Pro Comp Stage 3 Long Arm 4" Lift Kit, 4" Lift Kit, 4" Lift Kit, 4" Lift Kit lift kit Installation instructions

2360 Boswell Road

Chula Vista, CA 91914

Phone 619.216.1444

Fax 619.216.1474

E-Mail [email protected]

PRO COMP SUSPENSION

Suspension Systems that Work!

IMPORTANT: Because this vehicle will be equipped with a rear 4 link suspension. The exhaust system may need to be altered from the rear of the muffler back by a qualified exhaust shop depending on which year/model and exhaust system type the vehicle is equipped with.

IMPORTANT: This kit is designed to be installed on a vehicle that already has a slip yoke eliminator kit and CV style driveshaft in place. If your vehicle is not equipped with these items, you must purchase them before installing this kit. Pro Comp offers a slip yoke eliminator kit (PN 4007) and a

CV style driveshaft (PN 4042)

Part #

55794/55794MX

‘04-’06 4WD Jeep TJ

Unlimited/ Rubicon

6 cyl w/ automatic trans w/ Dana

44 & 35 rear diff and Dana 44 &

30 front diff

Stage 3 Long Arm

4” Lift Kit

Part #

55795/55795MX

‘04-’06 4WD Jeep TJ

Unlimited/ Rubicon

6 cyl w/manual trans w/ Dana

44 & 35 rear diff and Dana 44 &

30 front diff

Stage 3 Long Arm

4” Lift Kit

Part #

55796/55796MX

‘03-’06 4WD Jeep TJ

Unlimited/ Rubicon

6 cyl w/ automatic & manual trans w/ Dana 44 & 35 rear diff and Dana 44 & 30 front diff

Stage 3 Long Arm

4” Lift Kit

Part #

55797/55797MX

‘03-’06 4WD Jeep

Wrangler TJ/ Rubicon

6 cyl w/ automatic trans w/ Dana

44 & 35 rear diff and Dana 44 &

30 front diff

Stage 3 Long Arm

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.

Part #

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Box 1-PN 55794/55794MX-1/55795/55795MX-1/55796/55796MX-1/55797/55797MX-1 of 5

6.13.08

Description Qty Illus.

90-3984

90-3985

1 8 11

1 8 11

Box 2-PN 55794/55794MX-2/55795/55795MX-2/55796/55796MX-2/55797/55797MX-2 of 5

90-2764

BRAKE LINE INSULATION HOSE 1 - -

90-3998

70-0250751800

72-025100816

73-02500030

RELOCATION BRACKET: Rear Disk Brake Line

1/4" X 3/4" HEX BOLT USS GR. 8

1/4"GR. 8 STOVER NUT

1/4" SAE GR. 8 FLAT WASHER

1

1

1

2

70-0371001522

70-0311001800

72-03100100512

3/8” X 1” GR.5 SELF TAPPING HEX BOLT

5/16" X 1" GR. 8 HEX BOLT

5/16" NYLOCK NUT

5/16" SAE GR. 8 FLAT WASHER

2

4

4

8

4

4

4

4 73-03100034

90-6550 HARDWARE 1

70-0504001800 1/2" X 4" GR. 8 HEX BOLT 12 7 11

9

9

9

9

72-050100816

73-05000832

70-0501251800

72-050100816

73-0500830

90-3988

90-3993

90-5038

90-5042

90-3879

OR

1/2" GR.C STOVER NUT

1/2" SAE FLAT WASHER

1/2" X 11/4" GR. 8 COUNTER SUNK BOLT

1/2" X GR. C STOVER NUT

1/2" SAE FLAT WASHER

BELLY PAN FRAME MOUNT:

BELLY PAN FRAME MOUNT:

BELLY PAN FRAME MOUNT:

Drvr (Regular TJ)

Pass (Regular TJ)

Drvr (Unlimited)

BELLY PAN FRAME MOUNT:

Pass (Unlimited)

BELLY PAN FRAME MOUNT TOOL

12

24

14

12

12

1

1

1

1

1

12

12

12

12

7

7

8

8

8

5,6,7,8 10,11

5,6,7,8 10,11

5,6,7,8 10,11

5,6,7,8 10,11

6

15

15

15

15

11

11

11

11

11

10

72-043100816

73-04300830

Transmission Mount Crossmember

1 - -

7/16” STOVER NUT

7/16” SAE FLAT WASHER

4

4

8

8

11

11

Box 3-PN 55794/55794MX-3/55795/55795MX-3/55796/55796MX-3/55797/55797MX-3 of 5

90-3580

50C375HCS8Y

50NUCZ

50NWSAZ

50C250HCS8Y

50C200HCS8Y

90-2603

TRACK BAR DROP BRACKET 1 3

Track Bar Drop Bracket

1

1/2" X 3 3/4." GR. 8 HEX BOLT

1/2" STOVER NUT

2

4

3

3

8

1/2" FLAT WASHER

1/2" X 2 1/2" GR. 8 HEX BOLT

1/2" X 2" GR. 8 HEX BOLT

8

1

1

3

3

3

TRACK BAR SPACER

(.625" X .500 X .063 WALL)

1 - -

8

8

8

8

8

90-3726

90-3728

90-4152

90-1092

1

1

1

2

16 15

18 17

19,20 18,19

18 17

2

Part #

90-2009

90-2638

Description

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

Qty Illus. Page

STRIGHT SWAY BAR:

Rear

19

7/8" OFFSETSWAY BAR:

Front

2 14,17 15,16

37C150HCS5Z

37C250HCS5Z

37CNNE5Z

37NWSAZ

37NWUS8Y

600006

61150

60859H

600001

3/8” X 1 1/2 GR. 8 HEX BOLT

3/8” X 2 1/2 GR. 8 HEX BOLT

3/8” GR. 8 NYLON NUT

3/8” SAE FLAT WASHER

3/8” USS GR. 8 FLAT WASHER

5/8" BLACK HOURGLASS BUSHING

SLEEVE 5/8" X 3/8" X 1.480"

