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! ATTENTION: If you are up grading from an existing Pro Comp kit you will need to get a new factory center link from the dealer. It is install with the nut of the tie rod end to the front of the vehicle. As it was installed from the factory.
51088 Revised 12.1.05 Part # Description Qty. Illus. Page BOX 1 OF 5 PN 51088-1 90-1799 REAR CROSS MEMBER 1 10,12,13 12,14 90-2126 LATERAL COMPRESSION STRUT 2 13,14 14,15 90-2354 STEERING DROP/CENTER LINK 1 8 10 90-6286 15-11018 15-11031 15-11148 90-2108 90-2109 90-2110 73-03700030 72-03700100512 HARDWARE PACK: BUSHINGS/ SLEEVES BUMP STOP - LOW PROFILE - HEX CONE BUMP STOP - SHORT SHAFT BUSHING - DIFFERENTIAL MOUNT/COMP STRUT SLEEVE-GM (PASS.
51088 Revised 12.1.05 BOX 3 OF 5 PN 51088-3 Part # Description Qty. Illus Page 90-6083 90-2111 90-2112 90-2113 90-1215 90-1216 HARDWARE PACK: A-ARM DROPS SLEEVE W/ WASHER SLEEVE-.750”X.50”X3.94” SLEEVE-.750”X.50”X3.44” LOAD WASHER-FLAT SIDE-2.0” O.D.X.550” ID. LOAD WASHER-1.50” O.D. X .532” I.D. 1 2 2 2 6 2 11 11 11 11 11 13 13 13 13 13 90-6080 70-0375001500 70-0504001500 72-03700100512 72-05000100512 73-03700030 73-05000030 HARDWARE PACK: TORSION DROP 3/8” X 5” USS GR.
51088 Revised 12.1.05 Part # Description Qty. Illus. Page 90-6282 90-2055 90-2014 90-4053 90-4036 90-1820 90-2394 HARDWARE PACK: CENTER LINK DROP 1/2” ID X 1 1/2” OD X 3/8” SPACER SPACER, 3/4” OD X 1/2” ID X 1/4" STEERING LINK STEERING CONE REDUCER CAM BLOCK OFF PLATES CENTER LINK SPACER– (Steering Stabilizer) 1 2 4 2 4 8 2 8 8 8 8 11 10 10 10 10 13 90-6309 70-0372501800 72-03700100512 73-03700030 70-0504001800 72-05000100512 73-05000030 73-05000838 HARDWARE PACK: CENTER LINK DROP 3/8” X 2.
1088 Revised 12.1.05 Introduction: ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ This installation requires a professional mechanic! We recommend that you have access to a GM service manual for your vehicle to assist in the disassembly and reassembly of your vehicle. It contains a wealth of detailed information. Ensure that your work space is of adequate size and the work surface is level. Place the vehicle in neutral. Place your floor jack under the front cross member and raise vehicle.
51088 Revised 12.1.05 Special Equipment A special removal tool is required for safe removal and installation of the torsion adjuster arms. This special puller can be purchased from your local GM dealer (Tool #J36202) or from Kent Moore Tool Group in Roseville, MI. (800) 345-2233 or (313) 774-9500 (Part #J22517-C). You may be able to rent one of these at your local parts store. Please refer to your GM service manual for more information.
51088 Revised 12.1.05 FRONT DISASSEMBLY: 1. Measure and record the distance from the center of each wheel to the top of its fender opening. Record below. LF: RF: LR: RR: 2. 3. See Special Equipment Notice on Page 3. Front of vehicle the puller and torsion adjuster arm until the adjuster nut can be removed from the cross member. Remove the torsion bar adjusting screw. Release the puller to unload the torsion bar.
51088 Revised 12.1.05 Illustration 3 Driver Side 8. Remove the torsion bars from the lower A-arms. 9. Remove the torsion bar cross member by unbolting it from the frame. 10. If you have a steering damper mounted, remove it from the vehicle. 11. Remove the front shock absorbers. 12. Remove the nut from the OE tie rod end. Using an appropriate removal tool, remove the tie rod end from the spindle. 13. Remove the brake calipers from the rotor and secure them clear of the work area.
51088 Revised 12.1.05 19. 20. If vehicle has a differential skid plate, remove it at this time. 21. Unplug the differential’s electronic coupler and vent hose. 22. 23. Illustration 6 Detach the drive shaft at the differential and secure it out of the way. Remove the bolt that attached the rear of the differential to lower control arm/differential mount. Using a hack saw or suitable cutting tool, cut off the driver side rear wrap around differential bracket as shown in ILLUSTRATION 2.
51088 Revised 12.1.05 from the pitman and idler arm studs. 28. Detach the anti-sway bar mounts from the frame. Re-install, sway bar flipped over from the original position. 29. On the driver side lower A-arm pocket, carefully cut the rear section out using the weld in plate (PN 96-1313) and ILLUSTRATION 4 & 5 as a guide. FRONT INSTALLATION: 1. Tack the weld in plate (PN 96-1313) to the back of the pocket.
