Part # 57093 & 57094 Toyota T-100 4WD IFS 4
Contents
1. 100ft Ibs Crossmember Bolts 45 ft Ibs Eccentric Bolts 103 ft Ibs Center Differential Bolts 70 ft Ibs Pass Differential Brkt Bolt 70 ft Ibs Dvr Differential Brkt Bolt 70 ft Ibs Tapered Spindle Sleeve Bollt 100 ft Ibs Brake Hose Brkt to Spindle 120 ft Ibs Spindle to Upper Ball Joint 105 ft Ibs ie Rod ses 67 ft Ibs 100 ft Ibs 11 57093 57094 REVISED 2 1 06 ILLUSTRATION 10 LEAF SPRING 3 1 2 TAPERED 9 16 FLAT i ON 9 16 HIGH NUTS 57093 57094 REVISED 2 1 06 Use this only as a guide for hardware without a called out torque specification in the instruction manual Bolt Torque and ID All Torquesin Ft Lbs Maximums Grade 5 Grade B M 12 1 25x50 HACS Clu No of Marks 2 G Grade Bolt Strength P Property Class Bolt Strength D Nomina Diameter Inches D Nomina Diameter M illimeters T Thread Count Threads per Inch T Thread Fitch Thread Width L Length Inches L Length Millimeters Desenption Hex Head Cap Screw X Desenption Hex Head Cap Screw 13 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 Thi2. 90 2102 DRVR 57093 57094 REVISED 2 1 06 ILLUSTRATION 7 SWAY EXISTING 57093 57094 REVISED 2 1 06 ILLUSTRATION 9 5 16 LOCK NUT 5 16 x 1 HEX BOLTS REAR BRAKE CABLE EXTENSION 90 1276 10 REAR INSTALLATION 1 Place floor jack under rear axle and raise vehicle Place jack stands under frame to support vehicle Set emergency brake and block front wheel in front and behind tires Remove wheels and shocks 2 Unbolt brake equalizer arm bracket from axle Install rear brake cable extension 90 1276 to axle with OEM bolts and tighten Mount equalized cable bracket to top of ex tension using 5 16 x 1 hex bolts and 5 16 lock nuts and tighten See ILLUSTRATION 9 3 Loosen emergency cables by removing cotter pin pulling pin out from back side of brake plate at adjuster 4 Remove u bolts lower axle and install 3 tapered blocks with tapered end towards transmission as shown ILLUSTRATION 10 Install new u bolts washers and nuts and tighten Reinstall emergency brake cable keeping cable under spring 5 Install newer longer shock absorbers 329506 6 Install the rear wheels and lower the vehicle 57093 57094 REVISED 2 1 06 NOTE After installation is complete dou ble check that all nuts and bolts are tight Do not retighten nuts and bolts where loctite was used TORQUE SPECIFICATIONS A Arm Drop Bracket Bolts
3. 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 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 c
4. 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 57093 amp 57094 Toyota T 100 4WD IFS 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 3375 90 3377 90 3371 90 3372 90 57093 15 90 57093 16 OR 90 2102 90 2103 90 6124 15 11148 90 2109 90 6125 70 0504001500 72 05000100512 73 05000030 90 6136 90 1276 90 1278 90 1279 90 1325 90 1401 90 55089 5 90 6137 90 1301 90 2161 96 4026 90 6138 70 0311001500 70 0371501500 70 0433501500 70 0501251500 70 0501501500 70 0622501500 70 0624501500 72 03100100512 72 03700100512 72 05000100512 72 06200100512 72 04300100512 73 03100030 3 03 00030 73 04300030 73 05000030 Box 1 of 3 PN 57093 57094 1 Description Front A Arm Drop Brkt Drvr Front A Arm Drop Brkt Pass Rear A Arm Drop Brkt Pass Rear A Arm Drop Brkt Drvr Compression Strut Drvr 57093 Compression Strut Pass 57093 Compression Strut Drvr 57094 Compression Strut Pass 57094 Hardware Pack Containing Bushing Red Sleeves 3 4 x 1 2 x 2 3 4 Hardware Pack Containing 1 2 x 4 USS Gd 5 Hex Bolt 1 2 USS Nyloc Nut 1 2 SAE Flat Wa
5. aused 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 WARRANTY REGISTRATION Fax 619 216 1474 NUMBERS Ph 619 216 1444