SLEEVE

5/8" BLACK HOURGLASS BUSHING

2

2

4

4

2

4

2

2

4

18

19

18,19

18,19

16

16

16

16

17

18

18,19 17,18

17,18

17,18

17

17

17

17

90-2593

72-050200812

73-05000034

73-06200034

90170A212

Sway Bar Quick Disconnect

2 - -

1/2"-20 NYLOCK NUT

1/2" SAE FLAT WASHER

5/8" SAE FLAT WASHER

90-3579

90-2596

70-0251251800

72-025100512

90-2010

SWAY BAR CLAMP

SWAY BAR CLAMP SPACER

1/4"-20 X 1 1/4" HEX BOLT GR.8

SLEEVE

90-6475 HARDWARE

90-1867

90-2381

REAR SHOCK RELOCATOR

SHOCK SPACER

1

1

1

1

1

1

1

1

1

1

18

18

17

17

1 - -

2

19

19

19

19,20

18

18

18

18

18,19

16,18 15,16

17

23 21

90-6476 HARDWARE

.120C600HCS1Y

.120NWHDY

.120CNNEZCL10

12mm-1.75 X 60mm HEX BOLT 10.9

12mm HARDENED FLAT WASHER

12mm-1.75 NYLOCK NUT

31C100HCS8Y

31NWHDY/SAE

31CNUCZ

90-2627

HRS MX 10T

5/16” X 1” GR 8 HEX BOLT

5/16” HARDENED SAE FLAT WASHER

5/16” STOVER NUT

FRONT TRACK BAR JEEP:

W/ DANA 44

HARDWARE

ROD END, .750-16 THREAD W/JAM NUT

1 - -

2 23 21

4

2

2

4

2

1

1

23

23

23

23

23

1

-

-

21

21

21

21

21

-

-

-

15-11080

90-2249

TRACK BAR BUSHING, URETHANE

SPACER, .750” OD X .438” ID X 1.600”

90-6501

96-2647

3

2” X 1/2” BUMPSTOP SPACER

2

1

1

4

-

-

-

15

-

-

-

16

3

Part #

90-2736

90-3986

90-3987

Description

TRACK BAR BRACKET SPACER: (.625" X .700)

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Qty Illus. Page

1 - -

AXLE LOCK RELAY BRACKET: Front 1 4 9

AXLE LOCK RELAY BRACKET: Rear 1 4

Box 4-PN 55794/55794MX-4/55795/55795MX-4/55796/55796MX-4/55797/55797MX-4 of 5

9

90-2626

15-11310

90-2609

90-2604

100FNFJZ

90-3783

90-3789

70-0311751800

72-031100816

73-03100830

90-3802

90-3796

JMX14T

3/4" X .156 WALL X 2.0"

BUSHING JEEP UPPER ARM

UPPER FRONT ARMS:

Male

UPPER FRONT ARMS:

Female

2

4

13

13

15

15

1”-14 UPPER CONTROL ARM JAM NUT

LOWER CONTROL ARM FRONT:

Drvr

2 13 15

1 9 12

LOWER CONTROL ARM FRONT:

Pass

1 -

Lower Control Arm Pinch Clamp

5/16" X 1 3/4" GR.8 HEX BOLT

5/16" GR. C STOVER NUT

1 -

4

4

8,9

8,9

-

12

12

5/16" SAE WASHERS 8 8,9 12

LOWER CONTROL ARM REAR:

Drvr

1 -

LOWER CONTROL ARM REAR:

Pass

1 9 12

Lower Control Arm Rod Ends

1 - -

4

9,10 12

70-0563751800

72-056100816

73-05600830

90-2310

15-11255

Lower control Arm Rod Ends

1 - -

9/16" X 3 3/4" GR 8 HEX BOLTS

9/16" GR 8 STOVER NUTS

4

4

9,10

9,10

12

12

9/16" GR 8 SAE WASHERS 8 9,10 12

SLEEVE

1 - -

4 9,10 12

8 9,10 12

Box 5-PN 55794/55794MX-5/55795/55795MX-5/55796/55796MX-5/55797/55797MX-5 of 5

90-2626

15-11310

90-6553

JMX-12T

SJNR12

3/4" X .156” WALL X 2"

BUSHING JEEP UPPER ARM

2

4

14

14

16

16

HARDWARE PACK: Rear Upper Arm

Rod Ends

1 - -

2 14 16

NUTS 2 14 16

4

Part #

90-2449

Description

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

Qty Illus.

SPACER, .750” OD X .438” ID X 1.600” LONG 4 14

Page

16

70-0310751800

73-03100830

70-0372251800

72-037100816

73-03700030

72-043100816

70-0563001800

72-056100816

73-05600830

90-3757

90-4158

90-3781

90-3767

90-3893

5/16” X 3/4" GR 8 HEX BOLT

5/16” GR 8 SAE FLAT WASHER

3/8” X 2 1/4”GR 8 HEX BOLT

3/8” UNITORQUE NUT

3/8” HARDENED FLAT WASHER

7/16” STOVER NUT

9/16" X 3" GR 8 HEX BOLTS

9/16" STOVER NUTS

9/16" GR 8 SAE WASHERS

REAR AXLE TRUSS

REAR AXLE VENT TUBE

DANA 44 REAR DIFFERENTIAL SPACER PLATE

REAR AXLE TRUSS CLAMPS

DANA 35 REAR DIFFERENTIAL SPACER PLATE

4

4

8

8

16

1

2

2

4

1

1

1

2

1

11

11

11

11

11

11

11

11

11

13

13

13

13

13

13

13

13

13

11 13

11 13

11 13

11 13

11 13

37C100HCS8Y

37CNUCZ

37NWHDY

Axle Truss Overlap Plate

1

3/8” X 1” GR. 8 HEX BOLT

3/8” STOVER NUT

3/8” SAE HARDENED FLAT WASHER

90-6641 HARDWARE

90-5134

4

4

8

2

11 13

11 13

11 13

- -

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

7450

55497

55498

PACKAGED AND MUST BE ORDERED SEPARATELY.

