6.0. Version 3 Revised 01/2005. CARTON 1 continued Qty. FTS Master Hardware Box Kit. FTS Master Hardware Box Kit

Transcription

1

2 6.0 Version 3 Revised 01/2005 INSTALLATION INSTRUCTION Part # FTS / FTS / FTS Long Arm Suspension System Jeep Wrangler TJ / Jeep Rubicon Read instructions from start to finish before installation of components CARTON 1 HARDWARE AND COMPONENTS LIST Qty CARTON 1 continued Qty FTS Master Hardware Box Kit Master Hardware Kit 3/8 x 1.0 NC Gr.8 Bolt 9 3/8 x 3.75 NC Gr.8 Bolt 6 3/8 Metal Lock Nuts 7 3/8 Flat Washers 16 3/8 Tek Screw Inner Frame Brake Line Tab 3 10mm x 1.5 x 35mm Long Bolt 4 10mm Lock Washer 4 10mm Small Flat Washer 4 1/2 x 3.5 NC Gr.8 Bolt 6 1/2 x 2.5 NC Gr.8 Bolt 1 1/2 x 1.5 NC Gr.8 Bolt 7 1/2 SAE Flat Washer 26 1/2 Metal Lock Nut 10 1/2 x 5 NC Gr.8 Bolt 2 9/16 x 2.5 NCC Gr.8 Bolt 1 9/16 Metal Lock Nut 1 9/16 SAE Flat Washer 2 SLE153 Crush Sleeve, Frame 2 SLE154 Crush Sleeve, Frame Brake Line Kit 16-F Brake Line, Front 2 16-R Brake Line, Rear Brake Line Brkt, Front L/R & Driver Rear 3 Brake Line Retaining Clip Control Arm Greasable Bolt Kit 9/16 x 4 Gr.8 Bolt 6 9/16 x 4 Greasable Bolt 2 9/16 Metal Lock Nut 8 9/16 Flat Washer SAE 16 FTS Master Hardware Box Kit Long Arm Hardware Kit JM-16T 1 x 1-1/4-12 Male Rod End 4 1-1/4 Jam Nut High Mis-Alignment Spacer Kit High Mis-Alignment Spacer Shock Bracket Kit Rear Shock Bracket, Lower 2 1/2 x 2.5 Gr.8 Bolt 2 1/2 Metal Lock Nut 2 1/2 Flat Washers 4 SLE121 Sleeve Rear Support & V-Link Component Kit 3/4 x 4.5 Gr.5 Fine Thread Bolt 1 3/4 Flat Washer High Mis-Alignment Spacer Aluminum Spacer, RR Upper Mount Front Trac Bar Hardware Kit KMX-12 3/4 Chromoly Rod End Mis-Alignment Spacers 2 CA1018 Black Vecton Trac Bar Bushing 2 SLE 151 Trac Bar Sleeve 1 3/4 Jam Nut 1 CARTON 1 Qty SUSPENSION COMPONENTS Front Lower Control Arm-Uni Control Arm Frame Support, Right Control Arm Frame Support, Left Upper Front Link Mount, Right L Upper Front Link Mount, Left 1 FTS3001 Pitman Arm 1

3 HARDWARE AND COMPONENTS LIST CARTON 2 Qty Rear Lower Control Arm Upper Front Control Arm, Assembled Front Trac Bar Frame Cross Brace Front Adjustable Trac Bar Trac Bar Frame Mount Bracket Rear Upper V Link Support Compressor Mount Rubicon Only 1 1/4 X 3/4 Bolts & nuts 7 1/4 Metal Lock Nuts 7 1/4 Flat Washer Dana 35 Diff Reinforcement Plate Dana 44 Diff Reinforcement Plate Upper Reinforcement Plate w/nut 1 B516X1 5/6 X 1 Bolts 3 N516MLN 3 FW516 Flat Washer Rear Sway Bar Link Kit Rear Sway Bar Link Kit Assembled 1 FTS Front Sway Bar Link kit Assembled Sway Bar Link Relocation Brackets 2 (Weld-On) Bushing & Sleeve Kit MO3515 Lower Control Arm Bushings 8 MO2825 Upper Rear V-Bar Bushings 4 SLE10091 Control Arm Sleeve 4 SLE 155 Upper Rear V-Bar Sleeve Bump Stop Hardware Kit 10mm x 1.50 x 70mm Gr.5 Bolt 4 3/8 x 2 Self Tapping Bolt 4 CA1014 Lower Bump Stop, Front & Rear, 3 x CA1004 Upper Bump Stop, Front & Rear, 2 x2 4 Installation Instructions 1 CARTON 3 Qty Coil Spring, Front 6 TJ Coil Spring, Rear 6 TJ CARTON 4 Qty Upper Rear V-Link, Partial Assembled 1 WSSX-16T 1 Spherical Bearing Assembled 1 WHM-212 Retaining Ring Assembled 1 CARTON 5 Qty Center Skid Plate 6 TJ CARTON /04 Automatic Only Qty Front Skid Plate 6 TJ Mount bracket w/hdware 1

