Installation Instructions for the FORTEC® 3.0” / 4.0
Contents
1. gt aea NNNNNN gt o A A Illus N N NNN N Www fortec4x4 com FOLLOWING PARTS ARE USED IN CONJUNCTION WITH THIS KIT THEY ARE PACKED AND MUST BE ORDERED SEPARATELY 95399 JEEP FRONT COIL SPRING 1 95207 JEEP REAR COIL SPRING 1 924510 ES9000 SERIES FRONT SHOCK 2 924507 ES9000 SERIES REAR SHOCK 2 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 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 Read the instructions carefully and study the illustrations before attempting installation You may save yourself lot of extra work Check the parts and hardware against the parts list to assure that your kit is complete Separating 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 beginnin2. s discretion e Bent or dented product e Finish after 90 days e Leaf or coil springs used without proper bump stops e Light bulbs e Products with evident damage caused by abrasion or contact with other items e Damage caused as a result of not following recommendations or requirements called out in the installation manuals e Products used in applications other than listed in Pro Comp s catalog e Components or accessories used in conjunction with other manufacturer s systems e Tire amp Wheel Warranty as per Pro Competition Tire Company policy e Warranty claims without Proof of Purchase e 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 WARRANTY REGISTRATION NUMBER HERE Website www explorerprocomp com Fax 619 216 1474 JK JKS Adjustable Track Bar TOES REQUIRED Hydraulic Floor Jack amp Jack Stands Metric Standard Socket Wrench Set Torque Wrench 1 7 16 Open End Wrench Tape Measure Heavy Duty Ratchet Strap Anti Seize Lubricant Factory Service Manual recommended Asterisk den
3. asphalt Block the rear tires and set the emergency brake 2 Measure and record the distance from the center of each wheel to the top of its fender opening Record below LF RF LR RR 3 If you do not have access to a professional shop lift place the vehicle in neutral and put your floor jack under the front axle and raise the vehicle Place jack stands un der the frame rails 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 and behind the rear wheels 4 Unbolt and remove the transmission skid plate from the vehicle 5 Unbolt and remove the front and rear sway bar end links from the vehicle Save the rear sway bar links and hardware for reuse 6 Remove the shocks on both sides of the vehicle It may be necessary that you slightly raise the axle to unload the shocks for removal 7 Unbolt the front track bar and remove it from the vehicle Save the hardware for reinstallation 8 Unbolt the all the ABS mounting clips from the vehicle 9 Unbolt the front brake line brackets from the vehicle 10 Lower the front 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 11 Drill out the center of the front axle pad to 3 8 See Illustration 1 Illustration 1 Aluminum Bump Stop Install Aluminu
4. 5 Confirm that you removed the rear sway bar end links and moved them to the front 6 Unbolt the rear brake line brackets from the vehicle 7 Lower the rear axle enough to remove the coil springs from the rear spring pockets Save the factory isolators for re use Note Be sure to support the axle while the springs and shocks are removed 8 Install the driver side rear track bar relocation bracket 91 5841 into the original track bar mounting pocket using the supplied 9 16 x 1 4 bolt and supplied spacer 90 2650 See Illustration 2 9 Insert the 2 3 8 x 1 bolt into the track bar bracket and secure it to the driver side rear axle shock mount See Illustration 2 10 Tighten the previously installed 9 16 and 3 8 hardware 11 Install the U bolt around the rear axle tube and secure to the rear track bar relocation bracket 91 5841 using the supplied 1 2 washer and nut See Illustration 2 12 Torque the 3 8 1 2 U bolt and 9 16 track bar hardware according to the torque chart 13 Install the rear bump stop 91 5289 onto the axle pad Secure through the existing holes in the axle pad using the 2 supplied 5 16 X 1 bolts and hardware Torque bolts according to the torque chart 14 Carefully lower the rear axle to ease in the new rear coil spring installation Using the factory isolators install the Pro Comp rear coil sprigs 55207 into the spring buckets and raise the rear axle int
