Installation Instructions

Installation Instructions

2360 Boswell Road

Chula Vista, CA 91914

Phone 619.216.1444

Fax 619.216.1474

E-Mail [email protected]

Latest Revision:

12.4.12

PRO COMP SUSPENSION

Suspension Systems that Work!

Part #

55717/55717MX

2007-2013 Jeep

Wrangler 4WD 2

Door & 4 Door JK

Stage 1

4” Lift Kit

This document contains very important information that includes warranty information and instructions for resolving problems you may encounter. Please keep it in the vehicle as a permanent record.

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Box 1-PN 55717/55717MX-1

Description Qty Illus. Page Part #

90-4149 REAR BUMPSTOP EXTENSIONS 2 5 9

70-0501751800

72-050100812

73-05000830

Rear Bump Stop Lock Plate

1

1/2” X 1 3/4” GR. 8 HEX BOLT

1/2” NYLOCK NUT

1/2” SAE FLAT WASHER

2

2

2

-

5

5

5

-

9

9

9

70-0251001800

72-025100816

73-02500830

PACK: 1

1/4”-20 X 1” GR. 8 HEX BOLT

1/4”-20 STOVER NUT

1/4”-20 SAE FLAT WASHER

4

4

8

-

-

-

-

-

-

90-3719

90-1539

90-2650

90-5841

Brake Line/Track Bar/Bump Stop

1

REAR BUMPSTOP LOCK PLATE

BRAKE LINE DROP

REAR TRACK BAR SPACER

REAR TRACK BAR BRACKET

2

4

1

1

-

5

-

4

4

-

9

-

8

8

70-0563251800

72-056100816

73-05600830

70-0371001800

72-037100816

73-03700830

Rear Track Bar Bracket

1 - -

9/16” X 3 1/4” GR. 8 HEX BOLT

9/16” STOVER NUT

9/16” SAE FLAT WASHER

3/8” X 1” GR. 8 HEX BOLT

3/8” STOVER NUT

3/8” SAE FLAT WASHER

1

1

2

2

2

4

4

4

4

4

4

4

8

8

8

8

8

8

Rear Track Bar Relocation Bracket

4 8

72-050100816

73-05000830

1/2” STOVER NUT GR. C

1/2" SAE FLAT WASHER

2

2

4

4

8

8

73-01410940

72-01415008812 14mm– 1.5 NUT

90-3245

90-3718

1

- -

1

1

1

1

4

4

4

4

8

8

8

8

73-01210940

72-01215008812 12mm– 1.75 STOVER NUT

71-120601751000 12mm– 1.75 X 60mm 10.9 HEX BOLT

1

8

4

4

-

-

-

-

-

-

-

-

2 -

2

Part #

45359

60859

90-8012

90-2008

90-2207

71-120501051000

Description Qty Illus.

5/8” RUBBER HOURGLASS BUSHING

SLEEVE

4

4

2

2

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Page

6

6

JEEP SWAY BAR END LINK:

Rear

JEEP SWAY BAR END LINK:

Front

2 - -

2 2 6

Front X-Member Spacer

1 - -

2 - -

12mm– 1.5 X 50mm 10.9 HEX BOLT

1 - -

2 - -

2 - -

94-5987

90-6525

25C100HCS8Y

25CNUCZ

25NWSAZ

10999

90-4337

90-7203

90-7204

REAR BRAKE LINE DROP BRACKET 1 3 7

HARDWARE PACK: Front/Rear

Brake Line Bracket

1 - -

1/4”-20 X 1 HEX BOLT GR. 8 4 3 7

1/4”-20 STOVER NUT GR. C

1/4” SAE FLAT WASHER

4

8

3

3

7

7

11" ZIP TIE:

Black

4

- -

BRAKE LINE SLEEVING

FRONT BRAKE LINE BRACKET: Drvr

2

1

FRONT BRAKE LINE BRACKET: Pass 1

1 5

1 5

FOLLOWING PARTS ARE USED IN CONJUNCTION WITH THIS KIT. THEY ARE PACKAGED

AND MUST BE ORDERED SEPARATELY.

JEEP FRONT COIL SPRING 1 -

-

55397

55217

55207

926511

926501

MX6013

MX6151

JEEP REAR COIL SPRING (2 Door Vehicles) 1

JEEP REAR COIL SPRING (4 Door Vehicles) 1

ES9000 SERIES FRONT SHOCK 2

ES9000 SERIES REAR SHOCK

OR

MX-6 SERIES FRONT SHOCK

3

MX-6 SERIES REAR SHOCK

2

2

2

-

-

-

-

-

-

-

-

-

-

-

-

Introduction:

This installation requires a professional mechanic!

