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Instructions

1. Ph 619 216 1444 m n HERE
2. pd tue Note the Position PN 90 2054 Rear Installation Raise the rear axle until it begins to lift the vehicle off the rear jack stands Remove the track bar bolt at the rear axle and lower the axle Remove the stock brake line and replace with Pro Comp extended line PN 7425 E using the enclosed instructions 13 55099 Revised 12 5 05 Illustration 16 Track Bar Mount Brackets Rear Rear View o PN 90 2031 Pg PS D Please Note This Spacer I l NYa is Located at the OEM XP im n NAS Track Bar Location c N ON Fr ont of Vehicle Complete Assy __ 90 1072 5 16 X 1 Bolt RS and Nut Front View 4 Support the rear axle and remove the shocks U bolts and leaf spring from the passenger side Loosen the U bolts on the driver side but do not remove PN 13 90496 5 Using Illustration 16 as a guide Position the track bar mounting brackets PN 90 1072 amp 90 1073 as shown with spacer PN 90 2031 onto the stock axle mount Install all bolts It 3 8 NC Ny lock may be necessary to drill through the small Nuts 8 holes to install the 3 8 bolts Using the bracket Top amp Bottom IN h Su as a guide drill the final 3 8 hole in the back AS d SW AC terne of the factory shock mount and install the 3 8 X 1 and 3 8 X 1 1 4 bolts nut and washers where shown Torque the 1 2 X 3 1 4
3. e 55099 Revised 12 5 05 ILLUS 10 9 9 6 19 5 18 10 10 10 17 10 NO 55099 Revised 12 5 05 PART DESCRIPTION QUAN ILLUS 13 10332 1 2 NF GR8 HI NUT 8 2 70 050125 1800 1 2 X 1 1 4 GR 8 HEX BOLT 4 10 70 050325 1800 1 2 X 3 1 4 GR 8 HEX BOLT 1 16 72 050001008 16 1 2 USS GR 8 STOVER NUT 5 73 05000034 1 2 SAE HARDENED FLAT WASHER 10 73 05000042 1 2 USS HARDENED FLAT WASHER 2 70 043375 1800 7 16 X 3 3 4 USS GR 8 HEX BOLT 4 20 72 04300100816 7 16 USS GR 8 STOVER NUT 4 73 04300034 7116 SAE HARDENED FLAT WASHER 8 3 8 X 2 USS STUD 4 17 70 037 1001800 3 8 X 1 USS GR 8 HEX BOLT 2 16 72 037001008 16 3 8 USS GR 8 STOVER NUT 2 73 03700034 3 8 SAE HARDENED FLAT WASHER 8 72 037001005 12 3 8 USS GR 5 NYLOCK NUT 10 17 70 031075 1800 5 16 X 3 4 USS GR 8 HEX BOLT 1 16 72 03100100816 5 16 USS GR 8 STOVER NUT 1 73 03 10034 5 16 SAE HARDENED FLAT WASHER 2 96 6012 HARDWARE PACK CAMS SLEEVES SPACERS 1 90 2025 FRONT TRACK BRACKET SPACER 1 9 54314 SHOCK SLEEVE 1 2 X 5 8 X 1 480 2 13 90 1079 SHOCK ADAPTER 2 13 41 8243T YJ CAM BOLT 4 6 19 90 203 1 REAR TRACK BRACKET SPACER 1 16 PART DESCRIPTION QUAN ILLUS 13 9048 1 U BOLT 1 2 X 3 3 X 6 LARGE FRONT 2 2 13 90496 U BOLT 1 2 X 3 062 X 4 1 2 REAR 4 18 13 90504 U BOLT 1 2 X 3 062 X 6 SMALL FRONT 2 2 219201 YJ STEERING STABILIZER KIT 1 90 1053 REAR LOWER U BOLT PLATE 2 17 90 1054 REAR UPPER
4. TNL 65067 Puy CSO A IS0t 05057 do A9 9 Poul S60SS Poul 66155 0 5 0 GAME ISISUEIA fA 66718 1108 X2 9 S60SS Poul 66055 0520 I9 SUCIA fA 66718 do pey Ad t S60SS 6155 05405 GAM ISISUEIA fA 6 L8 do 3J0S A AD S60SS 6055 050 J9 SUCIA fA 66718 INT LD SANTI SONRIdS SONI SONS LDI S gt DOHS WOoOodvad OO NOHM INOW Inm 252 NOISHJ ANOO 9SINIHdS HQJ TONVHAA f 9 PART 90 1020 90 1022 90 1023 90 1039 90 1040 90 1045 90 1050 90 1059 90 1068 654031 90 6005 70 050325 1800 70 050375 1800 72 050001008 16 73 05000034 70 0564501800 72 05600100816 73 05600034 90 6006 15 11252 A 90 2026 90 1051 15 11252 B 90 2027 90 2028 90 1049 90 6008 70 050375 1800 72 050001008 16 72 050002008 16 73 05000034 90 6009 20 65991 13 30034 13 10332 70 0501251800 72 05000100816 73 05000034 70 043375 1800 72 043001008 16 73 04300034 70 037175 1800 70 0371501800 72 037001008 16 73 03700034 72 037001005 12 71 120301758800 90 6010 20 65991 13 30034 Part List DESCRIPTION REAR LOWER COIL MOUNT FRONT TRACK BRACKET REAR PLATE FRONT TRACK BRACKET FRONT PLATE UPPER CONTROL ARMS LOWER CONTROL ARMS ALUMINUM BUMP STOP SPACERS LOWER COIL RETAINER
