Installation Instructions
Contents
1. 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 HERE2. WASHER 3 8 X 2 1 4 GR 8 HEX BOLT 3 8 STOVER 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 OVERLAP PLATE HARDWARE PACK Axle Truss Overlap Plate 3 8 X 1 GR 8 HEX BOLT 3 8 STOVER NUT 3 8 SAE HARDENED FLAT WASHER Qty BP BNNKHwWOOR Re ANNE N BNE N o A A m Illus NNW RB ee eee eee eee 55800 55800MX Created 6 25 07 Page 6 6 AAD MANUAU 5 5 5 FOLLOWING PARTS ARE USED IN CONJUNCTION WITH THIS KIT THEY ARE PACK AGED AND MUST BE ORDERED SEPARATELY Unless you already have a suitable long enough after market rear brake line installed 7450 STAINLESS STEEL BRAKE LINE KIT 1 Optional Equipment Available from yourPro Com p 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 fr 55800 55800MX Created 6 25 07 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
3. 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 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
4. 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 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 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 installatio
5. 0 3893 for Dana 35 to the rear axle to ensure proper alignment Se cure using the OE bolts See ILLUSTRATION I 11 Place the rear axle truss 90 3757 on top of the differential housing Line up and install the 5 16 X 3 4 bolts that secure the rear axle dif ferential spacer plate to the rear axle truss Se cure 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 1 12 A new vent tube hole will need to be drilled on the front driver side of the rear axle 13 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 1 NOTE When drilling into an oil cavity pack the flutes of the drill bit with grease to catch all the metal shavings 14 Once the new vent tube hole is drilled un bolt and remove the axle truss Clean and re move any remaining metal chips from inside and outside the rear axle 15 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 16 Install the 3 8 vent tube 90 4158 through the hole in the rear axle truss See ILLUSTRA TION 1 17 Reinstall the axle truss 90 3757 by linin
6. 031 to the frame using the pre viously 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 sup plied 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 28 Connect the new brake line 7450 to the ex isting frame metal brake line and tighten 29 Slip the junction block end of the new brake 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 1 30 Attach the Pro Comp brake line junction block to the existing rear axle metal brake lines and tighten 55800 55800MX Created 6 25 07 NOTE Depending on brake application the steel lines may need to be carefully rerouted to attach to the junction block IMPORTANT MAKE SURE BRAKE LINES ARE CLEAN AND DRY OF ANY MA TERIAL BEFORE ABS BRAKE BLEEDING AND REASSEMBLY IMPORTANT BE VERY CAREFUL NOT TO LET THE MASTER CYL INDER RUN DRY WITH ABS BRAKES THIS SITUATION WILL DAMAGE THE SYS TEM IMPORTANT BLEEDING OF THE BRAKE SYSTEM SHOULD BE DONE AC CORDING TO A JEEP FACTORY SERVICE MANUAL Upper Rear Control Arm 90 2673 UPPER CONTROL ARMS 31 Assemble the rear upper control arms 90 2673 using bushings 15 11310 and sleeves 90 2626 See ILLUSTRATION 2 32 In
7. 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 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 Part 55800 1997 2006 Jeep Wrangler TJ w Dana 35 and 44 rear axle 2003 2006 Jeep Rubicon w Dana 44 rear axle 2004 2006 Jeep Wrangler Unlimited Rear Axle Truss 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 90 6505 90 2626 15 11310 90 2673 90 6553 JMX 12T SJNR12 90 2449 90 6551 70 03 10751800 73 03 100830 70 037225 1800 72 0371008 16 73 03700030 72 043 100816 70 0563001800 72 056100816 73 05600830 90 3757 90 4158 90 3781 90 3767 90 3893 90 3894 90 6577 37C100HCS8Y 37CNUCZ 37NWHDY Box 1 PN 55800 55800MX 1 Description HARDWARE PACK Rear Upper Arm 3 4 X 156 WALL X 2 BUSHING JEEP UPPER ARM UPPER ARMS REAR HARDWARE PACK Rear Upper Arm Rod Ends ROD END NUTS SPACER 750 OD X 438 ID X 1 600 LONG HARDWARE PACK Axel Truss 5 16 X 3 4 GR 8 HEX BOLT 5 16 GR 8 SAE FLAT
8. 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 3 55800 55800MX Created 6 25 07 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 cen ter of each wheel to the top of its fender opening Record below LF RF LR RR 3 Place the vehicle in neutral Place your floor jack under the rear axle and raise the vehicle Place jack stands under the front 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 Remove the rear wheels from the vehicle 5 Unbolt the rear sway bar from the rear axle Save the hardware for reuse 6 With the rear axle fully supported unbolt and remove the rear upper control arms from the ve hicle 7 Remove the rear axle vent tube and unbolt the brake line junction block from the rear axle 8 Drain the rear axle fluid and remove the dif ferential cover REAR AXLE TRUSS 9 With the axle clear of accessories test fit the axle truss assembly 10 Test fit the rear axle differential spacer plate 90 3781 for Dana 44 or 9