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♦ We recommend that you have access to a factory service manual for your vehicle to assist in the disassembly and reassembly of your vehicle. It contains a wealth of detailed information.

♦ Prior to installation, carefully inspect the vehicle’s steering and driveline systems paying close attention to the tie rod ends, ball joints, wheel bearing preload, pitman and idler arm. Additionally, check steering-toframe and suspension-to-frame attaching points for stress cracks. The overall vehicle must be in excellent working condition. Repair or replace all worn or damaged parts!

♦ Read the instructions carefully and study the illustrations before attempting installation! You may save yourself a lot of extra work.

♦ Check the parts and hardware against the parts list to assure that your kit is complete. Separating parts according to the areas where they will be used and placing the hardware with the brackets before you begin will save installation time.

♦ Check the special equipment list and ensure the availability of these tools.

♦ Secure and properly block vehicle prior to beginning installation.

ALWAYS wear safety glasses when using power tools or working under the vehicle!

♦ Use caution when cutting is required under the vehicle. The factory undercoating is flammable. Take appropriate precautions. Have a fire extinguisher close at hand.

♦ Foot pound torque readings are listed on the Torque Specifications chart at the end of the instructions.

These are to be used unless specifically directed otherwise. Apply thread lock retaining compound where specified.

Please note that while every effort is made to ensure that the installation of your Pro Comp lift kit is a positive experience, variations in construction and assembly in the vehicle manufacturing process will virtually ensure that some parts may seem difficult to install.

Additionally, the current trend in manufacturing of vehicles results in a frame that is highly flexible and may shift slightly on disassembly prior to installation. The use of pry bars and tapered punches for alignment is considered normal and usually does not indicate a faulty product. However, if you are uncertain about some aspect of the installation process, please feel free to call our tech support department at the number listed on the cover page.

We do not recommend that you modify the Pro Comp parts in any way as this will void any warranty expressed or implied by the Pro Comp Suspension company.

PLEASE NOTE:

Due to differences in manufacturing, dimensions and inflated measurements, tire and wheel combinations should be test fit prior to installation. Tire and wheel choice is crucial in assuring proper fit, performance, and the safety of your Pro Comp equipped vehicle. For this application, we recommend a 17” wheel not to exceed 10” in width with a maximum backspacing of

5” must be used. Additionally, quality tire of radial design, not exceeding 35” tall X 12.5” wide is also recommended. Please note that the use of a 35” X 12.5” tire may require fender modification. Violation of these recommendations will not be endorsed as acceptable by Pro Comp Suspension and will void any and all warranties either written or implied.

Optional Equipment Available from your

Pro Comp

Distributor!

TRACK BAR: JTB 402

JK LIGHT BAR: 23700

FRONT ARM CAMS: 20-65227

REAR ARM CAMS: 20-65228

Also, check out our outstanding selection of

Pro Comp tires to compliment your new installation!

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FRONT INSTALLATION:

1. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or asphalt). Block the rear tires and set the emergency brake.

2. Measure and record the distance from the center of each wheel to the top of its fender opening. Record below.

LF:

LR:

RF:

RR:

3. Place the vehicle in neutral. Place your floor jack under the front axle and raise the vehicle.

Place jack stands under the frame rails and lower the frame onto the stands. Remove the jack and place the vehicle back in gear, set the emergency brake, and place blocks both in front and behind the rear wheels.

4. Unbolt and remove the transmission skid plate from the vehicle.

5. Unbolt and remove the front sway bar end links from the vehicle. Save the hardware for reuse.

6. Remove the shocks on both sides of the vehicle. It may be necessary that you slightly raise the axle to unload the shocks for removal.

7. Unbolt the front track bar from the front axle mount and secure up and out of the work

Illustration 1

Front Brake Line

Bracket

OE Bolt

Front Spring

Pad

area. Save the hardware for reinstallation.

8. Unbolt the all the ABS mounting clips from the vehicle.

9. Unbolt the front brake line brackets and unclip it from the spring pad. Save the hardware for reinstallation.

10. Lower the front axle enough to remove the coil springs from the front spring pockets.

Save the factory isolators for re-use.

NOTE: Be sure to support the axle while

the springs and shocks are removed.