5. 55099 Revised 12 5 05 PN 654031 and lower coil retainer PN 90 1050 through the top of the coil spring allowing the retainer to restrain the bump stop at the bottom Lower the axle sufficiently to thread the coil into the upper mount until the open end of the coil contacts the outside of the mount Slide the bump stop spacer PN 90 1045 through the bottom of the spring over the bump stop stud and raise the axle up onto the stud Install the nuts and washers to retain assembly See Illustra tion 11 Note The coil is offset on the passenger side lower mount for coil clearance at the track bar mount The cast track bar mount may need to be ground away to provide clear ance for the coil Do not remove any more material than is required to clear the coil spring Illustration 10 Typical Spring Mount Assy Repeat steps 20 and 21 on the driver side Install the front shock PN 926500 with adapters PN 90 1079 as shown in Illustra tion 13 Torque the upper 5 8 mounts to 100 ft lbs Torque the lower 1 2 mounts to 75 ft Ibs Torque the U bolts to 45 ft lbs Do not over torque The bracket should not be deformed when finished Torque the 1 2 upper and lower arm to bolts to 90 ft Ibs and the 9 16 lower arm bolts to 105 ft Ibs Raise the front axle with a floor Illustration 11 jack to align the track bar with S ee Typical Upper Spring Mount cure it using the factory 12mm b i un 3 bolt
6. SON 296 Otor oror t Nd 3JeussArirp pue deo de Surmseour jurof 1o eurs poddmbo SIPMA uourioo Jsou SI pue de deo uroJg 9 6 3urof sosn Nd 3JeussArip 991 S opouir 96 punoj aseo LOTAN 943 30 100 IP IYL A INO 9582 TETAN 107 SI LOOP IW U0IS19AUO S E 8 X ST Sr 9218 unt poarmboa oup ST X STL X EL 51 9215 0 1 oum 9 X QE BURG pue o xe eue q amp 10399 0 pousisop SI ID SI 1 S60SS Nd sjunour Wy op oeus amp 40329 ju0 rj IY 03 SZULI 199 5 SSOTUTBIS S9nsr1939e 182 ZUHP UBD osoq 7039 sor1ossoooe doz 1030ur st IPMA IY MOY AIBA 22utjs pue PIAI IVT ABMS IY JO suoisiA0 d pue 5 80139935 oq SUIL SALON DSD 9 LOOV 0 570 5 J9 2UEIAA 6 L8 LOOV 0 570 5 ISIM 6 L8 9 S9JON 99S LOOT 0 570 AMY ISIM 6 L8 Jopul AO t S9ION 99S LOOT 0 570 5 ISIM 6 L8 LDI NOISHANNOD LMHS INL DS I3in 3 SNOLLdO 1JVHS3ATHO ANV LDI NOISHSNNOD
7. Torque them to 35 ft Ibs See Illustration 3 Reinstall the U bolt plate with the U bolts and snug to 15 ft lbs Again use a crossing pattern to evenly draw down the U bolts Make sure the U bolt plate is oriented as shown Illustration 5 Typical Lower Control Arm Position the front upper coil mount PN 90 1055 on the frame as shown in Illustrations 4 amp 7 N Note The upper coil mounts for the front and E rear are very similar The only difference is that NN the rear mounts have a stop welded at the end of PN 90 1049 the groove The front groove is open at both sides The 26 centerline to centerline dimension shown 1s a critical dimension and must be maintained It may be necessary to notch the shock mount slightly in the area indicated to 9 16 X 4 1 2 Bolt 2 I properly position the upper coil mount See PN 20 2027 the inset view in the illustration Once the mount is in place drill through the frame and install 7 16 X 3 3 4 bolts with washers through the mount Install the nuts and washers and torque these fasteners to 30 ft Ibs 8 12 13 14 15 16 Using Illustrations 7 amp 8 for 55099 Revised 12 5 05 Install bushings PN 15 11252 B and sleeves PN 90 2027 Axle End 1 2 ID PN 90 2028 Frame End 9 16 ID into all lower arms PN 90 1040 Install one arm into the U bolt plate and rear OEM leaf spring mount Note The radius on the lower arms is