5. Installation Instructions for the FORTEC 3 0 4 0 Suspension System with Nitrogen charged Gas Shocks Pro Comp Part 94 4002 90 6662 70 0372001800 3 8 x 2 hex bolt GR 8 72 0371100816 3 8 NYLOCK NUT 73 03700034 3 8 HARDWARE FLAT WASHER 91 5841 90 2650 13 90496 72 050100816 73 050000830 90 6722 70 0563251800 9 16 x 3 1 4 GR 8 HEX BOLT 72 056100816 9 16 STOVER NUT 73 05600830 9 16 SAE FLAT WASHER 70 0371001800 72 037100816 3 8 STOVER NUT 73 03700830 3 8 SAE FLAT WASHER 90 6529 73 01410940 14mm FLAT WASHER 72 01415008812 90 3245 90 3718 91 5289 90 6299 70 0311001800 72 0531100816 73 03100034 91 5182 90 6340 70 0431251800 72 043100816 73 0400830 1 PN 55728 55728 1 Description Front bump stop spacer Hardware pack Front bump stop spacer 2 2 4 REAR TRACK BAR BRACKET REAR TRACK BAR SPACER U BOLT Rear Track Bar Relocation Bracket 1 2 STOVER NUT GR C 1 2 SAE FLAT WASHER HARDWARE PACK Rear Track Bar Bracket 1 1 2 3 8 x 1 GR 8 HEX BOLT 2 A HARDWARE PACK Jeep Cam Kit 1 14mm 1 5 NUT NOTCHED CAM CAM BOLT REAR BUMP STOP HARDWARE PACK Rear Bump Stop 5 16 x 1 HEX BOLT GR 8 5 16 NYLOCK NUT 5 16 HARDENED FLAT WASHER FRONT SWAY BAR DROP BRACKET HARDWARE PACK Front Sway Bar Drop 7 16 x 1 1 4 HEX BOLT GR 8 7 16 x STOVER NUT GR 7 16 SAE FLAT WASHER 55728 55728MX Qty N ANNEN N
6. ace and tighten 5 8 Jam Nuts H firmly against the Lower Ends 1 Vehicle Part Number Maximum Length ldeal Swaybar Angle Acceptable Range PN 2030 0 JK Wrangler PN 2034 11 5 8 5 to 5 IMPORTANT DO NOT exceed Maximum measured from center to center indicated for your part number IMPORTANT Bushing cradles at both ends of Quicker Disconnect must remain parallel with each other when Jam Nut is tightened 5 INSTALL QUICKER DISCONNECTS Slide Upper Ends G Lower Ends 1 of Quicker Disconnects onto the Tapered Mounting Posts C K amp M e Insert Click Pins J as illustrated to secure CORRECT WRONG IMPORTANT When properly installed the ring on the Click Pin will snap against the shaft of pin When installed backwards the ring does not fit snugly against shaft mm Wwww fortec4x4 com 6 LUBRICATE QUICKER DISCONNECTS e Lubricate all Grease Zerk fittings on the Quicker Disconnects immediately after installation using common wheel bearing grease or equivalent IMPORTANT When disconnected the swaybar must be 7 CORRECT OPERATION OF QUICKER DISCONNECTS secured in the horizontal position to prevent interference with the tires Failure to secure the swaybar correctly can e Remove the Click Pins J from the Upper and Lower lead to severe tire damage Tapered Mounting Posts C K amp M e Completely remove Quicker Disconnects from vehicle and store safel
7. ack bar cam bolt until the wheels are centered under the vehicle 23 Torque track bar cam bolt to 103 ft Ibs 24 Drive the vehicle forward and backward a few feet to be sure that the axle is adjusted properly and the vehicle is tracking in a straight line IMPORTANT If the steering wheel is not centered properly it will trigger the antilock brake and traction control warning lights e On completion of the installation have the suspension and headlights re aligned e After 100 miles recheck for proper torque on all newly installed hardware e Recheck all hardware for tightness after off road use Www fortec4x4 com Use this only as a guide for hardware without a called out torque specification in the instruction manual Bolt Torque and 10 4 1 i wih i Decimal System Metric System GO oA H 0 9 All Torquesin Ft Lbs Lon i ths a Belt sire 5 Balt Size Chae 9 9 Can 10917 OS ei a MG 5 4 7 Grades Grade N 30 45 amp Me 18 2 7 i 45 D 32 45 50 112 amp 90 Miz 65 15 90 ale Eck emg Pm Progeny Claw Gish aie 95 130 Wid 85 120 145 Dumme Cinch 1 1 175 10 amp 20 Pach ath 34 185 280 Mis 70 240 290 Notice to Owner operator Dealer an
8. d 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 maneu vers 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 in cluded 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 F