11. Remove the OE bump stops from the vehicle.

12. Lower the front axle enough to remove the coil springs from the front spring pockets.

Save the factory isolators for re-use.

NOTE: Be sure to support the axle while

the springs and shocks are removed.

13. Install the front brake line drop (90-1539) into the original frame mounting hole using the previously removed OE bolt.

14. Secure the brake line to the supplied drop bracket (90-1539) using the supplied 1/4”-20

X 1” bolt and hardware.

15. Install the supplied bump stops (15-11309) into the OE bump stop mounting cup.

NOTE: To properly seat the newly installed bump stops, carefully lower the

weight of the vehicle onto the bump stops.

16. Carefully lower the front axle to ease in the new front coil spring installation. Using the factory isolators install the Pro Comp coil springs (55397-2) into the spring buckets and raise the front axle into place. Make sure the front coil spring seats properly on the lower spring perch.

STEPS 17 through 19 are for 2011- 2013

models ONLY!

17. Install the front brake line brackets (90-7203

drvr and 90-7204 pass) to the front spring pads and secure using the provided 1/4” X 1” bolts and hardware. See ILLUSTRATION 1.

1/4” X 1” Bolt

Brake Line Bracket 90-7203 drvr and 90-7204 pass

5

55717/55717MX

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(FRONT)

SWAY BAR

LINK

90-2008

BUSHING

45359

18. Secure the OE brake line brackets to the Pro

Comp brackets using the previously removed

OE hardware. See ILLUSTRATION 1.

19. Remove the retaining clips that retain the

ABS wire to the OE brackets. Wrap the OE

ABS lines with the provided protective sleeves (90-4337) and secure with the supplied zip ties (10999).

20. Assemble the front sway bar end links (90-

2041) using the supplied bushings (45359) and sleeves (60859) from hardware pack (90-

6042). See ILLUSTRATION 2.

21. Install the front sway bar end link (90-2008) into original mounting bracket on the axle using the OE hardware.

22. Bolt the remaining end of the sway bar end link to the front sway bar using the supplied

12mm X 60mm bolt and hardware. Torque the 12mm hardware according to the torque chart on page 10 .

23. Reinstall the transmission skid plate using the supplied (2) 1/2” spacers (90-2207) and

12mm-1.5 X 50mm bolts in the frame rail mounting bolts only. Secure the remaining rear hole to the frame using the previously removed OE bolt. Torque the crossmember hardware according to the torque chart on page 10 .

Illustration 2

Front Sway Bar End

Link Assembly

SLEEVE

60859

24. Install your new Pro Comp front shocks

(MX6013 or ES9013 w/shaft end up) using the OE hardware. Torque the upper mounting hardware to 17 ft./lbs. and the lower to 35 ft./lbs.

25. On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component.

Use zip ties to secure these items to the steering components. At full droop, cycle the steering from lock to lock while observing the reaction of these components. Reposition them if needed.

26. Reinstall the front wheels and lower the vehicle to the ground. Torque the lug nuts according to the wheel manufacturers recommendations.

27. Reinstall the OE front track bar to the axle mount using the previously removed OE hardware. Torque the track bar mounting bolt according to manufacturers specifications.

NOTES:

On completion of the installation, have the suspension and headlights realigned.

After 100 miles recheck for proper torque on all newly installed hardware.

Recheck all hardware for tightness after off road use.

6

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REAR INSTALLATION:

1. Block the front tires and raise the rear of the vehicle. Support the frame with jack stands forward of the rear springs.

2. Remove the rear wheels.

3. Unbolt the rear track bar from the rear axle mount and secure up and out of the work area. Save the hardware for reinstallation.

4. Remove the shocks on both sides of the vehicle. It may be necessary that you slightly raise the axle to unload the shocks for removal.

5. Unbolt and remove the rear sway bar end links from the vehicle. Save the hardware for reuse.

6. Lower the rear axle enough to remove the coil springs from the rear spring pockets.

Save the factory isolators for re-use.

NOTE: Be sure to support the axle while

the springs and shocks are removed.

7. Using a twisting motion remove the rear bump stops from the factory mounts.

8. Unbolt the rear brake line hangers from the underside of the floor board. Save the hardware for reinstallation.

9. Unbolt the rear brake line brackets from the vehicle. Save the hardware for reinstallation.

10. Install the rear brake line drop bracket (94-

5987) onto the OE studs and secure using the previously removed hardware. See ILLUS-

TRATION 3.