9. g 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 1 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 18 Install the 2 overlap plates 90 3894 to the axle truss using the 4 3 8 X 1 bolts and hard ware Reinstall the sway bar to it s original rear axle mounting position Secure the sway bar 55800 55800MX Created 6 25 07 Illustration 1 Rear Axle Truss Install Overlap Plate 90 3894 and 3 8 X 1 Bolts 4 5 16 X 3 4 Bolts Pro Comp Tz 3 QR 2 90 3767 Axle a i i Sat me Truss Clamp Block k wt y _ i Overlap a x 3 OES oe a H 8 3 8 X 2 Plate Sy SS Differential VM If 1 4 Bolts Cover j i apie i and 3 8 X 1 Bolts g P 9 amp OE Differential Bolts frame mounts to the overlap plates and rear end 24 Raise the differential cover into place and using the previously removed 4 OE sway bar secure using the OE bolts Torque the differen bolts See ILLUSTRATION 1 tial spacer plate and cover hardware according to the torque chart or manufacturers specifications 19 Torque
10. is 76 so M12 55 90 112 eo 142 13x 1 75 HHCS BAA G Grade Bolt Strength D Nominal Diameter Inches T Thread Count Threads per Inch L Length Inches X Description Hex Head Cap Screw Grade 5 Grade 8 No of Marks 2 1 Na M12 1 25x50 HHCS AAG A P Prop erty Class Bolt Strength D Nominal Diameter M illimeters T Thread Pitch Thread Width mm L Length Millimeters 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 carefull
11. n 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 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 backspac ing 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 re quire fender modification Violation of these recommendations will not be endorsed as acceptable by Pro Comp
12. stall the rod end JMX12T into the re maining end of the rear upper arms 90 2673 with the jam nut SJNR12 as shown in ILLUS TRATION 2 Adjust the arm length according to figure and tighten the jam nut 33 Insert the spacers 90 2449 into the rod end See ILLUSTRATION 2 34 Install the bushing end of the upper arm to the mounting pockets on the frame using the pre viously removed OE hardware See ILLUSTRA TION 2 35 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 See IL LUSTRATION 2 NOTE Centering of the rear axle under the vehicle and pinion angle adjustment are done using these rod ends 36 Torque the OE upper control arm mounting bolts according to factory specifications and the supplied 9 16 bolts to 130 ft Ibs 37 Install the wheels and tires Remove the jack stands and lower the vehicle Torque the lug nuts to manufacturers specifications 55800 55800MX Created 6 25 07 CHECKS AND ADJUSTMENTS gt Recheck all hardware for tightness af ter the first 100 miles Headlights should be adjusted gt The exhaust system may need to be al tered from the rear of the muffler back by a qualified exhaust shop gt Use this only as a guide for hardware without a called out torque specification in the instruction manual Bolt Toro Me an otic System and ID Decimal System All ee Ft te Maximums g
13. the rear axle truss Except the 4 See ILLUSTRATION 1 ee 5 16 bolts overlap plate and sway bar mount ing hardware according to the torque chart on P according to manufacturers recommen REAR BRAKE LINE 20 Unbolt and remove the rear axle differential PE ANIE If yon haye astisk roar rake line it will be necessary to purchase separately spacer plate 90 3781 for Dana 44 or 90 3893 P tainl teel Brake Line kit P for Dana 35 See ILLUSTRATION 1 a DIGI ESS Steg AEUR COLE EEN 21 Run a bead of silicone along the differential NOTE If you already have a suitable cover mating surface long enough after market rear brake line in 22 Reinstall the differential spacer plate 90 stalled skip this section 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 1 23 Run another bead of silicone on the face of the differential cover 25 Unbolt the rear rubber brake line from the frame Save the hardware for reuse 26 Detach the rear rubber brake line from the factory metal brake lines on the frame and the rear axle Illustration 2 Rear Upper Control Arm Install 90 2673 Upper Rear Control Arm SJNR12 Jam Nut JMX12T 90 2449 Misalignment Rod End Spacers a 4 Rear Truss 9 16 X 3 Bolt e Axle Assembly 27 Thoroughly clean all mating surfaces and secure the supplied 90 degree brake line mount ing bracket 90 1
14. y 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 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
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