STAINLESS STEEL BRAKE LINE KIT 1 -

1

1

15

-

-

16

-

324515

323509

924515

923509

MX6021

MX6106

COIL SPRING, PAIR (FRONT)

COIL SPRING, PAIR (REAR)

ES 3000 SHOCK ABSORBERS (FRONT)

ES 3000 SHOCK ABSORBERS (REAR)

OR

ES 9000 SHOCK ABSORBERS (FRONT)

ES 9000 SHOCK ABSORBERS (REAR)

OR

MX-6 SHOCK ABSORBERS (FRONT)

MX-6 SHOCK ABSORBERS (REAR)

2

2

2

2

2

2

15

-

15

-

15

-

16

-

16

-

16

-

Optional Equipment Available from your

Pro Comp

Distributor!

Winch Spacer, 1” (Front) - Pair: 55496

Steering Stabilizer: 219505

Slip Yoke Eliminator Kit: 4007

Jeep TJ CV Style Driveshaft: 4042

Also, check out our outstanding selection of

Pro Comp tires to

compliment your new installation!

♦

♦

♦

♦

♦

♦

Introduction:

This installation requires a professional mechanic!

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

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-to-frame 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, a wheel not to exceed 8” in width with a minimum backspacing of 3.25” must be used. Additionally, a quality tire of radial design, not exceeding 33” tall X 12.5” wide is recommended. Please note that the use of a 33” 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.

NOTE: If you are planning to install a differential air locker you will need to use a 90 degree 3/16” compression fitting to clear the axle truss (90-3757) and the accompanying parts and hardware.

6

INSTALLATION INSTRUCTIONS:

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: jack under the front axle and raise the vehicle.

Place jack stands under the front body mounts and lower the vehicle onto the stands. Place your floor jack under the rear axle and raise the vehicle. Place jack stands under the rear body mounts and lower the vehicle onto the stands.

Remove the jack and place the vehicle back in gear, set the emergency brake.

DISASSEMBLY:

4. Unbolt and remove the front track bar from the vehicle.

5. Unbolt the rear track bar and remove it from the vehicle.

6. Remove the cotter pin and nut from the drag link at the pitman arm. Using the proper tool, disconnect the pitman arm from the drag link

7. Remove the nut and washer from the steering gear shaft. Remove pitman arm using a proper pitman arm removal tool.

8. Disconnect the front sway bar end links and remove from the vehicle.

9. Disconnect the rear sway bar end links and remove from the vehicle.

10.Unbolt and remove the rear sway bar from the rear axle. Save the hardware for reuse.

11. Perform steps 12 through 17 on the front and rear of the vehicle.

12. Remove the wheels and tires from the vehicle.

13. Support the differential with your floor jack and remove the OE shock absorbers. It may be necessary to raise the differential housing slightly to facilitate their removal.

NOTE: Be sure to support the axle while

the springs and shocks are removed.

14. Carefully lower axle until coil spring is free from upper mount. Remove coil spring retainer bolt and remove the coil spring.

NOTE: After removal of the springs sup-

port the axles with jack stands or pole jacks.

15. Remove the OE bump stops from the bump stop mounting cups.

16. Unbolt the factory bump stop mounting cup from the frame. Save the hardware for reuse.

17. With the axles fully supported, locate the adjustment cam bolts, positioned on front of existing lower control arms. (Make an index mark as shown in ILLUSTRATION 1, for installation reference. FRONT ONLY). Unbolt and remove the lower control arms from the vehicle.

NOTE: If the vehicle is equipped with

ABS brakes remove sensor wire from the in-

board side of the lower control arm.

18. THIS STEP IS TO BE PERFORMED ON

RUBICON MODELS ONLY, Unbolt the axle lock relay bracket from the driver side frame rail.

19. Support the transfer case skid plate. The

Adjustment Bracket

Index Mark

Axle Bracket

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Illustration 1

Adjustment Cam Bolt

Adjustment Cam Bolt

Lower

Control

Arm

7

Frame Rail

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Frame Rail

Lower Arm

Frame Mounts

Illustration 2

Lower A-Arm Pocket

Removal

Lower Arm

Frame Mounts

transfer case and transmission are supported by the skid plate. Before removing the skid plate ensure that the transmission is properly supported. Remove the (6) bolts connecting the skid plate to the frame. The skid plate will not be reused. smooth. Clean the area thoroughly and paint the exposed metal with a good quality paint.

IMPORTANT!: Be sure not to cut into

fuel or brake lines. DO NOT cut into the frame

rail. This will weaken the frame structure con-

siderably.

20. Using a suitable cutting tool, (abrasive cutoff wheel, Sawz-all, etc.) cut off the front and rear lower arm mounting pockets as shown in ILLUS-

TRATION 2. After cutting the lower arm mounting pockets, sand the frame

Drill Pic

1/2”

Drill

Bit

Illustration 3

Front Track Bar

Bracket Install

Frame

1/2” X 3

3/4” Bolt

21. The factory nutserts in the bottom of the frame rails will need to be removed.

22. Drill out the factory nutsert using a 9/16” drill bit. The drilling will separate the inside portion of the nutserts from the body.

23. Once the insides of the nutserts are loose, with a cold chisel or a cut off wheel, knock off the bodies of the nutserts that hang below the frame.

24. Remove the inside portion of the nutserts from the frame rail.

NOTE: A magnet and compressed air will aid in the nutsert removal. Blow the nutserts down the rail toward the round frame hole

that can be accessed by a magnet for removal.

90-3580

Track Bar

Relocation

Bracket

1/2” X 2” bolt

ASSEMBLY:

25. Install the new pitman arm (YJ 400) using the OE retaining nut. Torque the retaining nut to

185 ft./lbs.

26. Reinstall the draglink onto the pitman arm.

Torque to 60 ft./lbs.

