Installation Instruction
Contents
1. 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 12 WARRANTY REGISTRATION Ph 619 216 1444 _ 619 216 HERE2. Coil Over Upgrade Kit 57008MX Also Check out our outstanding selection of Pro Comp tires to compliment your new installation K5074B K5075B Revised 7 7 08 Introduction e 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 de tailed information e 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 attach ing points for stress cracks The overall vehicle must be in excellent working condi tion Repair or replace all worn or damaged parts e Read the instructions carefully and study the illustrations before attempting installa tion You may save yourself a lot of extra work e 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 hard ware with the brackets before you begin will save installation time e Check the special equipment list and ensure the availability of these tools e Secure and properly block vehicle prior to beginning installation ALWAYS wear safety glasses when using power tools or working under the vehicle e Use caution when cu
3. OE shock mounts Torque the upper mounting hardware to 18 ft Ibs and the lower OE mounting bolt to 72 ft lbs 10 Reattach the sway bar end links to the sway bar using the previously removed OE hardware Torque the nut to 52 ft Ibs 11 Repeat the installation on the other side of the vehicle 12 Check all hardware at this time to ensure 1 Ww 14 K5074B K5075B Revised 7 7 08 that everything is tight Check for ade quate clearance on all repositioned brake lines and emergency brake cables Make sure you check with the suspension fully extended and compressed Reinstall the wheels and lower the vehicle to the ground Torque the lug nuts ac cording to the wheel manufacturers rec ommendations With the vehicle on the ground reinstall the track bar to the rear axle using the pre viously removed OE hardware Torque the OE hardware to 96 ft lbs See IL LUSTRATION 26 NOTES On completion of the installation have the suspension and head lights re aligned After 100 miles recheck for proper torque on all newly installed hard ware Recheck all hardware for tightness after off road use K5074B K5075B Revised 7 7 08 TACOMA REAR INSTALLATION NOTE In order to properly install the add a leaf spring it will be necessary to contain the elasticity in the leaf spring with C clamps when the center bolts are re moved Some springs have a factory helper spring consisting of one or more
4. newly installed hard ware Recheck all hardware for tightness after off road use Illustration 2 Rear Spring Leaf Spring Assembly Center Bolt 13129 Add A Leaf 97 380 NOTE This is just an example Your set up may differ slightly from illustration e evised Use this only as a guide for hardware without a called out torque specification in the instruction manual Bolt Torque and ID Decimal System Metric System All Torques in Ft Lbs Maximums Ooo gt S5 ee eae a O y y o s s o y Mo 32 45 po ST MZ pS BH 1H po AY w 20 i 17o 240 2 L paT 4 alleen oN E lt gt 40 9 Tha L w pee L Gi 112 13x1 75 HHCS Grade5 Grade 8 M12 1 25x50 HHCS Ko of Matks 2 M G Grade Bolt Strength P Froperty Class Bolt Strength D Nominal Diameter Inches D Nominal Diameter M illimeters T Thread Count Threads per Inch T Thread Fitch Thread Width mmi L Length Inches L Lengh Milllimeters X Description Heg Head Cap Screw X Description Hex Head Cap Screw K5074B K5075B Revised 7 7 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 passen ger cars or unmodified vehicles both on and off road You must drive your vehicle saf
5. spring Make sure the pin on the leaf spring fit into the holes on the new lift block See ILLUSTRATION 2 NOTE These blocks are slightly ta pered and the short side of the taper is ori ented to the front of the vehicle 10 Secure the assembly with the U bolts and high nuts and washers Do not torque the U bolts at this time See ILLUSTRA TION 2 NOTE Make sure the block sits flush on the axle perch 11 Repeat the installation on the other side of the vehicle 12 When the installation of the remaining side is complete torque the U bolts to 85 ft Ibs 13 Install your new Pro Comp shocks 925518 w shaft end up to the OE shock mounts Torque the upper mounting hardware to 18 ft lbs and the lower OE mounting bolt to 72 ft Ibs 14 Reinstall the wheels and tires and lower the vehicle to the ground Torque the wheels to the manufacturers recom mended specifications 15 Recheck the wheel lug torque on all four wheels at this time 16 Recheck all hardware for proper installa tion and torque at this time 17 On completion of the installation have the suspension and headlights re aligned 18 After 100 miles recheck for proper torque on all newly installed hardware K5074B K5075B Revised 7 7 08 19 Recheck all hardware for tightness after NOTES off road use On completion of the installation have the suspension and head lights re aligned After 100 miles recheck for proper torque on all
