Installation Instructions
Contents
1. nyloc nut Torque to 70 ft Ibs 10 Install passenger side differential drop bracket 90 1282 using 1 2 x 1 1 4 hex bolt with 1 2 HEX BOLT 1 2 x 2 1 2 LG ILLUSTRATION 5 HEX BOLT 1 2 x 2 1 4 LG DIFFERENTIAL BRACKET 90 1277 SPACER 90 2014 oo 57089 Created 12 5 05 flat washer and nyloc nut into upper hole of HEX BOLT 1 2 OEM rubber mount Wide part of the bracket x 11 4 LG should be at bottom with hole towards front as shown in ILLUSTRATION 6 Reinstall OEM PASSENGER SIDE bolt through the bracket and into side of differen ite DIFFERENTIAL tial using loctite Torque to 70 ft Ibs 525 7 DROP BRACKET EXISTING 90 1282 11 Install driver side of differential drop BOLT bracket 90 1283 using OEM bolts in two bot USE LOC S amp tom holes using loctite Use 1 2 x 1 1 4 hex bolts 1 2 flat washers and 1 2 nyloc nuts in two upper holes Torque to 70 ft Ibs see ILLUS TRATION 7 12 Remove tie rods from steering knuckles Remove two bolts on the back side of spindle which hold the metal bracket for the brake hose 13 Support the lower a arm with floor jack and separate upper ball joint from spindle Using file file corners off of OEM spindle to contour with the OEM spindle top surface Clean out hole on top of the steering knuckle spindle 14 Insert tapered spindle sleeve 90 4026 with small end going downward Install 5 8 x 22. 1 2 hex bolt and 5 8 lock nut see ILLUSTRATION 8 Torque to 100 ft Ibs 15 Referring again to ILLUSTRATION 8 reinstall brake hose bracket to new spindle with OEM bolts using loctite Torque to 120 ft lbs Insert spindle into upper ball joint tighten Torque to 105 ft lbs Reinstall tie rod Torque to 67 ft Ibs Reinstall all cotter pins 16 File down front bumpstop lip on each side of front for shock clearance Install new longer NYLOC ILLUSTRATION 7 shocks and tighten NUT 1 2 DRIVER SIDE 17 Remove stock bumpstop from bracket DIFFERENTIAL DROP BRACKET and attach to one end of bumpstop spacer 90 2134 Install the other end of the bumpstop spacer to the bumpstop bracket using a 3 8 x 1 hex bolt with a 3 8 washer and 3 8 nyloc nut see ILLUSTRATION 9 Repeat on other three bumpstops Keep front steel bumpstop spacers at an angle to clear shock Rear bumpstop spacers do not need to be at an angle 18 Reinstall sway bar with the two sway bar drop down brackets using OEM bolts and nuts in HEX BOLT 1 2 top holes adding a 5 16 flat washer to the OEM 4X 11 4 LG 57089 Created 12 5 05 flat washers tighten Install sway bar to bottom of drop down bracket using 5 16 x 1 hex bolts 5 16 flat washers and 5 16 nyloc nuts tighten see IL LUSTRATION 10 NOTE Driver side Use first forward round hole and rear slotted hole with slant downward open side
3. arm bracket from axle Install rear brake cable extension RE te d F 90 1276 to axle with OEM bolts and Ts nll TM DROP DOWN tighten Mount equalizer cable bracket to top BRACKET of extension using 5 16 x 1 hex bolts and ERA a P ser 5 16 nyloc nuts and tighten see ILLUS TRATION 12 4 Loosen emergency brake cables by removing cotter pin pulling pin out from al back side of brake backing plate at adjuster HEX BOLT on i 5 16 x 1 LG EP 41 5 Remove u bolts lower axle and 1 stall 3 1 2 tapered blocks with tapered end towards transmission see ILLUSTRATION 13 Install new u bolts washers and nuts then tighten Reinstall emergency brake cable keeping cable under spring 6 Install new longer shock absorbers 7 Install the rear wheels and lower the vehi cle NOTE After installation is complete double check that all nuts and bolts are tight Do not retighten nuts and bolts where loctite was used Recheck periodically HEX BOLT 3 8 x 1 LG TORQUE SPECIFICATIONS 10 57089 Created 12 5 05 ILLUSTRATION 12 HEX BOLT NYLOC NUT 5 16 15 16 x 1 LG EXISTING HEX BOLTS A Arm Drop Bracket Bolts 100 ft Ibs Crossmember 8501 555555 5 45 ft Ibs Eccentric Bolts cccccccccscees 103 ft Ibs Center Differential Bolts 70 ft lbs Pass Di