8. the vehicle will have moderate torque steer This means that it will pull slightly from side to side under acceleration and deceleration This is a natural side effect of lifted coil spring vehicles Recommended Tires and Wheels mans 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 wheel not to exceed 8 in width with a minimum backspacing of 4 must be used additionally a 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 Introduction This installation requires a professional mechanic We recommend that you have access to a Jeep YJ 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 attachin
9. FRONT LOWER COIL MOUNT REAR AXLE CLAMP CONE BUMPSTOPS CONTROL ARM PARTS PACK 1 2 X 3 1 4 USS GR 8 HEX BOLT 1 2 X 3 3 4 USS GR 8 HEX BOLT 1 2 USS GR 8 STOVER NUT 1 2 SAE HARDENED FLAT WASHER 9 16 X 4 1 2 NC GR 8 HEX BOLT 9 16 NC GD 8 STOVER NUT 9 16 SAE HARDENED FLAT WASHER CAM BOLT PARTS PACK UPPER CONTROL ARM BUSHINGS UPPER CONTROL ARM SLEEVES CAM SPACER 1 2 ID GROUND LOWER CONTROL ARM BUSHINGS LOWER CONTROL ARM SLEEVES 1 2 ID LOWER CONTROL ARM SLEEVE 9 16 ID LOWER CONTROL ARM SPACER 9 16 ID FRONT HARDWARE PARTS PACK 1 2 X 3 3 4 NC GR 8 HEX BOLT 1 2 NC GR 8 STOVER NUT 1 2 NF GR 8 STOVER NUT 1 2 SAE HARDENED FLAT WASHER FRONT HARDWARE PARTS PACK 1 2 U BOLT HARDWARE PACK 1 2 GR 8 UNPLATED FLAT WASHER 1 2 NF GR8 HI NUT 1 2 X 1 1 4 USS GR 8 HEX BOLT 1 2 NC GR 8 STOVER NUT 1 2 SAE HARDENED FLAT WASHER 7 16 X 3 3 4 USS GR 8 HEX BOLT 7 16 NC GR 8 STOVER NUT 7 16 SAE HARDENED FLAT WASHER 3 8 X 1 3 4 USS GR 8 HEX BOLT 3 8 X 1 1 2 USS GR 8 HEX BOLT 3 8 NC GR 8 STOVER NUT 3 8 SAE HARDENED FLAT WASHER 3 8 NC NYLOCK NUT 12mm X 30mm X 1 75 BOLT REAR SUSPENSION HARDWARE PACK 1 2 U BOLT HARDWARE PACK 1 2 GR 8 UNPLATED FLAT WASHER QUAN com RR A 45 45 dA FOR RAR RE ED p _ re
10. Torque this bolt to 65 ft Ibs Torque the lower 1 2 bolt to 90 ft Ibs Torque the 3 8 bolts to 35 ft Ibs Note By rotating the cams on the upper arm mounts align ment of the track bar bolt may be simplified Be sure to mark the alignment cam location prior to this step so they can be re turned to their original position J i V Detail of Correct Spring Noct Sit Install the lower Sway bar link Installation for the C A IL mount brackets PN 90 1095 as Front Springs EN m xd i 1 FrontCoil the existing 3 8 hole in the cen ___ 11 55099 Revised 12 5 05 Illustration 13 Typical Shock Mount Illustration 12 m Front Lower Sway Bar Link Mount ANS Drill two 3 8 holes in these locations Center hole existing ter and one 3 8 X 3 4 bolt nut and washers to hold this bracket in place Use the bracket as a drill guide and drill the two additional mount holes through the OEM shock mount and 1 2 X 1 1 2 Bolts finish installing the remaining 3 8 X 3 4 bolts nuts and wash ers 27 Install the sway bar links PN 90 2008 as shown in Illustration 14 Assemble the sway bar links using the steel sleeve PN 51792 at the lower mount end Note The sway bar modification kit will only fit a 1 1 8 diameter sway bar Illustration 14 Front Sway Bar Finish Dimension 38 1 2 X 2 1 2 Bolts 5 16 X 1 4 Set
11. Use a suitable pitman arm puller and remove the factory pitman arm Replace this with the new drop pitman arm PN YJ400 1 from this kit Install and torque the steering box to pitman shaft nut to 165 ft Ibs Install the drag link to the pitman arm Tighten the nut and install a new cotter pin Position both sides of the front track bar mount PN 90 1022 Front 90 1023 Rear with the spacer PN 90 2025 between them as shown in Illustration 9 Install a 1 2 X 3 3 4 bolt from the steering damper kit PN 219201 into the bottom hole and the 12mm factory track bar bolt through the top hole Snug the bottom bolt but do not tighten Using the brack ets as a guide drill through the flange on the axle with a 3 8 drill Loosely install the 3 8 X 1 1 2 bolts nuts