27. Install the front track bar bracket (90-3580) into the OE mounting position using the 1/2” X

Center punch Pic

8

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08 axle lock relay relocation brackets (90-3986) front

5/16” X

1” Bolt

Illustration 4

Relay Relocation

Bracket Install

Drvr Frame Rail

OE Axle

Lock Bracket axle lock relay relocation

brackets (90-3987 rear).

FRONT OF VEHICLE

3/8” Self

Tapping Bolt

5/16” Drill

Bit

Drvr Frame Rail

Drvr Frame Rail

2” bolt in the lower mounting hole. See ILLUS-

NOTE: If you have previously drilled the

OE lower hole out to 5/8” install the provided

sleeve (90-2736) in this hole.

28. With the track bar bracket (90-3580) bolted in place, use the two upper holes as guide holes to mark the frame for drilling. See ILLUSTRA-

TION 3.

29. Center punch the previously made marks in the frame and drill out to 1/2”. See ILLUSTRA-

TION 3.

30. Secure the upper holes of the bracket using the 1/2” X 3 3/4” bolts and hardware. Torque the

1/2” bolts to 65 ft./lbs. See ILLUSTRATION 3.

STEPS 31 THROUGH 34 ARE TO BE PER-

FORMED ON RUBICON MODELS ONLY.

31. Relocate the axle lock relay bracket using the axle lock relay relocation brackets (90-3986

front and 90-3987 rear). Place the relocation brackets over the top of the driver side frame rail, in between the floor, as shown in ILLUSTRA-

TION 4.

9

NOTE: The side with the single hole will go on the outside of the frame rail.

32. Secure the factory relay bracket to the new relocation brackets (90-3986 front and 90-3987

rear) using the provided (4) 5/16” X 1” bolts and hardware. See ILLUSTRATION 4.

33. With the brackets in place, using the holes in the outside of the relocation brackets as a guide, drill through the outside wall of the frame rail using a 5/16” drill bit. See ILLUSTRATION 4.

34. Secure the relocation brackets to the frame rail using the (2) provided 3/8” self tapping bolts.

See ILLUSTRATION 4.

IMPORTANT!: Be sure that the brake, vacuum and fuel lines are free from contact with any newly installed or existing parts as

rubbing may cause these lines to fail.

BELLY PAN INSTALLATION:

35. Test fit the belly pan frame mount brackets

(90-3988 drvr and 90-3993 pass for regular models or 90-5038 drvr and 90-5042 pass for

unlimited models) by clamping them to the

Frame Rail

1/2” Drill

Bit

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Large Reference

Hole in Frame

Illustration 5

Belly Pan Frame

Bracket Drilling

Belly Pan Frame Mount (90-3988 drvr and 90-3993 pass for regular models or 90-5038 drvr and 90-5042 pass for unlimited models)

frame rail. Locate the frame mount brackets by measuring 14 1/4” from the edge of the large hole in the frame, forward of the belly pan mounting position, to the edge of the front control arm mounting hole in the frame mount bracket. See ILLUSTRATION 5.

36. Repeat on the remaining side of the vehicle.

37. With the frame mount brackets clamped in place, test fit the belly pan (90-3784). The belly pan mounting holes should match up with the frame mounting bracket holes. Temporarily se-

Illustration 6

Belly Pan Frame

Bracket Drilling

1/2” Drill

Bit

90-3879 Belly

Pan Drill Tool

1/4” Drill Bit

Belly Pan Frame Mount (90-3988 drvr and 90-3993 pass for regular models or 90-5038 drvr and 90-5042 pass for unlimited models)

Front of Vehicle

cure the belly pan in place using (4) 1/2” X 1

1/4” countersunk bolts and hardware in the (4) corner holes. If the holes do not line up, loosen the clamps and readjust the assembly until the desired fit is achieved.

NOTE: The belly pan is temporarily bolted into place at this time to prevent any movement of the frame brackets during the

drilling process.

38. Using the frame mounting brackets (90-3988

drvr and 90-3993 pass for regular models or

90-5038 drvr and 90-5042 pass for unlimited

models) as a guide drill through the holes in the frame mount bracket using a 1/2” drill bit. Drill

ONLY through the outside wall of the frame rail.

Repeat for all holes in the frame mount bracket.

See ILLUSTRATION 5.

39. Install the frame drill tool (90-3879) into the previously drilled 1/2” hole and hold it against the frame mounting brackets and frame rail. See

ILLUSTRATION 6.

40. With the drill tool held firmly in place, drill a

1/4” hole through the inside frame rail wall. Repeat for all the previously drilled 1/2” holes. See

ILLUSTRATION 6.

NOTE: Be very careful not to drill

through any wiring, fuel or brake lines.

10

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Illustration 7

Belly Pan Frame

Bracket Install

Frame Rail

1/2” X

4” Bolt

1/2”

Hardware

Belly Pan Frame Mount 90-3993 pass

(regular) or 90-5042 pass (unlimited)

Frame Rail

Belly Pan Frame

Mount 90-3988 drvr (regular) or

90-5038 drvr

(unlimited)

7/16”

Hardware

Belly Pan

90-3784

Illustration 8

Belly Pan and trans crossmember Install

11

Belly Pan Frame Mount

(90-3988 drvr and 90-3993 pass for regular models or

90-5038 drvr and 90-5042 pass for unlimited models)

Transmission

Crossmember

90-3795

OE

Transmission

Hardware

(14) 1/2” X 1 1/4”

Countersunk Bolt

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

9/16” X 3 3/4” Bolts

(2) 90-4153

Misalignment Spacer

5/16” X 1 3/4”

Pinch Clamp Bolt

9/16” X 3

3/4” Bolts

OE

Cam

Bolt

(2) 90-4153

Misalignment

Spacer

JMX14T Rod

End

JMX14T

Rod End

Front Lower

Control Arm

90-3783 drvr

90-3789 pass

Illustration 9

Front Lower Control

Arm Install

(2) 15-11255

Bushings

90-2310

Sleeve

5/16” X 1 3/4”

Pinch Clamp Bolt

Rear Lower

Control Arm

90-3802 drvr

90-3796 pass

Illustration 10

Rear Lower Control Arm

Install

15-11255

Bushings

OE Bolt

90-2310 Sleeve

41. Drill out the 1/4” inner frame rail holes using a 1/2” drill bit. See ILLUSTRATION 6.

42. Secure the frame brackets (90-3988 drvr

and 90-3993 pass for regular models or 90-

5038 drvr and 90-5042 pass for unlimited

models) to the frame using the supplied 1/2” X

4” bolts and hardware. See ILLUSTRATION 7.