11. Secure the OE brake line hangers to the previously installed brake line drop bracket (94-

5987) using the supplied 1/4” X 1” bolts and hardware. See ILLUSTRATION 3.

12. Install the rear brake line drop (90-1539) into the original frame mounting hole using the previously removed OE bolt.

13. Install the driver side rear track bar relocation bracket (90-5841) into the original track bar mounting pocket using the supplied 9/16” X 3

1/4” bolt and supplied spacer (90-2650). See

ILLUSTRATION 4.

94-5987 Brake

Line Drop

Bracket

Vehicle Floor

Board

14. Insert the (2) 3/8” X 1” bolt into the track bar bracket and secure it to the driver side rear axle shock mount. See ILLUSTRATION 4.

15. Tighten the previously installed 9/16” and 3/8” hardware.

16. Install the U-bolt around the rear end axle tube and secure to the rear track bar relocation bracket (90-5841) using the supplied 1/2” washer and nut. See ILLUSTRATION 4.

17. Torque the 3/8”, 1/2” U-bolt and 9/16” track bar hardware according to the torque chart on page 10 .

18. Carefully lower the rear axle to ease in the new rear coil spring installation. Using the factory isolators install the Pro Comp rear coil springs (55217-2 two door or 55207-2

four door) into the spring buckets and raise the rear axle into place. Make sure the coil spring seats properly on the lower spring perch.

NOTE: Be sure to reinstall the factory

isolators before raising the springs into place.

19. Slide the 1/2” X 1 3/4” Bolt through the center of the bump stop lock plate (90-3719).

Install the lock plate assembly to the original bump stop frame mounting bracket. Secure using a 1/4 turn clockwise. See ILLUSTRA-

OE Brake Line

Hangers

Illustration 3

Rear Brake Line Drop

Bracket

OE

Hardware

1/4” X 1”

Bolts

7

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Illustration 4

Rear Track Bar

Relocation Bracket

Rear

Track

Bar

Cam

Hardware

13-90496

U-Bolt

90-5841 Rear Track

Bar Relocation Bracket

Rear Axle

3/8” X

1” Bolts

90-3718

Cam Bolt

OE Track

Bar Mount

Pocket

Rear Track

Bar Spacer

90-2650

9/16” X 3

1/4” Bolt

1/2” U-Bolt Hardware

TION 5.

20. Slide the rear bump stop extensions over the mounted lock plate assembly and secure using the supplied 1/2” hardware from pack

(90-6536). Torque hardware to 35 ft./lbs.

See ILLUSTRATION 5.

21. Reinstall the OE bump stop to the newly installed bump stop drop brackets.

22. Assemble the rear sway bar end links (90-

8012) using the supplied bushings (45359) and sleeves (60859) from hardware pack (90-

6042). See ILLUSTRATION 1.

23. Install the rear sway bar end link (90-8012) into original mounting bracket on the axle using the OE hardware.

24. Bolt the remaining end of the sway bar end link to the rear sway bar using the supplied

12mm X 60mm bolt and hardware. Torque the 12mm hardware according to the torque chart on page 10.

25. Install your new Pro Comp rear shocks

(MX6151 or ES9151 w/shaft end up) using the OE hardware. Torque the upper mounting hardware to 20 ft./lbs. and the lower to 35 ft./lbs.

26.

On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses.

There must be no pinching, rubbing, or stretching of either component. Use zip ties to secure these items to the steering components.

At full droop, cycle the steering from lock to lock while observing the reaction of these components. Reposition them if needed.

27. Reinstall the rear wheels and lower the vehicle to the ground. Torque the lug nuts according to the wheel manufacturers recommendations.

28. Install the rear track bar to the relocation bracket (90-5841) using the supplied adjustable cam bolt (90-3718) and hardware from hardware pack (90-6529). Do not torque the cam bolt at this time. See ILLUSTRATION 4.

29. Position your vehicle on a smooth, flat, hard

8

Illustration 5

Rear Bump Stop Lock

Plate Assembly

90-4149 Rear Bump

Stop Extension

90-3719

Bump Stop

Lock Plate

OE Bump

Stop

1/2” X 1 3/4”

Bolt

55717/55717MX

Created

12.4.12

Bump Stop Frame

Mount Cup

1/2”

Hardware

surface (i.e. concrete or asphalt).