and wash ers Assemble as shown Illustration 9 Front Track Bar Mount Install the steering damper assembly AX Uea N Key PN 90 2025 PN 219201 as per the instructions en CARY PN 90 2025 closed with the damper kit 2 Assemble and install the passenger side lower coil mount PN 90 1059 to the U bolt plate using the 1 2 X 1 1 4 o bolts as shown in Illustration 10 Rotate gt dy m AP the lower mount back until it contacts the U bolts and torque these bolts to 75 i ft 165 3 8 X 1 1 2 Bolts For the front coil PN 55596 1 heav ier wire diameter place the bump stop 10 22 20 24 25 26
12. m Nominal Demeter M T Thread Count Threads per Ee T Thread Pitch Thread Width me LE Length i ner L Hex eig Cap Ix Deportes Het Head Sew Install handling decal to windshield 17 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 passen ger 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 loss of control which can result in serious injury or even death AI ways avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking Pro Comp re minds 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 How ever Pro Comp reserves the right to update as necessary without notice and will not be held responsible for mis prints changes or variations made by vehicl
13. offset slightly the short straight section is mounted to the frame Use the 1 4 thick spacers with i 9 16 diameter hole PN 90 6 1049 on both sides of the ALL CAM BOLTS lower arm bushings at the frame mount See Illustration uA P bolt nut and washer at the frame mount and a 1 2 X 3 c 3 4 bolt nut and washer at a the U bolt plate Do not tighten these fasteners at this time Install bushings PN 11252 A and sleeves PN 90 2026 into all upper arms PN 90 1039 a Install one end into a front up LN b per arm cam mount PN 90 E 1076 Use the 1 4 thick spacer with 1 2 diameter hole PN 90 1051 on both sides of the rear upper arm bushing and one cam bolt assembly PN 41 8243T See Illustration 6 Install the upper arm into the front axle mount using the 1 2 X 3 1 4 bolts nuts and washers Do not tighten The Illustration 7 upper arm cam mount will be PN 90 1076 positioned and secured later PN 90 1055 Front just let it hang loose for now a ange aa Note The Groove Closed at one side pue mounts are mounted with the e long tab oriented in the di eee p rection of the control arm Use ea Pd 26 Front Axle Illustration 21 for reference EM icc 26 1 2 Rear Axle 15 1 4 Front Axle es Nc Support the pinion to prevent en Y J Je the axle from rolling over Re T X
14. 2360 Boswell Road Chula Vista CA 91914 Phone 619 216 1444 Fax 619 216 1474 E Mail tech explorerprocomp com PRO COMP SUSPENSION Suspension Systems that Work Part 55099 87 95 Y Wrangler Coil Spring Suspension System 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 55099 Revised 12 5 05 Special Notes This kit will NOT fit right hand drive vehicles This kit is for vehicles equipped with power steering only A transfer case slip yoke conversion is required for this Pro Comp Suspension system Correct rear drive shaft angles can only be obtained by elimination the slip yoke and replacing it with a CV joint The following Pro Comp kits are recommended More detailed information is available on the next page 9 4007 Tail shaft conversion kit NP231 transfer case only 9 4040 CV Style drive shaft 9 4041 CV Style drive shaft Installation of this suspension conversion allows for the use of larger tires This along with the increase in ground clearance raises the center of gravity and will greatly affect the stability and handling of your vehicle both on and off highway It is very important that you familiarize yourself with the new handling characteristics of your vehicle before driving at speeds above 25 mph either off road or on the highway In addition