4. of the installation process please feel free to call our tech support de partment 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 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 maximum backspacing of 3 5 must be used Diameter of wheel may be any of the follow ing 3 choices 15 16 17 Any other diameter either smaller or larger will not be en dorsed as acceptable by Pro Comp Suspension and will void and and all warranties writ ten or implied In addition a quality tire of radial design not to exceed 33 tall x 12 5 wide is recommended 57089 Created 12 5 05 Installation Instructions FRONT 1 Place floor jack under front axle and raise vehicle Place jack stands under frame to support vehicle Set the emergency brake and block rear wheels in front and behind tires Remove front wheels 2 Remove clip from front brake line and bracket Cut bracket to center of hole to remove brake line out of bracket Install new brake line drop down bracket 90 55089 5 to OEM bracket and put 3 8 flat washer on top Insert the 3 8 x 1 hex bolt through both brackets and tighten with 3 8 ny loc nut on bottom You may need to reform t
5. 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 57089 86 95 Toyota 4WD 4 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 Part 90 1296 90 1290 90 2134 90 6108 90 55089 5 90 1280 90 1277 90 1282 90 1283 90 1278 90 1279 90 1276 90 6109 90 1301 90 2014 90 2022 90 2136 96 4026 90 6110 70 0622501500 70 0624501500 70 0502501500 70 0502251500 70 0501251500 72 06200100512 72 05000100512 73 05000030 90 6111 70 0431001500 70 0371001500 70 0311001500 72 04300100512 72 03700100512 72 03100100512 73 04300030 73 03700030 73 03100030 Box 1 of 2 PN 57089 1 Description A Arm Drop Bracket Rear Crossmember Bumpstop Spacer Bracket Pack Containing Front Brake Drop Down Brkt Rear Brake Drop Down Brkt Center Differential Brkt Differential Drop Brkt Pass Differential Drop Brkt Drvr Sway Bar Drop Down Brkt Pass Sway Bar Drop Down Brkt Drvr Rear Brake Cable Extension Brkt Bracket Bag Containing Locating Washer Toyota Spacer 750 x 120 Wall x 250 Sleeve 750 510 ID x 870 Spacer Tube 750 x 120 Wall x 1 220 Spindle Cone Spacer Toyota Hardware Pack Con
6. STING tice ILLUSTRATION 4 HEX BOLT 7 16 x 1 LG A ARM DROP BRACKET HEX BOLT n 7 16 x 1 LG CROSSMEMBER 90 1290 WASHER 7 16 NUT 7 16 57089 Created 12 5 05 7 Install the new rear crossmember 90 1290 using a 7 16 x 1 bolts 7 16 flat washers and nyloc nuts Torque to 45 ft lbs Using a straight edge align upper tabs with lower tabs and tighten bolts Torque to 100 ft lbs see ILLUSTRATION 4 8 Install lower a arms into lower a arm brackets Reinstall OEM eccentric bolts with hole in OEM cam washers at bottom Install OEM nuts and tighten nuts NOTE Tighten nut not bolt be cause cam will not turn inside of tabs Torque to 103 ft lbs Refer back to ILLUSTRATION 3 if necessary 9 Lower differential keep steady to avoid pulling out the front driveshaft Install center differ ential bracket 90 1277 at rear of front differential see ILLUSTRATION 5 a Install the 1 4 spacer tube 90 2014 at rear lower mounting between differential and bracket Install existing OEM bolts through bracket spacer and into the two bottom holes with loc tite Torque to 70 ft Ibs b Install 1 1 8 spacer tube 90 2136 at rear of upper OEM rubber mount with 1 2 x 2 1 2 hex bolt 1 2 flat washer and 1 2 nyloc nut Torque to 70 ft Ibs c Install 3 4 spacer tube 90 2022 at rear of upper OEM rubber mount with 1 2 x 2 1 4 bolt 1 2 flat washer and 1 2