Torque the mounting hardware to 65 ft./lbs.

43. Unbolt and remove the belly pan from the vehicle.

44. Install the new transmission crossmember

(90-3795) by placing the crossmember over the mounting studs on the belly pan frame mounts.

Secure using the supplied 7/16” nuts and washers. Only tighten the 7/16” nuts a few turns. See

ILLUSTRATION 8.

45. Lower the transmission onto the crossmember (90-3795), align the transmission mounting holes and secure using the OE hardware. Torque the transmission mounting hardware according to the factory manuals specifications. See ILLUS-

TRATION 8.

46. Torque the transmission crossmember (90-

3795) hardware to 55 ft./lbs.

47. If necessary install the slip yoke eliminator kit and install the CV style rear driveshaft at this time. Refer to the instructions provided with the kit.

48. Raise the belly pan (90-3784) back into place and secure to the belly pan frame mounts and secure using the (14) supplied 1/2” X 1 1/4” counter sunk bolts and hardware. See ILLUS-

IMPORTANT! Due to the fact that the countersunk bolts create increased friction on their mating surfaces, we recommend holding

the Allen head end and tightening the nut.

LOWER CONTROL ARMS:

Check the arm length chart on page 22 for suggested lower arm measurements

49. Perform steps 49 through 55 on the front and rear of the vehicle.

50. Insert the bushings (15-11255) and sleeve

(90-2310), using a thin layer of lubricant, into the

(4) new lower control arms (90-3783 front drvr,

90-3789 front pass, 90-3802 rear drvr and 90-

3796 rear pass) as shown in ILLUSTRATION 9

12

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

3/8”

Hardware

90-3757

Axle

Truss

(4) 5/16” X

3/4” Bolts

Illustration 11

Rear Axle Truss Install

Overlap

Plate

(90-3894) and 3/8” X

1” Bolts

OE Rear

Sway Bar

OE Sway

Bar Bolts

Rear

Axle

OE

Differential

Cover

(2) 90-3767 Axle

Truss Clamp

(8) 3/8” X 2

1/4” Bolts

Overlap

Plate

(90-3894) and 3/8” X

1” Bolts

7/16”

Stud

Rear Differential Spacer Plate 90-3781

Dana 44 or 90-3893 Dana 35

OE

Differential Bolts

90-4158

Vent Tube

Pro Comp

Brake line

Junction

Block

& 10.

51. Install the rod ends (JMX14T) into the pinch clamp end of the rear lower arms. Install the pinch clamp 5/16”X 1 3/4” bolts and hardware.

See ILLUSTRATION 9 & 10. Adjust the arm length according to the arm length chart on page

22 and tighten the jam nut.

52. Insert the (2) misalignment spacers per arm

(90-4153) into the rod end. See ILLUSTRA-

TION 9 & 10.

53. Install the rod end of the lower arm to the mounting pockets on the belly pan frame bracket using the supplied 9/16” X 3 3/4” bolts and hardware. See ILLUSTRATION 9 & 10.

54. Install the bushing end of the lower arms to the mounting pockets on the axle using the supplied OE bolts and hardware. Torque the OE bolt to 85 ft./lbs. See ILLUSTRATION 9 & 10.

55. Torque the OE lower control arm mounting bolts according to factory specifications and the

13 supplied 9/16” bolts to 130 ft./lbs.

REAR AXLE TRUSS:

56. With the rear axle fully supported unbolt the rear upper control arms from the rear axle.

57. Remove the rear axle vent tube and unbolt the brake line junction block from the rear axle.

58. Drain the rear axle fluid and remove the differential cover.

59. With the axle clear of accessories, test fit the axle truss assembly.

60. Test fit the rear axle differential spacer plate

(90-3781 for Dana 44 or 90-3893 for Dana 35)

to the rear axle to ensure proper alignment. Secure using the OE bolts. See ILLUSTRATION

11.

61. Place the rear axle truss (90-3757) on top of the differential housing. Line up and install the

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

5/16” X 3/4” bolts that secure the rear axle differential spacer plate to the rear axle truss. Secure the truss to the rear axle using the (2) axle truss clamps (90-3767), 3/8” X 2 1/4” clamp bolts and hardware. See ILLUSTRATION 11.

62. A new vent tube hole will need to be drilled on the front, driver side of the rear axle.

63. Use the hole in the axle truss (90-3757) , next to the 7/16” brake line mounting stud, on the front side of the rear axle as a guide to drill a new vent hole in the rear axle tube using a 3/8” drill bit. See ILLUSTRATION 11.

NOTE: When drilling into an oil cavity, pack the flutes of the drill bit with grease to

catch all the metal shavings.

64. Once the new vent tube hole is drilled, unbolt and remove the axle truss. Clean and remove any remaining metal chips from inside and outside the rear axle.

65. Run a bead of silicone around the new vent tube hole in the rear axle. Also seal the original vent tube hole in the rear axle.

NOTE: There is no pressure on the rear axle vent system so do not overload the holes

with silicone.

66. Install the 3/8” vent tube (90-4158) through the hole in the rear axle truss. See ILLUSTRA-

67. Reinstall the axle truss (90-3757) by lining up and reinstalling the 5/16” X 3/4” bolts that secure the rear axle differential spacer plate (90-

3781 for Dana 44 or 90-3893 for Dana 35) to the rear axle truss. Reinstall the axle clamps (90-

3767) to the rear axle. Secure the clamps using the supplied 3/8” X 2 1/4” bolts and hardware.

See ILLUSTRATION 11.