15. COIL MOUNT 2 20 90 1055 FRONT UPPER COIL MOUNT 2 7 90 1063 FRONT AXLE CLAMP PASSENGER 1 2 90 1065 FRONT AXLE CLAMP DRIVER 1 25 90 1069 FRONT U BOLT PLATE 2 2 90 1072 REAR TRACK BRACKET FRONT PLATE 1 16 90 1073 REAR TRACK BRACKET REAR PLATE 1 16 90 1076 FRONT amp REAR CAM MOUNT 4 6 8 19 90 1095 LOWER LINK MOUNT 2 12 90 2008 SWAY BAR LINK 2 13 YJ400 1 PITMAN ARM 1 90 6007 SHOCK ADAPTER PARTS PACK 1 70 050275 1500 1 2 X 2 3 4 GR 5 HEX BOLT 2 13 72 050001005 12 1 2 NYLOCK NUT 2 73 050001005 12 1 2 SAE HARDENED FLAT WASHER 4 72 062001005 12 5 8 NYLOCK NUT 2 73 06200032 5 8 USS HARDENED FLAT WASHER 2 90 6011 BRAKE LINE PARTS PACK 1 7425 FRONT BRAKE LINE 2 7425 E REAR BRAKE LINE 1 90 1031 BRAKE LINE BRACKET 2 7425 P BRAKE LINE CLAMP KIT 1 5 PART 90 6035 90 2053 90 2054 45359 51792 90 6043 70 0502501800 72 050001008 16 73 05000034 70 037075 1800 37F200SCB 72 03700100816 37FNCB 73 03700034 31C25KKC PART 55596 1 PART 55594 1 PART 926500 923500 DESCRIPTION SWAY BAR KIT SWAY BAR SLEEVE SWAY BAR COLLAR 5 8 HOURGLASS BUSHING SLEEVE 5 8 X 1 2 X 1 350 SWAY BAR HARDWARE PACK 1 2 X 2 1 2 GR 8 HEX BOLT 1 2 USS GR 8 STOVER NUT 1 2 SAE HARDENED FLAT WASHER 3 8 X 3 4 GR 8 HEX BOLT 3 8 X 2 SAE 12 POINT BOLT 3 8 GR 8 STOVER NUT 3 8 12 POINT NUT 3 8 SAE HARDENED FLAT WASHER 5 16 X 1 4 ALLEN SET SCREW Box 3 of 5 PN 55099 3 DESCRIPTION
16. Screws OEM Hardware PN 90 2054 12 28 29 55099 Revised 12 5 05 To modify the sway bar measure to the center of the sway bar and cut through using an abra sive saw Remove any rust and scale that may be present and de burr the ends Slip the cut ends of the bar into the extension PN 90 2053 until the width shown in Illustration 14 is achieved Make sure there is equal engagement on both sides of the extension before drilling The extension is drilled undersize and is to be used as a drill guide for the final 3 8 diameter hole Drilling of the sway bar must be done on a drill press to assure an accurate centered hole Assemble the sway bar as shown using parts 90 2053 90 2054 45359 and 51792 Leave the collars PN 90 2054 loose until the sway bar is installed and centered in the vehicle Use the provided 3 8 X 27 12 point bolts through the sleeve and sway bar and install the 3 8 12 point nuts Torque these to 40 ft Ibs The collars should have 1 8 clearance between them and the rubber mounts Tighten the set screws The collars will keep the sway bar centered in the vehi cle Install the sway bar links and torque the bolts to 55 ft 165 Use the OEM sway bar mount for the upper mount and the 1 2 X 2 1 2 bolt provided for the lower mount See Illustrations 14 amp 15 30 When complete the front end assembly should look similar to Illustration 15 Illustration 15 Complete Assembly Front Pass View
17. YJ FRONT COIL Box 4 of 5 PN 55099 4 DESCRIPTION YJ REAR COIL Box 5 of 5 PN 55099 5 DESCRIPTION YJ FRONT SHOCK YJ REAR SHOCK QUAN NANARNN RA gt Np QUAN QUAN QUAN 55099 Revised 12 5 05 ILLUS 14 14 14 14 14 12 14 14 14 ILLUS 10 ILLUS 10 ILLUS 13 13 Front Installation Measure the front pinion angle at ride height and on level ground Record this angle for future reference 55099 Revised 12 5 05 Illustration 1 This measurement is in degrees and will be needed to a ve properly set up the front upper arm cam mounts Refer to Illustration 1 NOTE This step is for unmodified vehicles Vehi cles with a previously installed aftermarket suspension system may not provide an accurate angle for refer ence Raise the front of the vehicle and support the frame be hind the front spring hangers with jack stands Raise the rear of the vehicle and support it with jack stands for ward of the rear spring hangers Having the vehicle level See instruction 1 Angle exaggerated for clarity during the entire installation will assist in the accuracy of the pinion angle set up WARNING NEVER WORK UNDER OR AROUND AN UNSUPPORTED VEHICLE Remove the stock front brake lines and replace them with Pro Comp extended brake lines PN 7425 A and brackets PN 90 1031 Use the existing bolt to secure them in the facto