7. 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 flam mable Take appropriate precautions Have a fire extinguisher close at hand e 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 gt e 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 diffi cult 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 installa tion 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
8. ays 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 15 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 obli gation under this warranty is limited to repair or
9. ckup w 3 25 Rear U Bolts 3 1 2 Rear Tapered Blocks 7 8 Pin 9 16 U bolts 3 25 Wide 9 16 U bolt Nut 9 16 U bolt Washers 900 793 4 Runner Lower Link Relocating Bracket Upper Link Relocating Bracket Bump Stop Extension Trac Bar Relocating Bracket Sway Bar Extension Brake Hose Limiting Strap Qty OO OO A N OO N mi N N NN 57089 Created 12 5 05 Illus 8 8 14 14 14 PLEASE NOTE ON SOME V6 MODELS A HIGH MISALIGNMENT DRIVE SHAFT MAY BE REQUIRED IF THE ORIGINAL EQUIPMENT DRIVESHAFT BINDS AT THE CONSTANT VELOCITY JOINT AFTER THE LIFT KIT IS INSTALLED 57089 Created 12 5 05 Introduction e This installation requires a professional mechanic Werecommend 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 informa tion e Prior to installation carefully inspect the vehicles 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 e Read the instructions carefully and study the illustrations before attempting installation You may save yourself a lot of extra work Check the parts
10. fferential Brkt 80 70 ft lbs Drvr Differential Bolts 70 ft Ibs Tapered Spindle Sleeve Bolt 100 ft lbs Brake Hose Brkt to Spindle 120 ft Ibs Spindle to Upper Ball Joint 105 ft Ibs Tie Rod sees DE Ee 67 ft Ibs Ed GO EE 100 ft Ibs 11 57089 Created 12 5 05 ILLUSTRATION 13 HIGH NUT 9 16 12 57089 Created 12 5 05 Use this only as a guide for hardware without a called out torque specification in the instruction manual AN mi 11 ui 14 1 AAI A Grade Grade 8 112 1 5 50 HACS No of Marks 2 ty G Grade Bolt Strength P Property Class Bolt Strength D Nominal Diameter inches D Nomina Diameter M illimeters T Thread Count Threads per Inch T Thread Pitch Thread Width mm L Length Inches L Length Millimeters X Desenption Hex Head Cap Screw X Description Hex Head Cap Screw 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 Alw
11. he line slightly Be sure not to kink or cause any inter ference of line Reinstall OEM brake line clip to hose at bracket see ILLUSTRATION 1 3 Remove shocks sway bar and bumpstops on each side four bumpstops total Remove ec centric bolt and nut front and rear Remove front crossmember from mounting bracket On passen ger side only cut the mounting bracket tabs off of the existing bracket between the bolt holes for dif ferential clearance see ILLUSTRATION 2 4 Remove the eccentric bolts front and rear on front lower a arm HEX BOLT 3 8 x 1 LG FT BRAKE LINE DROP DOWN BRACKET 90 34 CUT HERE FOR DIFFERENTIAL CLEARANCE 5 Install the four a arm drop brackets 90 1296 into the OEM brackets Use new 5 8 x 4 1 2 hex bolts and 