9. ds and adjustment threads of track bar e Mount Axle End A of Adjustable Track bar to the axle bracket by loosely installing the original mounting hardware i 5 POST INSTALLATION e Take measurements again to ensure axle housing is perfectly centered and make any final adjustments if necessary IMPORTANT The front axle housing must be in perfect lateral alignment with vehicle chassis before you proceed with installation e Once all adjustments are complete fully tighten the Jam Nut C to prevent Adjustable Track bar length from changing HINT It may be easier to tighten Jam Nut with the Adjust able Track bar removed from vehicle e Using a torque wrench tighten mounting hardware at both ends of track bar to 125 ft lbs e A professional steering alignment should be performed to correct toe position and to ensure vehicle meets proper alignment specifications Maintenance Torque specifications regularly Regular cleaning with pressurized water is recommended to maximize reliability JKS JKS Quicker disconects Tools Required e 15 16 Open End Wrench e Grease Gun with Zero Fitting Coupler e Wheel Bearing Grease e Factory Service Manual recommended PASSENGER SIDE WARNING NOT COMPATIBLE WITH right hand drive vehicles CHECK TORQUE SPECIFICATIONS regularly IMPORTANT SAFETY INFORMATION SOME VEHICLES MAY REQUIRE extended front brake h
10. g 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 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 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 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 Www fortec4x4 com 1 Position your vehicle on a smooth flat hard surface i e concrete or
11. m Bump Stop 90 4002 12 Install the aluminum bump stop 90 4002 into the previously drilled 3 8 hole using the supplied 3 8 x 2 bolt and hardware See Illustration 1 13 Carefully lower the front axle to ease in the new front coil illustration Using the factory isolators install the Pro Comp coil springs 55399 into the spring buckets and raise the front axle into place Make sure the front coil spring seats properly on the lower spring perch 14 If your kit includes JKS front disconnects install them now see attached instructions Otherwise remove the rear axle sway bar end links and reinstall them in the front You ll notice a difference in length of the links 15 Reattach the sway bar hardware to 35 ft Ibs 16 Torque the sway bar hardware to 35 ft Ibs 17 Reinstall the transmission skid plate using the previ ously removed OE hardware 18 Install your Pro Comp front shocks with the MX6024 body end up or 924510 with the shaft end up using the OE hardware Torque the upper mounting hardware to 17 ft lbs and the lower to 35 ft Ibs 19 Reinstall the ABS and brake line brackets to the vehi cle using the previously removed OE hardware For 2007 2010 models you will need to use the front brake line spacers For 2011 models simply remove the brake line bracket and ensure proper routing of the line You will not need to reuse the brackets for 2011 models 20 On both sides of the vehicle check
12. o place Make sure the coil spring seats properly on the lower spring perch Note Be sure to install factory isolators before raising the springs into place Notes wji Da LUI 17 15 Install your Pro Comp rear shocks MX6155 with body end up or 924507 with shaft end up using the OE hardware Torque the upper mounting hardware to 20 ft Ibs and the lower to 35 ft Ibs 16 Install the extended rear sway bar end links 17 Reinstall the rear brake line brackets to the vehicle using the extended brake line drop brackets and previously removed OE hardware 18 On both sides of the vehicle check the routing of the brake lines and the ABS wiring harnesses There must be no pinching rubbing or stretching of either component Use zip ties to secure these items to the steering components All full droop cycle the steering from lock to lock while observing the reaction of these components Reposition them if needed 19 Reinstall the rear wheels and lower the vehicle to the ground Torque the lug nuts according to the wheel manufacturer s recommendations 20 Install the rear track bar to the relocation bracket 91 5841 using the supplied adjustable cam bolt 90 3718 and hardware from hardware pack 90 6529 Do not torque the cam bolt at this time See Illustration 2 21 Postion your vehicle on a smooth flat hard surface i e concrete or asphalt 22 Rotate the tr