6. 2360 Boswell Road Chula Vista CA 91914 Phone 619 216 1444 PRO COMP SUSPENSION Suspension Systems that Work K5075B 2005 2009 Toyota Tacoma K5074BB 4WD 2WD Pre 2006 2008 Runner 3 Lift Kit W Add A Leaf 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 Toyota F 4WD 3 Lift Kit K5074B K5075B Revised K5074B FJ Kit Parts List 7 1 08 Part Description Qty Illus Page 57491 Front Coil Spring 2 1 6 57492 Rear Coil Spring 2 622053 ES6000 Front Strut 2 1 6 923553 ES9000 Rear Shock OR K5075B Tacoma Parts List 57491 Front Coil Spring 1 6 622053 ES6000 Front Strut 2 1 6 925518 ES9000 Rear Shock 567096B 5 Tacoma Add A leaf Box 13129 Add A Leaf 2 10 90 3825 Hardware Pack Add A Leaf 1 98 00250 1 2 1 2 Spring Plate Clamps 4 2 10 98 00250 1 2 1 2 Spring Plate Straps 4 2 10 97 380 3 8 X 5 Center Bolt 2 2 10 8337 1 3 8 Fine Gr 8 Nut 2 2 10 Optional Equipment Available from your Pro Comp Distributor Tacoma 4WD 2WD Pre Runner Suspension Lift Kit 57096 57096MX Coil Over Upgrade Kit 57097 57097MX Traction Bars 72500B Mounting kit 72083B Skid Plate 57196 Light Bar 25000 CV Style Driveshaft 57098 To be used in conjunction with Pro Comp lift kit 57096 57096MX FJ 4WD amp 2WD Suspension Lift Kit 57007 57007MX
7. COMA FRONT INSTALLATION 1 Prior to installing this kit with the vehicle on the ground Measure the height of your vehicle This measurement can be re corded from the center of the wheel straight up to the top of the inner fender lip Record the measurements below LF RF LR RR 2 Ensure that your work space is of ade quate size and the work surface is level Place the vehicle in park Place your floor jack under the front cross member and raise vehicle Place jack stands under the frame rails behind the front wheel wells and lower the frame onto the stands Remove the jack and place the vehicle back in gear set the emergency brake and place blocks both in front of and be hind the rear wheels 3 Remove the front wheels Save the hard ware for reinstallation 4 Remove the front skid plate if applicable 5 Disconnect the ABS lines 6 Disconnect the sway bar end links and remove the lower ball joint cotter pin and nut 7 Loosen but do not remove the lower a arm bolts to allow the lower control arm to pivot on the bushings 8 Remove the 2 bolts from the lower ball joint bracket Save bolts for reinstallation 9 Remove the lower strut bolt from the lower control arm and remove the strut assembly from the vehicle NOTE the direction of the bolt for reinstallation 10 Remove upper strut tower nuts holding the strut assembly to the strut tower 3 on each side of the vehicle Save for rein stallat
8. ON CONTROL WARNING LIGHTS NOTES gt On completion of the installation have the suspension and head lights re aligned After 100 miles recheck for proper torque on all newly installed hard ware Recheck all hardware for tightness after off road use FJ REAR INSTALLATION 1 Block the front tires and raise the rear of the vehicle Support the frame with jack stands forward of the rear springs 2 Remove the rear wheels 3 Remove the shocks on both sides of the vehicle It may be necessary to slightly raise the axle to unload the shocks for re moval 4 Lower the rear axle enough to remove the coil springs from the front spring pockets Save the factory isolators for re use NOTE Be sure to support the axle while the springs and shocks are removed 5 Unbolt the track bar from the rear axle mount and secure up and out of the work area Save the hardware for reinstallation 6 Unbolt the sway bar end links from the sway bar Save the hardware for reuse 7 On both sides of the vehicle support the rear end with a jack and unbolt the lower control arm at the axle 8 Carefully lower the rear end to ease in the new coil spring installation Using the factory isolators install the Pro Comp coil springs 57492 into the spring buckets and raise the rear axle into place Make sure the coil spring seats properly on the lower spring perch 9 Install your new Pro Comp shocks 923553 w shaft end up to the
9. X 8 non hub centric wheel with a maximum backspacing of 4 1 2 PN 8089 7883 Additionally a quality tire of radial design not exceeding 33 tall X 12 5 wide tire PN 27033 is recommended Installation of larger wheels may be possible but must not exceed 5 of backspacing Be sure to check fit all wheel and tire combinations before purchasing and installation 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 IMPORTANT 17 OR LARGER WHEELS MUST BE USED IN CONJUNCTION WITH THIS LIFT KIT Please Note Front suspension and head light realignment is necessary Speedometer and ABS recalibration will be necessary if larger tires 10 more than stock diameter are installed Always use NEW cotter pins on re assembly These items are NOT supplied IT IS ADVISABLE THAT YOU HAVE HELP AVAILABLE WHEN INSTALLING THIS KIT SOME COMPONENTS ARE HEAVY AND AWKWARD ADDI TIONAL HELP IS GOOD INSURANCE AGAINST INJURY NOTE The final height of this kit is dependant upon the engine transmission and body configurations Special Tools Please refer to your service manual for more information A special removal tool is required for safe removal of the tie rods These tools may be purchased at your local Toyota dealer You may be able to rent any of these tools at your local parts store K5074B K5075B Revised 7 7 08 FJ amp TA