18. actory author ized 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 amp 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 tech explorerprocomp com PLACE Website www explorerprocomp com WARRANTY REGISTRATION Fax 619 216 1474
19. bolt to 90 ft Ibs 3 8 bolts to 30 ft lbs and the 5 16 X 1 bolt to 22 ft Ibs Do not install the track bar at this time 6 Drill out the two small holes in the stock axle BB spring mount to 7 16 Position the rear axle F PN 90 1053 bracket PN 90 1068 on the axle and pull it down with a C clamp DO NOT use a hammer to install this part The bracket should fit snugly on the axle tube and should almost touch the inside of the spring Illustration 17 per ch Passenger Side Rear Note The tabs on the top of PN 90 1068 should angle towards the front of the vehicle This will produce adequate clearance for the rear coil 14 55099 Revised 12 5 05 7 Position the U bolt plate PN 90 1053 on the spring perch and start one of the 3 8 X 2 studs from the bottom using a 3 8 NC Ny lock nut inside the window of the axle bracket It may be necessary to use a clamp to squeeze the bottom of the bracket together to install the second 3 8 stud Be extra careful to properly start the threads on these bolts Do not cross thread the 10 11 fasteners Slide the U bolts PN 13 90496 over the upper bracket flange and through the U bolt plate Install the washers and nuts Snug the U bolt nuts using a crossing pattern as shown in Illustration 2 making sure the U bolts are square to the axle tube Torque the 3 8 studs to 25 ft Ibs and the U bolts to 45 ft lbs Install one of the previou
20. e 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 or dinary 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 re lated 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 in curred 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 f
21. ee Illustration 7 Raise or lower the pinion until the oe pinion and the drive shaft FK are on the same line This means there should be 0 misalignment between the drive shaft and the pinion shaft at this height With the axle held firmly in position center the cam bolt in the cam mount and slide it onto the frame rail until the cam mount is firmly against the bottom of the frame rail Drill through the frame with a 1 2 drill and install the 1 2 X 3 3 4 bolts nuts and washers Torque these fasteners to 60 ft Ibs See Illustration 8 By locating the upper arm cam mounts using this sequence the rear pinion will have enough adjustment to compensate for varied ride height Note EFI models may require removal of the gas filter shield to install 90 1076 on the driver side 2 A j f 407111111 C 15 The Coil Spring stop on the rear coil mount is located Assemble the lower coil mount PN 90 1020 using Illustration 10 amp 11 as a guide and install the assembly to the rear coils Lower the axle enough to install the rear coils Rotate the coils until the coil end contacts the stop on the upper mount See detail in Illustration 20 Install the lower 1 2 X 1 1 4 bolt nut and washers Rotate the lower coil mount until it almost contacts the U bolts and torque the 1 2 bolts to 70 ft Ibs See Illustration 19 Install y
