ftlbs and leaving them. If I trash them, Iím moving on to something different. Good luck with your new arms. If I end up having issues, Iíll revisit the thread with an update


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Old 07-22-2019, 08:52 PM   #22
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A few hundred miles? No I use my Jeep. I started with rock krawler arms. They rubbed a lot but no issues. Sold them for the evo as an upgrade and now I’m replacing those because they didn’t hold up. Maybe because of my “error” of the slots not being aligned and pinch bolt not tight enough but others have the same issue too. I’m not going to raise a fuss but I’m moving on to core 4x4 and hopefully they hold up. At least they have a lifetime warranty.
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Old 07-23-2019, 08:42 PM
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He didn't say that... I did.
I had clunks since day one though.

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35,000 miles??? I thought they were only a few months old. 50ftlb isn’t much more than 45. I’ve got mine torqued at 80ftlbs and leaving them. If I trash them, I’m moving on to something different. Good luck with your new arms. If I end up having issues, I’ll revisit the thread with an update


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2017 JKU on 40" Cooper STT Pros
EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
Dynatrac XD60 front XD80 rear 72.5" wide
Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 07-23-2019, 11:02 PM   #24
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Quote:
Originally Posted by preeb View Post
I had LetzRoll Offroad, my local shop, look at it and they found that it was needed to cut the slits wider and bring the torque up so high that the bolts got crooked. It was the only way to stop the JJ's from rattling and get them locked. They also found that the rear top arms brackets on the body side (frame) were cracked on both sides so I was lucky to catch this in time.
I made a decision to cut the arms shorter and weld a standard threaded end with a jam nut and call it the day. This will take care of that poor design issue.
As far as the brackets cracking, I will get rid of those and replace the two rear upper arms with a beefy single arm from the diff to a center bracket and do a 3 link instead of 4 as I don't see any other solution since those brackets will surely crack again as the fix was a temporary welding repair.
Kind of disappointed with the EVO high clearance long arm kit but I have to add that I ride hard once or twice a week and damages are always a part of the game... but with that said, EVO was always tough enough for me otherwise.

Thanks for the input everybody. I will post some photos of the changes here soon.
Andrew and his crew know their shit... It will be good.

Quote:
Originally Posted by zimm View Post
A few hundred miles? No I use my Jeep. I started with rock krawler arms. They rubbed a lot but no issues. Sold them for the evo as an upgrade and now I’m replacing those because they didn’t hold up. Maybe because of my “error” of the slots not being aligned and pinch bolt not tight enough but others have the same issue too. I’m not going to raise a fuss but I’m moving on to core 4x4 and hopefully they hold up. At least they have a lifetime warranty.
Very pleased with my Core 4x4 arms. Their "you break it, we replace it" warranty is a no brainier. I went tier 3 but the tier 4 are awesome.
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Old 07-25-2019, 08:14 AM   #25
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Good to know. I went tier 4, they're arriving today. Hurry up mail truck!
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Old 11-11-2019, 04:32 PM
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Andrew and his crew know their shit... It will be good.
Far from it.
Andrew sent me to EVO saying (quote) "It's their baby, have them fix it"
Doesn't look like Andrew wants to or able to service the EVO long arm system.

Currently looking for somebody else to turn my work to in the Phoenix area so hopefully I'll be able to strengthen the weak brackets and tighten the joints for a smooth trouble free run.

Will post any interesting progress here when/if issues get resolved
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EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
Dynatrac XD60 front XD80 rear 72.5" wide
Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 11-22-2019, 10:06 AM   #27
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I would like to see where the bracket cracked so I can keep an eye out on mine. I found this thread because I have a clunk that happens when the suspension load changes, acceleration/deceleration/hard turn. I'll check out the sleeves to the johnny joints. I thought I had read somewhere that the slits are not supposed to be lined up, but I just re-read the instructions and there is no mention of it. I'll dive into this deeper soon.

Overall, I am disappointed with EVO products.
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Old 11-23-2019, 06:39 AM
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I would like to see where the bracket cracked so I can keep an eye out on mine. I found this thread because I have a clunk that happens when the suspension load changes, acceleration/deceleration/hard turn. I'll check out the sleeves to the johnny joints. I thought I had read somewhere that the slits are not supposed to be lined up, but I just re-read the instructions and there is no mention of it. I'll dive into this deeper soon.

Overall, I am disappointed with EVO products.
Check the welding line around the rear upper arm brackets.
The many clunks I have are coming from the arm joints. The brackets mounting holes also get enlarged around the bolts quickly indicating the material is weak or not thick enough for the forces this kit is supposed to handle.
My rig is clunking so bad at this point that I don't enjoy driving it... It is driving me nuts.
Already gave up trying to talk to Mel and his ORE crew about any issues I am having. I plan to replace the weak parts but need to find someone who can do the fabrication.

Please post your findings here if you manage to pin point and solve the issues.
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EVO DTD + EVO Lever + King Air bumps rear
EVO high clearance long arms
Dynatrac XD60 front XD80 rear 72.5" wide
Rock Krawler Aluminum tie-rod and drag-link
4.88 gears, ARB Air lockers, PSC XD-II + ram
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Old 11-23-2019, 12:02 PM   #29
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Wow. I was considering the EVO high clearance long arms, based on EVO’s reputation propagated in other forums, but this thread has given me second thoughts. Maybe I’ll just stick with my Synergy short arms, which have held up great for about 7 years so far.
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Old 11-23-2019, 02:28 PM   #30
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I considered long arms for about an hour but the work, and $$$ changed my mind. I spent just a little less time thinking about coil-over system. Nothing wrong with either but just not for me.

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