30. Rotate the track bar cam bolt until the wheels are centered under the vehicle.

31. Torque track bar cam bolt to 103 ft./lbs.

32. Drive the vehicle forward and backward a few feet to be sure that the axle is adjusted properly and the vehicle is tracking in a straight line.

IMPORTANT!: If the steering wheel is not centered properly it will trigger the anti-lock brake and traction control warning lights

.

NOTES:

On completion of the installation, have the suspension and headlights realigned.

After 100 miles recheck for proper torque on all newly installed hardware.

Recheck all hardware for tightness af-

ter off road use.

9

10

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Created

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55717/55717MX

Created

12.4.12

Revision Page:

5.16.11: Updated kit to fit up to 2011 vehicles. Added (94-5987) Rear Brake Line drop bracket, Hardware pack (90-6525), Zip ties (10999), Brake line sleeving (90-4337), Front Brake line bracket: (90-

7203 Drvr and 90-7203 Pass) to the BOM box-1, text and illustration #2.

8.30.12: Moved (90-3718) cam bolt into hardware pack (90-6529).

10.1.12: Changed kit fitment to include 2013.

12.4.12: Updated front brake line bracket note to include 2011 to 2013 models.

11

Notice to Owner operator, Dealer and Installer:

Vehicles that have been enhanced for off-road performance often have unique handling characteristics due to the higher center of gravity and larger tires. This vehicle may handle, react and stop differently than many passenger cars or unmodified vehicles, both on and off–road. You must drive your vehicle safely! Extreme care should always be taken to prevent vehicle rollover or loss of control, which can result in serious injury or even death. Always avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking! Pro Comp reminds you to fasten your seat belts at all times and reduce speed! We will gladly answer any questions concerning the design, function, maintenance and correct use of our products.

Please make sure your Dealer/Installer explains and delivers all warning notices, warranty forms and instruction sheets included with Pro Comp product.

Application listings in this catalog have been carefully fit checked for each model and year denoted. However, Pro

Comp reserves the right to update as necessary, without notice, and will not be held responsible for misprints, changes or variations made by vehicle manufacturers. Please call when in question regarding new model year, vehicles not listed by specific body or chassis styles or vehicles not originally distributed in the USA.

Please note that certain mechanical aspects of any suspension lift product may accelerate ordinary wear of original equipment components.

Further, installation of certain Pro Comp products may void the vehicle’s factory warranty as it pertains to certain covered parts; it is the consumer’s responsibility to check with their local dealer for warranty coverage before installation of the lift.

Warranty and Return policy:

Pro Comp warranties its full line of products to be free from defects in workmanship and materials. Pro Comp’s obligation under this warranty is limited to repair or replacement, at Pro Comp’s option, of the defective product. Any and all costs of removal, installation, freight or incidental or consequential damages are expressly excluded from this warranty. Pro

Comp is not responsible for damages and / or warranty of other vehicle parts related or non-related to the installation of Pro

Comp product. A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will assume all risk and responsibility for potential damages incurred as a result of their chosen modifications. Warranty coverage does not include consumer opinions regarding ride comfort, fitment and design. Warranty claims can be made directly with Pro Comp or at any factory authorized Pro Comp dealer.

IMPORTANT!

To validate the warranty on this purchase please be sure to mail in the warranty card.

Claims not covered under warranty-

• Parts subject to normal wear, this includes bushings, bump stops, ball joints, tie rod ends and heim joints

• Discontinued products at Pro Comp’s discretion

• Bent or dented product

• Finish after 90 days

• Leaf or coil springs used without proper bump stops

• Light bulbs

• Products with evident damage caused by abrasion or contact with other items

• Damage caused as a result of not following recommendations or requirements called out in the

installation manuals

• Products used in applications other than listed in Pro Comp’s catalog

• Components or accessories used in conjunction with other manufacturer’s systems

• Tire & Wheel Warranty as per Pro Competition Tire Company policy

• Warranty claims without “Proof of Purchase”

• Pro Comp Pro Runner coil over shocks are considered a serviceable shock with a one-year

warranty against leakage only. Rebuild service and replacement parts will be available and sold

separately by Pro Comp. Contact Pro Comp for specific service charges.

• Pro Comp accepts no responsibility for any altered product, improper installation, lack of or

improper maintenance, or improper use of our products.

E-Mail: [email protected]

Website: www.explorerprocomp.com

Fax: (619) 216-1474

Ph: (619) 216-1444

PLACE

WARRANTY REGISTRATION

NUMBER

HERE: __________________

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