6. bottom of drop down 57093 57094 REVISED 2 1 06 ILLUSTRATION 6 SPACER SPINDLE 90 4010 PASS 90 4009 DRVR bracket using 5 16 x 1 hex bolts 5 16 flat washers and 5 16 lock nuts tighten See ILLUSTRATION 7 Driver side use first for ward round hole and rear slotted hole with slant downward open side inward Passen ger side use first slotted hole and rear round hole with slant going downward open side inward Tighten sway bar bracket bolts and sway bar pins in a arm 17 Install lower end of the compression strut into the tabs located a arm drop brackets using the bushings and hardware provided Install the upper compression strut mount as shown in ILLUSTRATION 8 using existing hardware 18 Install the front wheels and lower the vehicle NOTE Measure from center of eccentric adjustment bolt to ground to ensure proper height 3 On alignment both sides inner 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 gt After installation is complete dou ble check that all nuts and bolts are tight Do not retighten nuts and bolts where loctite was used Re check pe riodically ILLUSTRATION 8 1 27 LOCK NUT COMER COMPRESSION STRUT 90 57093 PASS 90 57093 DRVR OR 90 2103 PASS
7. ckets NOTE Locating spacers will go in only one way all 8 spacers are the same Reinstall front crossmembers with OEM bolts Hand tighten bolts until brackets are aligned See ILLUSTRATION 2 6 Using a straight edge line up bottom a bracket tabs with upper OEM tabs Then 7 7 16 FLAT tighten bolts Torque to 100 ft Ibs Not WASHER crossmember bolts yet Install OEM bolts and nut into front crossmember to front dif ferential Tighten bolts and then tighten crossmember bolts 7 16 LOCK 94 Y NUTS lower tabs and tighten bolts Torque to 100 7 Install rear crossmember using 7 16 X 3 1 2 bolts 7 16 flat washers lock nuts and spacers 90 2161 Torque to 45 ft Ibs Using a straight edge align upper tabs with 57093 57094 REVISED 2 1 06 ft lbs See ILLUSTRATION 3 ILLUSTRATION 4 8 Install lower a arms in 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 because cam will not turn inside of tabs Torque to 103 ft Ibs Refer back to ILLUSTRATION 2 if necessary 9 Lower differential keep steady so not to pull out front drive shaft Install center differential bracket at rear of front differential as shown in ILLUSTRATION 4 10 Install differential drop plate using OEM bolts in two bottom holes using loc tite Use 1 2 x 1 1 4 hex bolts 1 2 flat wa
8. le Pass 1 6 9 16 Nut and Washer Pack 1 10 9 16 U Bolts 2 1 2 Wide 4 10 3 1 2 Rear Tapered Blocks 9 16 2 10 Box 3 of 3 PN 57093 57094 3 ES3000 Shocks Front 2 ES3000 Shocks Rear 2 The following parts are available for use with this kit and must be ordered separately 7212 Stainless Steel Brakelines 57193 Aluminum Skid Plate REVISED 2 1 06 Page Also check out our outstanding selection of Pro Comp tires to compliment your new installation 57093 57094 REVISED 2 1 06 Introduction 9 9 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 a
9. nd 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 com pound 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 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 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 modif
10. ove the shocks sway bar and bump stops on each side 4 bump stops in BEFORE YOU BEGIN total Remove eccentric adjustment bolt nuts from mounting bracket Read the instructions and study 4 Remove eccentric bolts front and the illustrations before attempting in rear on front lower a arm stallation Separating parts according to the areas where they will be used 5 Install the a arm drop brackets into and placing the hardware with the the OEM brackets Use new 5 8 x 4 1 2 brackets before you begin will save hex bolts and 5 8 lock nuts placing the a installation time arm drop bracket locating spacers on the outside and the 1 dia tube spacer between Check the parts and hardware against the parts list to assure that your kit is complete Secure and properly block vehicle prior to beginning installation ES Always wear safety glasses when using power tools INSTALLATION INSTRUCTIONS 1 Place floor jack under front axle and raise vehicle Place jack stands under frame to support vehicle Set emergency brake and block rear wheels in front and behind tires Remove front wheels 2 Remove clip from front of brake line and bracket Cut bracket to center of hole to remove brake line from bracket Install new brake line drop down bracket 90 55089 5 to OEM bracket as shown in ILLUSTRA WASHER 57093 57094 REVISED 2 1 06 ILLUSTRATION 2 NOTE BOLT MUST BE IN LOCATING the drop bra