13. oses or other modifications to compensate for additional suspension travel NEVER DISCONNECT swaybar when operating vehicle on public roads WHEN DISCONNECTED the Quicker Disconnects must be completely removed from vehicle WHEN DISCONNECTED the swaybar must be secured to the chassis in the horizontal position to prevent interference with tires e Metric Standard Socket Wrench Set e Torque Wrench e Medium Strength Threadlocker e 1 Philips Screwdriver or Small Punch e Angle Measuring Tool 12mm Nylock Nut Offset Polyurethane Spacer 12mm Upper Tapered Mounting Post Spherical Bushing Press In Grease Zerk Grease Zerk Cap Upper Male Threaded End Assembly 5 8 Jam Nut Lower Female Threaded End Assembly Click Pin 1 2 Lower Tapered Mounting Post D S 1 2 Nylock Nut 1 2 Lower Flat Mounting Post P S TAlGC TAT MoOIODWDSYD Www fortec4x4 com 1 REMOVE ORIGINAL EQUIPMENT OE SWAYBAR LINKS e Remove front swaybar drop links hardware per the factory service instructions for your vehicle 2 INSTALL UPPER MOUNTING POSTS e Locate the stainless steel 12mm Upper Tapered Mounting Posts C with attached Offset Polyurethane Spacers B e Mount the 12mm Upper Tapered Mounting Posts on out board side of the swaybar ensuring small Click Pin holes are horizontal or parallel with the ground e Apply medium strength threadlocker to the tip of mounting post threads e Secure mounting
14. otes tools that are not required for some applications Thoroughly read instructions first to deter mine which tools will be required for your application IMPORTANT NOT COMPATIBLE WITH right hand drive vehicles CHECK TORQUE SPECIFICATIONS regularly DESCRIPTION QTY A Male Threaded Axle End 1 B Female Threaded Chassis End 1 C 1 NF Jam Nut 1 D Rubber Bushing 2 INSTALLATION 1 REMOVE FRONT TRACK BAR e Raise and support the vehicle chassis with jack stands positioned behind the front lower suspension arm brackets e Raise and support the front axle housing with a hydraulic jack to relieve any tension from the mounting bolts e Remove the front track bar mounting hardware from the axle and chassis brackets per the factory service manual instructions for your vehicle Retain original hardware e Remove original track bar from vehicle 2 MOUNT ADJUSTABLE TRACKBAR TO CHASSIS BRACKET Apply anti seize lubricant to bolt threads of original track bar mounting hardware Insert Chassis End B of Ad justable Track bar into the chassis bracket Loosely install the original mounting hardware Wwww fortec4x4 com JKS Adjustable Track Bar 3 CENTER FRONT AXLE HOUSING e Remove jack stands and lower vehicle to ground HINT Vehicle must be at normal ride height on level ground with the suspension supporting the full vehicle weight e Determine if the axle housing is centered by measu
15. posts to swaybar by installing 12mm Nylock Nuts A from the inboard side and tighten to 65 ft lb using a torque wrench HINT A small Philips head screwdriver or punch inserted into the Click Pin hole will enable you to prevent the mounting post from rotating when tightening the nut 3 INSTALL LOWER MOUNTING POSTS e Insert stainless steel 1 2 Lower Tapered Mounting Posts K amp M into lower swaybar link holes on front axle Position DriverSide i K posts with tapered ends pointing inboard ensuring small Click Pin holes are horizontal parallel with the ground Passenger Side M IMPORTANT The passenger side lower post is squared off to provide sufficient clearance between the post and the OE 1 2 Lower Tapered Mounting Posts trackbar bracket on the axle PN 2030 2034 e Apply medium strength threadlocker to the tip of mounting post threads e Install 1 2 Nylock Nuts L on outboard side of lower swaybar link brackets and tighten to 65 ft lb using a torque wrench mm www fortec4x4 com 4 SET QUICKER DISCONNECT LENGTHS e Determine the Ideal Swaybar Angle for your vehicle according to the following chart Adjust the length of your Quicker Disconnects until swaybar is at the Ideal Angle or within Acceptable Range Vehicle must be at normal ride height and located on level ground e Once adjusted lay Quicker Disconnects on a flat surf
