PRO COMP SUSPENSION PN# 55506 96
Contents
1. 3 4 5 5 6 90 6540 HARDWARE PACK End Link Retaining Brackets 1 90 3726 SWAY BAR RETAINER 1 1 4 90 3728 SWAY BAR HOLDER 1 1 4 90 4152 Locking Pin Round 1 1 4 S Optional Equipment Available from your Pro Com p Distributor Winch Spacer 1 Front Pair 55496 Steering Stabilizer 219200 Also check out our outstanding selection of Pro Comp tires to ompliment vour new installation gt o Introduction This installation requires a professional mechanic 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 at tention 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 special2. 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 instruc tions 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 sup port 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 co
3. 2360 Boswell Road Chula Vista CA 91914 Phone 619 216 1444 PRO COMP SUSPENSION Suspension Systems that Work PN 55506 96 06 J eep T Sway Bar Quick Dsconnect Kit To Be Used in Conjunction With 3 5 Lift Kits 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 BILL OF MATERIALS Revised 5 14 07 Part Description Qty Illus Page 90 1092 ADAPTER MOUNT 2 2 3 4 5 90 6024 HARDWARE PACK End Links 1 37C150HCS5SZ 3 8 16 X 1 1 2 HEX CAP SCREW GR 5 ZINC 2 3 5 37C250HCSSZ 3 8 16 X 2 1 2 HEX CAP SCREW GR 5 ZINC 2 2 4 37CNNESZ 3 8 16 NYLON INSERT L N GR 5 ZINC 4 2 3 4 5 37NWSAZ 3 8 SAE FLAT WASHER ZINC 4 2 3 4 5 37NWUS8Y 3 8 USS FLAT WASHER GR 8 ZINC YELLOW 2 2 3 4 5 90 6046 HARDWARE PACK Bushings and Sleeves 1 45359 5 8 BLACK HOURGLASS BUSHING 4 61150 SLEEVE 5 8 X 3 8 X 1 480 2 60859H SLEEVE 2 600001 5 8 BLACK HOURGLASS BUSHING 4 90 6523 HARDWARE PACK End Link Clamps 2 90 2593 QUICK DISSCONNECT PIN 1 3 5 72 050200812 1 2 20 NYLOCK NUT 1 3 5 73 05000034 1 2 SAE FLAT WASHER PLATED 1 3 5 73 06200034 5 8 SAE FLAT WASHER PLATED 1 3 5 90170A212 LOCKING PIN 1 3 4 5 90 3579 SWAY BAR CLAMP 1 2 4 4 5 90 2596 SWAY BAR CLAMP SPACER 1 2 4 70 0251251800 1 4 20 X 1 1 4 HEX BOLT GR 8 PLATED 1 2 4 72 025100512 1 4 20 NYLOCK NUT 1 2 4 90 2638 SWAY BAR END LINK 2
4. and hardware can be tightened down See ILLUSTRATION 4 16 Repeat on the remaining side of the vehi cle 17 Secure the sway bar to the sway bar inner fender bracket 90 3728 by inserting the up per locking pin 90 4152 through the sway bar retaining bracket 90 3726 and the inner fender bracket See ILLUSTRATION 4 18 Lock the pin 90 4152 in place by secur ing the clevis over the opposite end of the locking pin See ILLUSTRATION 5 19 Reinstall the front wheels and tires Torque the lug nuts according to factory specifications 20 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 NOTES After 100 miles recheck for proper torque on all newly installed hardware gt Recheck all hardware for tightness af ter off road use 90 4152 Upper Locking Pin 90 3726 Sway Bar Retainer 90 3728 Sway Bar Pa Inner Fender Bracket Illustration 5 Sway Bar to fender bracket Bolt Torque and ID Decimal System Metric System All Torques in Ft Lbs Class 9 8 Class 10 9 Class 12 9 1 2 13x1 75 HHCS Grade5 Grade 8 M12 1 25x50 HHCS AAA No of Marks 2 A G Grade Bolt Strength P Property Class Bolt Strength D Nominal Diameter Inches D Nominal Diameter M illimeters T Thread Count Threads per Inch T Thread Pitch Th
5. 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 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 Fax 619 216 1474 WARRANTY REGISTRATION Ph 619 216 1444 m E HERE
6. les 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 obli gation 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 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
7. mpany INSTALLATION INSTRUCTIONS FRONT SWAY BAR 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 hard surface i e concrete or asphalt Block hardware loose at this time See ILLUSTRA the rear tires and set the emergency brake TION 2 1 Position your vehicle on a smooth flat 2 Place the vehicle in neutral Place your 8 Install the adapter 90 1092 and sway bar floor jack under the front axle and raise the retaining bracket 90 3726 onto the sway bar front of the vehicle Place jack stands under using the 3 8 X 1 1 2 bolt and hardware as the frame rails to support the vehicle shown in ILLUSTRATION 2 Aa abolvand remove fDi sway barend ig iaaio bag end Inks 002638 auto the adapter 90 1092 using the 3 8 X 2 1 2 4 Install hour glass bushings 600001 and bolt and hardware 61150 sleeve in the top and 60859H bay sleeve in the bottom of the sway bar end links NOTE Ti he j og in the Sway bar will 90 2638 face towards the outside of the vehicle See ILLUSTRATION 3 5 Remove the OE inner fender bolts shown in ILLUSTRATION 1 Save the hardware 10 Secure the quick disconnect pin 90 forreise 2593 to the factory lower sway bar mount location using the supplied 1 2 washer and 6 Install the sway bar inner fender bracket 1 2 nylock nut 90 3728 into the inner fender using the pre SEA viously remo
8. read Width mm L Length Inches L Length Millimeters X Description 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 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 vehic
9. ved OE bolts into their original _ __ NOTE The pin will face toward the holes See ILLUSTRATION 1 inside of the vehicle See ILLUSTRATION 3 11 Slide the lower end of the sway bar end link onto the quick disconnect pin and secure Illustration 2 Sway Bar Clamp and Adapter Install Sway Bar Clamp 90 3579 i 7 Install sway bar clamp 90 3579 onto sway bar approximately 6 from the end of the bar with the holes facing down Secure it ve xie Bolt and N Hardware 90 3726 Sway Bar 90 2596 LS x 1 Retainer 1 4 Spacer AY ais Adapter 90 1092 Illustration 1 Sway Bar Fender Bracket Install Illustration 3 Adapter Sway Bar and pin Install 90 1092 ii 3 8 x2 gt 1 2 Bolt Quick Disconnect Pin 90 2593 Illustration 4 Sway Bar Disconnected Lower Locking Pin 90170A212 Sway Bar End Link with the locking pin 90170A212 and 5 8 washer See ILLUSTRATION 3 12 Repeat on the remaining side of the vehi cle 13 Temporarily install the front wheels and turn lock to lock to check for interference When Disconnected 14 When disconnecting the sway bar links swing the end links up into the previously installed clamp on the sway bar above Se cure the sway bar end link 90 2638 into the clamp 90 3579 using the previously re moved locking pin 90170A212 See ILLUS TRATION 4 15 Once the sway bar has been raised into the clamp and secured the 1 4 x 1 1 4 bolt
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