11. s 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 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
12. sher Bracket Bag Containing Rear Brake Cable Exten Brkt Sway Bar Drop Brkt Pass Sway Bar Drop Brkt Drvr Center Differential Mount Differential Drop Plate Front Brake Drop Down Brkt Hardware Pack Containing Spacer Locating Spacer 1 x 1 2 x 5 8 Sleeve Tapered Spindle Hardware Pack Containing 5 16 x 1 USS Gd 5 Hex Bolt 3 8 x 1 1 2 USS Gd 5 Hex Bolt 7 16 x 3 1 2 USS Gd 5 Hex Bolt 1 2 x 1 1 4 USS Gd 5 Hex Bolt 1 2 x 1 1 2 USS Gd 5 Hex Bolt 5 8 x 2 1 2 USS Gd 5 Hex Bolt 5 8 x 4 1 2 USS Gd 5 Hex Bolt 5 16 USS Nyloc Nut 3 8 USS Nyloc Nut 1 2 USS Nyloc Nut 5 8 USS Nyloc Nut 7 16 USS Nyloc Nut 5 16 SAE Flat Washer 3 8 SAE Flat Washer 7 16 SAE Flat Washer 1 2 SAE Flat Washer Loctite Tube Red Qty N llb lc Illus coo NN ND IN CO CO ANNO CO CO CO O N J 0 J O N 57093 57094 REVISED 2 1 06 Page OO gt O N O 6 CO 3 CO N NO Part 90 4009 90 4010 20 65302 13 90126 95 350 318514 329506 57093 57094 Description Qty Illus Box 2 of 3 PN 57093 57094 2 Spacer Spindle Drvr 1 6 Spacer Spind
13. shers and 1 2 lock nuts in two upper holes Torque to 70 ft Ibs See ILLUSTRA TION 5 11 Remove tie rods from steering knuck les Remove two bolts on back side of spin dle which hold the metal bracket for the brake hose 12 oupport lower a arm with floor IDIERERENTIAT jack and separate upper ball joint from 2 DROP PLATE spindle Using file file corners off of spindle to contour with bottom of new spindle adapter so that the bottom of the d 1 2 FLAT new spindle seat surface is in contour WASHER with OEM spindle top surface Clean out hole on top of steering knuckle spindle 13 Insert tapered spindle sleeve 96 4026 with small end going downward Install 5 8 x 2 1 2 hex bolt and 5 8 lock nut as shown ILLUSTRATION Torque to 100 ft Ibs 14 Referring again to ILLUSTRA TION 6 reinstall brake hose bracket to new spindle with OEM bolts using loc tite Torque to 120 ft lbs Insert spindle into upper ball joint tighten Torque to UPPER BALL JOINT TAPERED SPINDLE _ SLEEVE 96 4026 5 8 x 2 1 2 HEX BOLT 105 5 Reinstall the rod Torque to 67 ft llbs Reinstall all cotter pins 15 Install new long shocks and tighten 318514 16 Reinstall sway bar with the two sway bar drop down brackets using OEM bolts and nuts in top holes adding a 5 16 flat washer to the OEM flat washers tighten Install sway bar to
14. y the Pro Comp parts in any way as this will void any warranty expressed or implied by the Pro Comp Suspension company Please Note Front end and head light realignment is necessary opeedometer and ABS recalibration will be necessary if larger tires 1096 more than stock diameter are installed 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 any and all warranties written or implied In addition a quality tire of radial design not to exceed 33 tall x 12 5 wide is recommended 57093 57094 REVISED 2 1 06 FRONT INSTALLATION PLEASE NOTE TION 1 Put 3 8 flat washer on top Insert 3 8 x 1 1 4 hex bolt through both brackets and tighten with 3 8 lock nut on bottom You may need to reform the brake line slightly Be sure not to kink or cause any in terference of the line Reinstall OEM brake line clip to hose at bracket See ILLUSTRA TION 1 This is a mechanical change a 4 in front 3 in rear ES Front end alignment is needed after installation set to factory specs gt Do not adjust torsion bars leave at factory specs 3 Rem
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