10. ely Extreme care should always be taken to prevent vehicle rollover or loss of control which can result in serious injury or even death Al 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 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 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 warrantie
11. flat leaves installed at the bottom of the leaf pack DO NOT install the add a leaf spring in or be low the helper spring 1 Block the front tires and raise the rear of the vehicle Support the frame with jack stands forward of the rear springs 2 Remove the rear wheels 3 Remove the shocks on both sides of the vehicle It may be necessary to slightly raise the axle to unload the shocks for re moval 4 Work on one side of the vehicle at a time 5 Support the rear axle with a floor jack and remove the U bolts on the driver side Loosen the U bolts on the passenger side and lower the rear axle NOTE Be sure not to over extend the rear brake lines 6 Use C clamps to hold the leaves of the rear leaf spring together and remove spring center bolt 7 Disassemble the leaf spring and insert the add a leaf 13129 See ILLUSTRA TION 2 NOTE Add a leaf will be placed in the spring assembly progressively according to length For example if the existing leaves are 32 long and 25 long and the add a leaf is 28 long place the add a leaf between the existing leaves 8 Using the C clamps re clamp and bolt the leaf pack back together using the supplied center bolt 97 380 with the head of the bolt facing down See ILLUSTRATION 2 9 Install the lift block Zf the vehicle is equipped with one making sure the pins fit properly into the holes on the spring perch Use your floor jack to raise the axle to the
12. ion 11 Scribe an index mark on the top of the OE coil spring to the upper strut mount ing plate CAUTION The coil is under ex treme pressure and severe bodily injury may occur if the coil spring is disassembled with out using a coil spring compressor 12 Compress the coil spring on the strut as sembly with a suitable coil spring com pressor so that the coil spring has about 3 8 play in the strut and remove the up per strut isolator retaining nut NOTE Do not use an impact gun to remove the retaining nut It will damage the strut shaft 13 Remove the OE coil spring isolator from the upper strut mounting plate See IL LUSTRATION 1 NOTE Inspect the front shock as semblies for any damage or fluid leakage Replace if necessary 14 Install the new compressed coil spring 57491 and OE isolator onto the new strut assembly 622053 and re attach the upper strut mount plate using the stock hardware Torque the upper strut mount ing plate retaining nut to 20 ft lbs See ILLUSTRATION 1 15 Decompress the coil spring on the strut assembly Make sure that the spring is seated correctly into the strut assembly and aligned with the previously scribed index mark on the upper strut mounting plate See ILLUSTRATION 1 16 Install the lower strut bolt in the original position and torque to 100 ft Ibs for the FJ and 61 ft Ibs for the Tacoma 17 Install the strut assembly into the strut tower and start the uppe
13. r three OE nuts 18 Make sure that the bottom of the strut is aligned as well See ILLUSTRATION 1 Using the floor jack raise the lower con trol arm and connect the lower ball joint bracket to the knuckle using the 2 previ K5074B K5075B Revised 7 7 08 21 Reinstall the front skid plate if applicable 22 Reinstall the front wheels Reinstall the wheels and lower the vehicle to the ground Torque the lug nuts according to the wheel manufacturers recommenda tions ously removed OE bolts Apply thread locking compound to the bolts Torque the bolts to 118 ft lbs 19 Reconnect the sway bar end links using the previously removed OE hardware Torque the nut to 52 ft Ibs 20 Reconnect the ABS lines NOTE Trimming of the wheel well liner on the backside of the fender well may be necessary depending on the tire wheel combination 23 Lower the vehicle onto the ground and tighten the upper strut tower OE nuts to 47 ft lbs Illustration 1 Strut Assembly OE Shock mount Hardware Coil Bucket Strut Assembly K5074B K5075B Revised 7 7 08 24 With the vehicle on the ground torque the lower A arm cam bolts to 100 ft lbs 25 Recheck all hardware for proper installa tion and torque at this time IMPORTANT BE SURE TO BRING THE VEHICLE TO A REPUTA BLE ALIGNMENT SHOP TO BE ALIGNED IMPORTANT IF THE STEERING WHEEL IS NOT CENTERED PROPERLY IT WILL TRIGGER THE ANTI LOCK BRAKE AND TRACTI
14. s 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 factory 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
15. tting 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 assem bly 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 disas sembly prior to installation The use of pry bars and tapered punches for align ment is considered normal and usually does not indicate a faulty product How ever 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 K5074B K5075B Revised 7 7 08 Important 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 17
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