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 # 55495 ‘97-2002 4WD Jeep Wrangler TJ “Stage I” 3” to 4” Lift Now Manufactured With Chromolly Arms 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.
55495 Created 12.5.
55495 Created 12.5.05 FOLLOWING PARTS ARE USED IN CONJUNCTION WITH THIS KIT. THEY ARE PACKAGED AND MUST BE ORDERED SEPARATELY.
55495 Created 12.5.05 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.
5495 Created 12.5.05 Installation Instructions: DISASSEMBLY - FRONT 1) Raise and support vehicle with jackstands. Support axle with a floor jack. Remove wheels and tires. 2) Place reference marks (as shown in ILLUSTRATION 1) on front drive shaft and axle. Disconnect the front drive shaft from axle. NOTE: If vehicle is equipped with ABS brakes remove sensor wire from the inboard side of the lower control arm. 3) Locate adjustment cam bolts, positioned on front of existing lower control arms.
55495 Created 12.5.05 NOTE: If you vehicle is equipped with ABS brakes reinstall sensor wire to inboard side of gusset located on lower control arm. ILLUSTRATION 3 BUSHING 15-11255 SLEEVE 90-2310 3) Install new bumpstop pad (90-4002) as shown in ILLUSTRATION 5. Mark center of lower coil spring pad. Using a 11/32” diameter drill bit, drill a pilot hole in the previously marked area. Install, using 3/8” self-tapping hardware provided. Torque to 20 ft./lbs.
55495 Created 12.5.05 ILLUSTRATION 5 ILLUSTRATION 7 COIL SPRING BUSHING, 45359 (FRONT) SWAY BAR LINK 90-2008 HEX BOLT SELF TAPING 3/8” x 2” LG. SLEEVE, 61150 (3/8” I.D.) SPRING PLATE FLAT WASHER, 3/8” BUSHING 45359 BUMPSTOP PAD 90-4002 SLEEVE 60859H (12mm I.D.) DRILL 11/32” PILOT HOLE ILLUSTRATION 8 ILLUSTRATION 6 NYLOC NUT, 3/8” FLAT WASHER, 3/8” SHOCK HARDWARE SWAY BAR FRONT MOUNT 20-55499-9 FLAT WASHER, 3/8” STOCK BUMP STOP SHOCK ABSORBER 324515 HEX BOLT, 3/8” x 2 1/2” LG.
55495 Created 12.5.05 ILLUSTRATION 9 TRANSFER CASE SKID PLATE hardware provided. Install assembly into the existing mounting location using hardware previously removed. See ILLUSTRATION 10. NOTE: It is very important that the shifter pivot rod protrudes through the selfaligning bearing on the pivot bracket approximately 3/8”. By bending the opposite bracket on the Transfer Case, you can easily achieve this.
55495 Created 12.5.05 ILLUSTRATION 12 INSTALLATION - REAR 1) Position rear lower control arms (90-2058) into existing front and rear mounting brackets and install using hardware previously removed. Do not tighten at this time. FRAME BUMPSTOP, EXTENSION 90-4003 2) Install new rear bumpstop extension (904003) using the supplied 10mm hardware as shown in ILLUSTRATION 12. Torque to 27 ft./ lbs. 3) Assemble sway bar links 90-2009 using 60001 bushing and install as shown in ILLUSTRATION 13.
55495 Created 12.5.05 ILLUSTRATION 14 FLAT WASHER, 1/2” HEX BOLT, 5/16” x 1” LG. FLAT WASHER, 5/16” HEX BOLT, 5/16” x 1” LG. NYLOC NUT, 3/8” REAR TRACK BAR MOUNT 90-1011 HEX BOLT, 1/2” x 3” LG. FLAT WASHER, 1/2” SLEEVE (1.60”) 90-2010 NYLOC NUT, 5/16-18 FLAT WASHER, 5/16” HEX BOLT, 3/8” x 1” LG. NYLOC NUT, 1/2”-13 FLAT WASHER, 3/8” FLAT WASHER, 5/16” NYLOC NUT, 5/16”-18 6) Attach track bar into new track bar mounting bracket, as shown in ILLUSTRATION 15 using hardware provided.
55495 Created 12.5.05 CHECKS AND ADJUSTMENTS: ⇒ Recheck all hardware for tightness after the first 100 miles. ⇒ To adjust location of front axle (side to side), place vehicle on a flat surface. Remove existing track bar bolt on passenger side of front axle tube. Center the axle under vehicle by turning steering wheel. Redrill track bar mounting hole in the area shown in ILLUSTRATION 16, and install bolt. Use the track bar as a guide for exact hole location.
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.