5 8 lock nuts NOTE Locating spacers will go in only one way and all eight spac ers are the same Reinstall front crossmember with OEM bolts Hand tighten bolts until the brackets are aligned see ILLUSTRATION 3 6 Using a straight edge line up bottom bracket tabs with upper OEM tabs Then tighten bolts Torque to 100 ft Ibs not crossmember bolts yet Install OEM bolts and nut into front crossmem ber to front differential Tighten bolts and then tighten crossmember bolts 57089 Created 12 5 05 ILLUSTRATION 3 HEX BOLT 5 8 x 4 1 2 LG NOTE BOLT MUST BE IN LOCATING SPACER STALLED AS SHOWN 90 1301 LOCK NUT 5 8 EXI
12. inward Passenger side Use first slotted hole and rear round hole with slant downward open side inward Tighten sway bar bracket bolts and sway bar pins in a arm 19 Install the front wheel and lower the vehicle NOTE gt Measure from center of eccen tric adjustment bolt to ground to ensure proper height On alignment both sides in ner and outer tie rods may need to be pulled out of adjusting sleeve and cut 1 2 off tie rod ends so proper adjustment can be achieved When installing larger tires and wheels check for clearance at upper a arm STAN DARD OFFSET WHEEL MUST BE USED After installation is complete double check that all nuts and bolts are tight Do 01 BUMPSTOP retighten nuts and bolts where loctite was SPACERS used recheck periodically REAR 86 89 4 Runner 86 95 Pickup 1 Place floor jack under rear axle and raise ve hicle Place jack stands under frame to support vehi cle Set emergency brake and block front wheels in front and behind tires Remove wheels and shocks 57089 Created 12 5 05 ILLUSTRATION 10 2 Pull out brake line clip at rear brake hose bracket Bolt rear brake line drop down bracket 90 1280 to existing bracket using Fr ark 3 8 x 1 hex bolt 3 8 flat washer and 3 8 a d i nyloc nut tighten Install brake line into lower bracket hole and reinstall OEM brake line clip see ILLUSTRATION 11 3 Unbolt brake equalizer
13. 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 e 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 WARRANTY REGISTRATION Ph 619 216 1444 HERE
14. 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 cover age 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 e 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
15. taining 5 8 x 2 1 2 USS Gd 5 Hex Bolt 5 8 x 4 1 2 USS Gd 5 Hex Bolt 1 2 x 2 1 2 USS Gd 5 Hex Bolt 1 2 x 2 1 4 USS Gd 5 Hex Bolt 1 2 x 1 1 4 USS Gd 5 Hex Bolt 5 8 USS Nyloc Nut 1 2 USS Nyloc Nut 1 2 SAE Flat Washer Loctite Tube Red Hardware Pack Containing 7 16 x 1 USS Gd 5 Hex Bolt 3 8 x 1 USS Gd 5 Hex Bolt 5 16 x 1 USS Gd 5 Hex Bolt 7 16 USS Nyloc Nut 3 8 USS Nyloc Nut 5 16 USS Nyloc Nut 7 16 SAE Flat Washer 3 8 SAE Flat Washer 5 16 SAE Flat Washer Qty A A N m GO hel pd hek ED JN GN OO DY CON GN OO N OO A EN 57089 Created 12 5 05 Illus 3 4 4 9 1 11 5 6 7 5 6 7 5 6 7 1 9 11 10 12 1 9 11 10 12 1 9 11 10 12 Part 90 4009 90 4010 One of the following rear kits will be used in conjunction with this base kit 57589 95 350 13 90126 13 10423 Z 13 30330 Z OR 57789 20 830671 2 13 90321 13 10423 Z 13 30330 Z OR 57489 90 1204 90 1272 90 2130 90 1268 90 2133 90 7210E 5242 1 Box 2 of 2 PN 57089 2 Description Spindle Adapter Drvr Spindle Adapter Pass 86 89 4 Runner Leaf Spring Rear 86 95 Pickup 2 5 Rear U Bolts 3 1 2 Rear tapered Blocks 9 16 9 16 U bolts 2 1 2 Wide 9 16 U bolt Nut 9 16 U bolts Washers 86 89 4 Runner with 3 25 Rear U Bolts 86 95 Pi
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