NOTE: The vent tube should line up

with the newly drilled hole on the rear axle.

NOTE: Be sure the inside of the vent

tube is clear of silicone after installation.

68. Install the (2) overlap plates (90-3894) to the axle truss using the (4) 3/8” X 1” bolts and hardware. Reinstall the sway bar to it’s original rear axle mounting position. Secure the sway bar

14 frame mounts to the overlap plates and rear end using the previously removed (4) OE sway bar bolts. See ILLUSTRATION 11.

69. Torque the rear axle truss (Except the (4)

5/16” bolts), overlap plate and sway bar mounting hardware according to the torque chart on page 23 or according to manufacturers recommendations.

70. Unbolt and remove the rear axle differential spacer plate (90-3781 for Dana 44 or 90-3893

for Dana 35). See ILLUSTRATION 11.

71. Run a bead of silicone along the differential cover mating surface.

72. Reinstall the differential spacer plate (90-

3781 for Dana 44 or 90-3893 for Dana 35) to the rear axle truss using the (4) 5/16” X 3/4” bolts and hardware. See ILLUSTRATION 11.

73. Run another bead of silicone on the face of the differential cover.

74. Raise the differential cover into place and secure using the OE bolts. Torque the differential spacer plate and cover hardware according to the torque chart on page 23 or manufacturers specifications. See ILLUSTRATION 11.

75. Unbolt the rear rubber brake line from the frame. Save the hardware for reuse.

76. Detach the rear rubber brake line from the factory metal brake lines on the frame and the rear axle.

77. Thoroughly clean all mating surfaces and secure the supplied 90 degree brake line mounting bracket (90-1031) to the frame using the previously removed OE bolt. At the upper end of the brake line (7450), insert the threaded end of the brake line from the bottom through the supplied brake line mounting bracket (90-1031).

Install the supplied jam nut to threaded end of the brake line (7450) and tighten. Position the line so it doesn’t make contact with any other parts.

78. Connect the new brake line (7450) to the existing frame metal brake line and tighten.

79. Slip the junction block end of the new brake

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

OE Brake Line Clip

1/4” X

3/4” Bolt

OE Brake

Line

Illustration 12

Rear Brake Line

Relocation Bracket

90-3998

Brake Line

Relocation

Bracket

driver side brake line to the front of the axle.

Bolt the new brake line bracket (90-3998) to the hole in the top of the rear axle lower control arm mounting pocket using the provided 1/4”-

20 X 3/4” bolt and hardware. Secure the brake line to the new bracket (90-3998) using the previously removed clip. See ILLUSTRATION 12.

Be sure the brake line does not contact any parts. If so use the provided 1/4” rubber hose

(90-2764) as a sheath for the brake lines. This

hose can cut and applied as needed.

FR

O

NT

O

F

VE

H

IC

LE

Lower

Control

Arm

Mounting

Pocket

line (7450) over the 7/16” stud on the front of the axle truss. Secure using the supplied 7/16” nut from pack (90-6551). See ILLUSTRATION 11.

IMPORTANT: MAKE SURE BRAKE

LINES ARE CLEAN AND DRY OF ANY MA-

TERIAL BEFORE ABS BRAKE BLEEDING

AND REASSEMBLY. BE VERY CAREFUL

NOT TO LET THE MASTER CYLINDER

RUN DRY! WITH ABS BRAKES THIS

SITUATION WILL DAMAGE THE SYSTEM!

80. Attach the Pro Comp brake line junction block to the existing rear axle metal brake lines

NOTE: Depending on brake application, the steel lines may need to be carefully rerouted

Check the arm length chart on page 22 for suggested upper arm measurements

to attach to the junction block.

81. With the front and rear axles fully supported unbolt and remove the front and rear upper con-

NOTE: FOR MODELS WITH FAC-

TORY INSTALLED DISC BRAKES ONLY,

trol arms from the vehicle.

Unclip the driver side metal brake line from the factory bracket. Relocate the

Illustration 13

Front Upper Control

Arm Install

Upper Control

Arm

82. Install the bushings (15-11310) and sleeves

(90-2626) into the female end of the front upper

90-2604 Upper Arm End

90-2609 Upper

Arm Threaded

End

90-2626

Sleeve

OE Nut

Plate

Frame

Pocket

100FNFJZ

Jam Nut

(2) 15-11310

Bushings

OE Bolts

OE Bolts

Axle

15

Axle

Illustration 14

Rear Upper Control Arm

Install

OE Nut

90-2673 Upper

Rear Control

Arm

SJNR12 Jam Nut

JMX12T

Rod End

9/16” X 3”

Bolt

Shock

Hardware

Bump

Stop

Spacer

(96-2647

Bump Stops

(15-11309)

Front

Coil

Spring

55497

Existing

Spring

Retainer

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Belly Pan Control Arm Mount

control arms (90-2604). See ILLUSTRATION

13.

90-2449

Misalignment

Spacers

Rear Truss

Axle Assembly

OE

Bolt

83. Thread the upper control arm jam nut

(100FNFJZ) onto the male end of the upper control arms (90-2609). See ILLUSTRATION 13.

84. Assemble the female ends (90-2604) and male ends (90-2609) of the upper control arms.

See ILLUSTRATION 13. Adjust the arm length according to the arm length chart on page 22 and tighten the jam nut.

85. Install the bushing end of the upper arm to the mounting pockets on the frame using the previously removed OE hardware. See ILLUSTRA-

TION 13.

86. Install the clevis end of the upper arm to the mounting pockets on the front axle using the OE bolts and hardware. See ILLUSTRATION 13.

87. Assemble the rear upper control arms (90-

2673) using bushings (15-11310) and sleeves

(90-2626). See ILLUSTRATION 14.

Illustration 15

Front Spring and Shock

Install

88. Install the rod end (JMX12T) into the remaining end of the rear upper arms (90-2673) with the jam nut (SJNR12) as shown in ILLUS-

TRATION 14. Adjust the arm length according to the arm length chart on page 22 and tighten the jam nut.