22. g points for stress cracks The overall vehicle must be in excellent working condition Repair or replace all worn or damaged parts Additionally very close attention must be given to the condition of the rear axle spring pads Spring pads that are not perfectly flat must be repaired or replaced Use only a factory replacement pad Pro Comp kits use the spring pad as a mounting surface Read the instructions carefully and study the illustrations before attempting installation The more familiar you are with the procedures the easier and quicker your installation will be 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 Secure and properly block vehicle prior to beginning installation ALWAYS wear safety glasses when using power tools or working under the vehicle NEVER work under or around an unsupported 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 N 7 4 ans nA S a uomnensnir3um Fm SAION 296
23. in the axle castings some material may need to be removed from the casting so the clamp will fit properly Drop the U bolts PN 13 90481 and PN 13 90504 over the clamp flanges and install the U bolt plate PN 90 1069 from the bottom Install the hardened washers PN 13 30034 and Hi Nuts PN 13 lt 12mmXx30mm OR 10332 from parts pack PN 20 65991 Align VON oar N 12 X 1 1 4 Bolt the U bolts with the brackets and snug the OSs OO see Instruction 8 bolts to 15 ft 165 using a crossing pattern See the inset view in Illustration 2 On the passenger side drill a 3 8 diameter hole through the cast spring pad at the rear of the housing using the lower axle clamp as a guide Install one 3 8 X 1 3 4 bolt with a washer through the rear hole as shown in Illus tration 2 and either a 12mm X 30mm or a 1 2 X 1 1 4 bolt through the existing hole in the front The size of the bolt used 1s deter mined by the size of the bolt used by the manu Illustration 4 Front Shock Mount Pass Remove material as needed to clear the upper coil mount PN 90 1055 facturer for the factory steering damper L9 X94 Bole On the drivers side both holes will need to be PEPA drilled using the axle clamp as guide E ___ Remove the U bolt plate from the U bolts and P install the nuts and washers as needed from the bottom onto the pr eviously installed bolts x Be 26 Center to Center
24. move the driver side leaf WW VL 7 EN A SS spring U bolts shackles and wW Sy eS U bolt plate Se bw 7 _ md a H f 17 18 19 20 2 55099 Revised 12 5 05 Illustration 8 Typical Upper Cam Mount m Repeat steps 7 thru 14 on the driver side except in step 7 both holes must be drilled to 3 8 and two 3 8 X 1 1 4 bolts washers and nuts used 1 2 X 3 3 4 Bolts reference Raise the axle evenly on both Nm sides of the vehicle until is 15 1 4 CG e of space between the top surface of the VAG Ni PN 90 1076 U bolt plate and the bottom of the S frame While maintaining this distance set the pinion angle by rotating the axle until the original angle recorded in step 1 1s duplicated Locate the upper arm cam mount onto the frame and adjust its location until the alignment cam 15 in the centered position and clamp the cam mount to the frame Make sure the mount is tight against the bottom of the frame Both front cam mounts must be the same distance from the lower rear arm mounting bolts The original leaf spring bolt Drill through the frame with a 1 2 drill Install the 1 2 X 3 3 4 bolts nuts and washers provided and torque them to 65 ft Ibs Note On 4 cylinder models the motor mount will need to be trimmed to install the upper cam mount Remove the nut and cotter pin and separate the drag link from the pitman arm