16. r ing the distance between the tire and chassis using the exact same points on each side of the vehicle to en sure accuracy HINT For example measure from the edge of a tire tread lug to the outboard side of the chassis then repeat the Ratchet Strap preferred measurement on the other side of vehicle using exact same points e Attach a heavy duty ratchet strap to the chassis on one side of the vehicle and to the axle housing on the other side Ifthe two measurements are equal the axle is centered If the measurements vary divide the difference in half to e Tighten the strap in small increments to pull the chassis determine the amount of adjustment required alignment with the axle HINT If the axle housing is not centered the chassis can e Take measurements after each adjustment until centered be laterally shifted using either of the following methods Steering Wheel e Have a partner turn the steering wheel in small increments to shift the vehicle chassis side to side e After each adjustment have your partner hold the steering wheel steady while you take measurements 4 SET ADJUSTABLE TRACKBAR LENGTH AND MOUNT TO AXLE e With the axle housing centered beneath the chassis adjust the length of Adjustable Track bar by rotating the Axle End A until the steel sleeve in the Rubber Bushing D aligns with the mounting holes on the axle bracket e Apply anti seize lubricant to original mounting bolt threa
17. the routing of the brake lines and the ABS wiring harnesses There must be no pinching rubbing or stretching of either compo nent Use zip ties to secure these items to the steering components All full droop cycle the steering from lock to lock while observing the reaction of these components Reposition them if needed 21 Reinstall the front wheels and lower the vehicle to the ground Torque the lug nuts according to the wheel manufacturer s recommendations 22 Reinstall the OE front track bar to the axle mount using the previously removed OE hardware Torque the track bar mounting bolt according to the manufacturer s specifications If your kit includes an upgraded HD track bar install it in place of the factory component Notes e On completion of the installation have the suspension and headlights re aligned e After 100 miles recheck for proper torque on all newly installed hardware e Recheck all hardware for tightness after off road use Www fortec4x4 com 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 Unbolt the rear track bar from the rear axle mount and secure up and out of the work area Save the hardware for reinstallation 4 Remove the shocks on both sides of the vehicle It may be necessary that you slightly raise the axle to unload the shocks for removal
18. urther 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 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 as sume all risk and responsibility for potential damages incurred 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 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 e Parts subject to normal wear this includes bushings bump stops ball joints tie rod ends and heim joints e Discontinued products at Pro Comp
19. y inside vehicle e To reconnect remove Click Pins J from mounting posts and rotate swaybar down e Slide Quicker Disconnects back onto mounting posts and reinstall Click Pins HINT Install passenger side Quicker Disconnect first for easiest reinstallation Troubleshooting Maintenance If swaybar does not rotate freely remove from vehicle It is important to lubricate Quicker Disconnects frequently clean and apply rubber lubricant to chassis mounted for the first three 3 months after installation to evacuate bushings and reinstall contaminants that may build up during break in period After break in period Quicker Disconnects should be lubricated regularly as part of vehicle maintenance schedule Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability Always lubricate afterwards to evacuate any moisture www fortec4x4 com
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