89. Insert the spacers (90-2449) into the rod end.

See ILLUSTRATION 14.

Shock

Absorber

324515 or

924515 or

MX6021

NOTE: Install frame brace (90-5134) at this time. See enclosed frame brace instructions.

90. Install the bushing end of the upper arm to the mounting pockets on the frame using the previously removed OE hardware. See ILLUSTRA-

TION 14.

91. Install the rod end of the upper arm to the mounting pockets on the rear axle truss using the supplied 9/16” X 3” bolts and hardware. Do not tighten the rod end jam nut at this time. See IL-

LUSTRATION 14.

NOTE: Centering of the rear axle under the vehicle and pinion angle adjustment are

done using these rod ends.

16

Illustration 16

Sway Bar End Link

Assembly

(Front)

Sway Bar

Link

90-2638

Bushing 600006

Sleeve,

61150

(3/8” I.D.)

Bushing

600006

Sleeve

60859H

(12mm I.D.)

92. Torque the OE upper control arm mounting bolts according to factory specifications and the supplied 9/16” bolts to 130 ft./lbs.

FRONT BRAKE LINE:

93. At the driver side, unbolt the brake line bracket from the frame rail. locate the rubber

OE Inner

Fender

Bolt

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

brake hose that runs from caliper to frame. Pinch it closed with vise grips or a small “C” clamp and detach it from the caliper and factory metal line.

Plug or cover the caliper opening and remove the brake line from the vehicle.

94. Thoroughly clean all mating surfaces and secure the supplied 90 degree brake line mounting bracket (90-1031) to the frame using the previously removed OE bolt. At the upper end of the brake line (7450), insert the threaded end of the brake line from the bottom through the supplied brake line mounting bracket (90-1031).

Install the supplied jam nut to the threaded end of the brake line and tighten the nut, securing it to the brake line bracket. Connect the new brake line (7450) to the existing frame metal brake line and tighten. Install the brake line to the caliper using the factory banjo bolt and new crush washer. Position the line so it doesn’t make contact with any other parts. Make sure brake lines are clean and dry of any material before ABS brake bleeding.

95. Repeat on the remaining side of vehicle.

BLEEDING OF THE BRAKE SYSTEM

SHOULD BE DONE ACCORDING TO A

Sway Bar

Illustration 18

Sway Bar Clamp and

Adapter Install

Sway Bar

Clamp 90-3579

90-3728

Sway Bar

Inner

Fender

Bracket

Inner Fender

Illustration 17

Sway Bar Fender

Bracket Install

1/4” X 1 1/4”

Bolt and

Hardware

90-2596

1/4” Spacer

Adapter

90-1092

90-3726

Sway Bar

Retainer

3/8” x

1 1/2”

Bolt

17

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Adapter

90-1092

3/8” x 2

1/2” Bolt

Illustration 19

Sway Bar and pin Install

Lower Locking

Pin 90170A212

Sway Bar

End Link

90-2638

Sway Bar

End Link

90-2638

Finished Lower Mount

Quick

Disconnect

Pin 90-2593

1/2”

Hardware

Lower Axle Mount

JEEP FACTORY SERVICE MANUAL.

IMPORTANT: BE VERY CAREFUL

NOT TO LET THE MASTER CYLINDER

RUN DRY! WITH ABS BRAKES THIS

SITUATION WILL DAMAGE THE SYSTEM!

IMPORTANT: Move the control arm assembly up and down to its limits several times to check for binding and to ensure that there are no interference or pinching problems with the

brake lines and/or ABS wiring.

FRONT AND REAR BUMP STOPS:

96. Bolt the front bump stop cups to the frame using the previously removed OE bolt and install the 1/2” X 2” bump stop spacer (96-2647). See

ILLUSTRATION 15.

97. Install the supplied bump stops (15-11309) into the OE bump stops mounting cups. See IL-

LUSTRATION 15.

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

the vehicle onto the bump stops.

FRONT COIL SPRINGS:

98. Position new front coil spring (55497) on axle pad. Reinstall coil spring retainer and bolt.

Torque to 16 ft./lbs. Raise the axle into position until coil spring seats in upper mount, then raise axle another 2”. Install new longer shock absorbers (324515 or 924515 or MX6021) as shown in

ILLUSTRATION 15. Torque upper shock nuts to 17 ft./lbs. and lower nuts to 20 ft./lbs.

FRONT SWAY BAR:

99. Remove the OE inner fender bolts shown in

ILLUSTRATION 17. Save the hardware for reuse.

100. Install the sway bar inner fender bracket

(90-3728) into the inner fender using the previously removed OE bolts into their original holes.

See ILLUSTRATION 17.

101. Install hour glass bushings (600006) and

(61150) sleeve in the top and (60859H) sleeve in the bottom of the sway bar end links (90-2638).

18

Sway Bar Clamp 90-3579

Lower

Locking Pin

90170A212

Illustration 20

Sway Bar Disconnected

Sway Bar

End Link

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

102. Install sway bar clamp (90-3579) onto sway bar approximately 6” from the end of the bar with the holes facing down. Secure it to the sway bar using the 1/4”-20 X 1 1/4” bolt, spacer (90-

2596) and hardware in the top hole (closest to the sway bar). Leave hardware loose at this time.

See ILLUSTRATION 18.

103. Install the adapter (90-1092) and sway bar retaining bracket (90-3726) onto the sway bar using the 3/8” X 1 1/2” bolt and hardware as shown in ILLUSTRATION 18.

104. Install sway bar end links (90-2638) into the adapter (90-1092) using the 3/8” X 2 1/2” bolt and hardware.

NOTE: The jog in the sway bar will face towards the outside of the vehicle. See IL-

LUSTRATION 19.

105. Secure the quick disconnect pin (90-2593) to the factory lower sway bar mount location using the supplied 1/2” washer and 1/2” nylock nut.

NOTE: The pin will face toward the in-

side of the vehicle. See ILLUSTRATION 19.