25. our new Pro Comp shocks PN 923500 and lower the axle until it hangs on the shocks Rotate the drive shaft and make sure there 1s adequate clearance around both U joints It the drive shaft binds drive shaft modification or lowering of the transfer case may be required to rectify the problem Install the wheels and lower the vehicle to the ground Install the track bar into the rear track bar mount Use washers on both sides of the track bar bushing Use factory bolt and torque to 65 ft Ibs See Illustration 12 Final caster adjustment on the front axle and rear pinion angle adjustments should be done at this time When you are finished torque all adjustment cams to 70 ft Ibs 16 55099 Revised 12 5 05 General Part Orientation All Torquesin Ft mis DE Final Checks and Adjustments BH Center the steering wheel Have the front alignment mejo di ted 12 amp 40 TE 5 75 5 16 E 130 Mid 1a Readjust the headlights Bleed the brakes front and rear Re check all hardware after the first 100 miles of use and after each off highway use Turn the steering wheel full left and full right to check 3 11 T5 HHCS M123 125 3 HA 12 1 Graded Graded rl A for brake line clearance iHa of Make i k Li LILI LI Read and adhere to all warnings je Bok Strength Ps Property hes Bat Strength Drareter D
26. ry location Be sure to clean the banjo mounting surface on the caliper Use new crush washers and check for sufficient clearance between the steering shaft and the factory brake line on the drivers side It may be necessary to slightly bend the lower lip of the inner fender to clear the brake line or bracket Remove the wheels steering stabilizer front shocks and the track bar bolt where it attaches to the front axle Save this hard ware Support the front axle with a floor jack and remove the passenger side leaf spring U bolts U bolt plate and sway bar link Loosen the driver side U bolts but do not remove them at this time This will ease alignment of the passenger side brackets and allow you to maintain control of the axle assembly Remove the sway bar links from the sway bar Loosen the bolts that secure the sway bar rubber mounts Swing the sway bar down and finish removing it from the vehi cle Using Illustrations 2 amp 3 as reference set the passenger side front axle clamp PN 90 1063 on the axle tube Make sure the clamp fits tightly against the axle tube Due Illustration 2 Passenger Side Front 3 8 X 1 3 4 Bolts PN 13 90481 Front U bolt Large Radius PN 13 90504 Front U bolt Small Radius 10 11 55099 Revised 12 5 05 Illustration 3 Passenger Side Front t PN 90 1063 Pass Side PN 90 1065 Driver Side to variations
27. sly assembled lower arms PN 90 1040 with bushings and sleeves into the U bolt plate mount and stock leaf spring mount See Illustrations 5 amp 18 Use 1 4 spacers on both sides of the bushing at the stock spring mount Assemble one of the previously assembled upper arms PN 90 1039 to the upper arm cam mount PN 90 1076 and install them into the upper axle bracket Do not tighten the arm mounting hardware at this time See Illustrations 6 amp 19 Notch the flange on the rear cross member as shown in Illustration 20 Position the rear upper coil mount PN 90 1054 on the frame using Illustration 7 as a reference for a proper installation location 26 1 2 from the lower leaf spring mount Be sure the coil mount fits against the bottom of the frame rail and drill through the frame Install the 7 16 X 3 3 4 bolts nuts and washers Torque to 30 ft Ibs Repeat steps 4 thru 11 on the driver side of the vehicle Remember to support the axle pinion to prevent the axle from rolling 3 Illustration 18 Passenger Side Rear Illustration 19 Passenger Side Rear 12 Install your new CV style 13 14 15 16 17 18 19 20 55099 Revised 12 5 05 Illustration 20 Upper Coil Mount Rear drive shaft to the transfer case Raise the axle evenly on both sides until the distance between the top of the spring perch and the bottom of the frame rail 1s 15 1 4 For reference s

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