51088 Revised 12.1.05 and PN 90-2108) install using the OEM nuts and washers, install the passenger side differential drop to the OEM mount as shown in ILLUSTRATION 7. 4. Hang the differential from the drivers side drop (PN 90– 3012) using the supplied 9/16” X 4” bolt. Install the supplied torque strut (PN 90-2124) to diff. drop using 9/16” hardware as shown in ILLUSTRATION 6.
51088 Revised 12.1.05 Illustration 10 OEM Hardware Rear Crossmember Bump Stop– Hex PN 1511018 Bump Stop– Cone PN 1511031 8. 9. Top Rear Crossmember PN 90-1799 Check clearance between the differential and the weld in plate. If needed, remove more material until adequate clearance is achieved. See ILLUSTRATION 8. Finish welding the weld in plate (PN 96-1313). Paint the welded areas to prevent rust. 10.
51088 Revised 12.1.05 Illustration 11 Load Washer 90-1215 Driver Side A-Arm Drop 9/16” X 4” Grade 8 Hex Bolt Drill out Cam Block Off Plate 90-1820 Sleeve w/ Washer 90-2111 (3.94” LG.) 9/16” X 4” Grade 8 Hex Bolt Upper A-Arm Drop Bracket 90-1155 Sleeve 90-2113 (3.44” SM.) Load Washer 90-1216 (Use if needed to shim bracket to frame.) Sleeve, 90-2112 (3.94” LG.
51088 Revised 12.1.05 18. Install the driver side upper a-arm drop bracket (901155) into the stock a-arm location points and onto the frame. Reference ILLUSTRATION 11 and note the following Illustration 12 Front Suspension Front of vehicle 5/8” X 5 1/2” Grade 8 Bolt a) Temporarily bolt (or hold tightly) the new upper a-arm drop bracket in place. Use an angle indicator to insure the bracket sits parallel (90 degrees) to the frame rail. If it doesn’t, grind a little more where the bump stop was cut off.
51088 Revised 12.1.05 upper control arm to brackets per ILLUSTRATION 11. Be sure that the anti-sway bar body is pivoted down so it is below the upper control arm’s front leg. Install OEM cam bolts and adjust bolts to a neutral, or centered position (torque to 75-90 ft./lbs.) 20. Attach CV axle flange to differential. Use OEM bolts and loctite. Torque to 60 ft./lbs. 21. Raise the lower control arm using the floor jack. Attach the front knuckle to the upper ball joint. Fasten with the OEM nuts. 22.
51088 Revised 12.1.05 27. Assemble both ends of the compression struts as shown in ILLUSTRATION 13 & 14 using the bushings (PN 15-11148) and sleeves (PN 90-2109). 28. Position the compression struts (PN 902126) into the tabs on the rear cross member using the supplied 1/2” X 4” bolts, washers, and nuts. See ILLUSTRATION 13. The strut ends welded at an angle go to the front, the struts are angled from the front of the vehicle rearward to the outside of the vehicle.
51088 Revised 12.1.05 35. Re-install the torsion bar cross member by flipping torsion crossmember brackets so they mount under the frame, install the new aluminum torsion bar drop brackets (PN 90-4011) as shown in ILLUSTRATION 15. Torque all fasteners to spec. 36. Install the torsion bars by reversing the order in which they were removed. Again, be very careful to install them with the same orientation that they were removed (i.e. left front to left front, right front to right front!).
51088 Revised 12.1.05 REAR INSTALLATION: ADD-A-LEAF (13124) 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 bolt is removed. Some springs have a factory helper spring consisting of one or more flat leaves installed at the bottom of the leaf pack. DO NOT install the add-a-leaf spring in or below the helper spring. 3) Remove the axle u-bolts.
51088 Revised 12.1.05 9) ing leaves. 6) 7) 8) Apply a small amount of grease to the end of the add-a-leaf, place it in the spring assembly as described in the note above, and reassemble the leaf springs using the “C” clamps. Raise the axle housing up until the pin in the spring aligns with the hole in the block. 10) Re-mount the axle to the springs using the new u-bolts, washers and nuts and the existing spring plates; tighten and torque u-bolt nuts to 85-100 ft./lbs. See ILLUSTRATION 17.
51088 Revised 12.1.05 of the vehicle is approximately 1/2” above the final desired ride height. Bars will settle slightly after vehicle is driven. NOTE: ⇒ Make sure to check rear brake line for any pinching, rubbing or excess stretching. Modify rear drop if needed. ⇒ Each bar may require slightly different adjustment to level vehicle side to side. ⇒ At maximum ride height, there still must be at least 3/16” of clearance between the bump stop and the front lower control arm.
51088 Revised 12.1.
51088 Revised 12.1.05 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.