106. Slide the lower end of the sway bar end link onto the quick disconnect pin and secure with the locking pin 90170A212 and 5/8” washer. See

ILLUSTRATION 19.

107. Repeat on the remaining side of the vehicle.

108. Temporarily install the front wheels and turn lock to lock to check for interference.

109. When disconnecting the sway bar links, swing the end links up into the previously installed clamp on the sway bar above. Secure the sway bar end link (90-2638) into the clamp (90-

3579) using the previously removed locking pin

90170A212. See ILLUSTRATION 20.

110. Once the sway bar has been raised into the clamp and secured the 1/4” x 1 1/4” bolt and hardware can be tightened down. See ILLUS-

TRATION 20.

111. Repeat on the remaining side of the vehicle.

112. Secure the sway bar to the sway bar inner fender bracket (90-3728) by inserting the upper locking pin (90-4152) through the sway bar re-

19

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

90-3728 Sway Bar

Inner Fender Bracket

Illustration 21

Sway Bar to fender bracket

90-4152 Upper

Locking Pin

90-3726

Sway Bar

Retainer

taining bracket (90-3726) and the inner fender bracket. See ILLUSTRATION 21.

113. Lock the pin (90-4152) in place by securing the clevis over the opposite end of the locking pin. See ILLUSTRATION 21.

114. Cycle steering lock to lock and inspect steering, suspension and driveline systems for proper operation, tightness and adequate clearance. Recheck brake hose/fitting for leaks. Be sure all hoses are long enough.

FRONT TRACK BAR INSTALLATION:

Check the arm length chart on page 22 for the suggested front track bar measurement

115. Install the rod end (HRSMX10T) into the track bar with the jam nut (SJNR12). Adjust the

Locking

Clevis

track bar according to the arm length chart on page 22 and tighten the jam nut.

116. Insert the sleeve (90-2603) into the rod end of the front track bar (90-2627).

NOTE: The sleeve may be a tight fit and

may need to be pressed in.

117. Install the front track bar bushings (15-

11080) and sleeve (PN 90-2249) into the track bar (PN 90-2627).

118. Install the front track bar to the passenger side axle mount. Using the previously removed

OE bolt. Torque this bolt to manufacturers specifications

119. Bolt the front track bar to the newly installed track bar bracket (90-3580). Secure using the provided 1/2” X 2 1/2” bolt and hardware.

Torque the bolt to 90 ft./lbs.

REAR COIL SPRINGS:

120. Position new rear coil spring (55498) on axle pad. Reinstall coil spring retainer and bolt.

Torque to 16 ft./lbs. Raise the rear axle into position until coil spring seats in upper mount.

REAR SHOCKS:

121. Using the supplied 12mm X 60mm bolt and hardware, install the rear shock relocation bracket (90-1867) to the rear axle. See ILLUS-

TRATION 23.

122. Install the supplied 5/16” X 1” bolt and hardware from pack (90-6476) to the bracket.

The bolt head should be facing up. See ILLUS-

TRATION 23.

123. Install the new longer shock absorbers

(323509 or 923509 or MX6106). Secure the upper shock mount using the previously removed

OE hardware. Secure the lower mount to the relocation bracket (90-1867) using the previously removed OE hardware. Torque the shock mount hardware according to the torque chart on page

23 or manufacturers specifications.

20

90-1867

Shock

Relocation

Bracket

Sleeve

90-2381

Illustration 24

Rear Sway Bar End Link

Install

Rear Sway Bar

Link 90-2009

Retainer Bolt

Sway Bar

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

Illustration 23

Shock Relocation Bracket

OE Bolt

12mm X

60mm

Bolt

REAR SWAY BAR END LINKS:

124. Assemble sway bar links 90-2009 using

60001 bushing and install as shown in ILLUS-

TRATION 24. Bolt the sway bar end links to the frame and sway bar using the previously removed

OE bolts and hardware. Torque the sway bar end link hardware to 40 ft./lbs.

125. Check the suspension and driveline systems for proper operation, tightness and adequate clearance. Recheck brake hose/fitting for leaks.

Be sure all hoses are long enough.

126. Install the wheels and tires. Remove the jack stands and lower the vehicle.

5/16” X

1” Bolt

Bushing 600001

OE

Hardware

Bushing

600001

OE Bolt

CHECKS AND ADJUSTMENTS:

⇒

Recheck all hardware for tightness after the first 100 miles.

⇒

To adjust location of front axle (side to side), place vehicle on a flat surface. With the vehicle fully on the ground and the driver side of the track bar NOT attached, center the front differential to the vehicle chassis by measuring the clearance between each tire and inner fender. This is easier done with assistance. Have your assistant sit in the drivers seat and turn the steering wheel slightly from side to side until the axle is centered. When the axle is centered, make sure your assistant holds the steering wheel in position and screw the rod end in or out until the 1/2” X 2” bolt fits through the hole and the rod end without moving the axle. Install the bolt, washers and nut. Torque the bolt according to the chart on page 23.

⇒

Steering stops can be adjusted by use of spacers behind welded jam nuts, or be use of a secondary jam nut (not provided).

Sway

Bar

⇒

Headlights should be adjusted.

⇒

A professional alignment using a 4 wheel alignment machine will be necessary after the kit is installed and the final adjust-

ments to the arms and track bar are made.

21

⇒

The exhaust system may need to be altered from the rear of the muffler back by a

qualified exhaust shop.

Upper

Arm

Threaded

End

90-2604

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

SUGGESTED CONTROL ARM/TRACK BAR

MEASUREMENT CHART

Front Upper Arms Lower Arms:

35 1/4”

18 3/8”

Upper

Arm

End

90-2609

Rear Lower Control Arm 90-3802 drvr 90-3796 pass

28 1/4”

24”

Upper Rear Control Arm 90-2673

Front Lower Control Arm 90-3783 drvr 90-3789 pass

Front Track Bar

33 1/4”

Front Track Bar

(90-2627).

22

23

55794/55794MX-55795/55795MX

55796/55796MX-55797/55797MX

Revised

6.13.08

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

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