4 IMPORTANT NOTES WARNING: This suspension system will enhance the off-road performance of your vehicle. It will handle differently, both on and off-road, from a factory equipped passenger car or truck. Extreme care must be used to prevent loss of control or vehicle rollover during abrupt maneuvers. Failure to drive this vehicle safely may result in serious injury or death to the driver and passengers. ALWAYS WEAR your seat belts. Reduce your speed, and AVOID sharp turns and other abrupt maneuvers. Before installing this system, have the vehicle s alignment checked by a certified technician. The alignment must be within factory specifications and the frame of the vehicle must be sound (no cracks, damage or corrosion). Do not chrome, cad or zinc plate any of the components in this system. Changing the coated surface of components will void the warranty of your Full Traction Suspension. This suspension system was developed using the following tire & wheel combination: 35 x12.50 tire, 15 x 8 wheel with 4.5 inches of wheel backspacing. Before installing any other combination, consult your local tire and wheel specialist. Mandatory Requirements Jeep TJ *Slip Yoke Eliminator *Rear CV Drive Shaft Replacement *Exhaust Modification - See Pg Jeep Rubicon *Rear CV Drive Shaft Replacement *Exhaust Modification - See Pg.4 ADDITIONAL INFORMATION Congratulations on your purchase of the highest quality suspension system available for the Jeep TJ. Some of the service procedures require the use of special tools designed for specific procedures. The following tools and supplies are recommended for proper installation of this system. - Jeep Factory Service Manual - Pitman Arm Puller Tool - Coil Spring Compressor - Universal Steering Linkage Puller - Ball Joint Separator - Prevailing Torque Nuts (for steering linkage) - Die Grinder - Drill Motor - Assorted Drills: 1/8 & larger - Tie Down Strap - Torque Wrench - 1/2 drive Ratchet and Sockets - Assorted Combination Wrenches - Heavy Duty Jack Stands - Wheel Chocks or Blocks - Hydraulic Floor Jacks - Center Punch - File - Large C Clamps, Bench Vise and Adjustable Straps. - Hammer - Hole Saw - Wire Brush ( to clean mounting surfaces) - White Lithium Silicone Spray Lubricant - Grease Gun with Assembly Lube - Tape measure - Safety Glasses ( wear safety glasses at all times) - Semi Gloss Black Spray Paint See Pg.13 for basic specifications. The required installation time for this system is approximately hours. Installation time will vary. Allow time for transfer case and exhaust modifications. Thank you for purchasing the best suspension system available. For the best installed system, follow these instructions. If you do not have the tools or are unsure of your abilities, have this system installed by a certified technician. FULL TRACTION SUSPENSION IS NOT RESPONSIBLE FOR DAMAGE OR FAILURE RESULTING FROM AN IMPROPER OR MODIFIED INSTALLATION. Jeep TJ Wrangler / Rubicon 2.

5 Part # FTS Jeep TJ Wrangler / Jeep Rubicon 6.0 Long Arm Suspension System 3.

6 IMPORTANT READ BEFORE YOU BEGIN INSTALLATION The installer of this system should be prepared to modify the exhaust system as shown in Fig.1 The new suspension system cannot be installed around the stock exhaust, therefore the vehicle is disabled without the exhaust. A rear slip yoke eliminator conversion (97-04 models) & CV type drive shaft is required to complete the installation. On models, no change in the front drive shaft is required. Check the parts and hardware against the parts list to assure that your kit is complete. Refer to page #2 of these instructions for a list of tools and supplies needed to perform the installation. Use these instructions as a guide, however experienced installers may want to change the order of installation procedures to suit their needs. Fig.1 General Disassembly 1. Raise and support the vehicle frame with jack stands. Support the front axle with a floor jack. Remove all wheels. Place reference marks on the front driveshaft and axle. Disconnect and remove the front driveshaft from the axle. Fig.2 2. Remove the rear driveshaft. Support the Yoke of the driveshaft and support the transfer case with a stand or a tie down strap. Fig.2 Remove the center factory transfer case skid plate from the vehicle. Save factory bolts. NOTE: For Rubicon models only. Due to the factory oversized NP241 transfer case, the floor pan in the area of the transfer case must be relieved with the aid of a ball peen hammer. After removing the factory transfer case skid plate, support the transfer case with a stand. Using a jack, lift the transfer case into the confined area all the way to indent the area to be relieved. Next lower the transfer case down to allow the hammer to make an impression in the floor. Make a large enough impression so that the transfer case does not hit the floor after the new skid plate is installed. 3. Cut the exhaust as shown in Fig.1 Remove the entire remaining exhaust system from the vehicle. The exhaust may also be unbolted from the B pipe flange next to the engine block. ** It is the installers decision how to do the exhaust. Fig.3 4. With the front axle supported, remove the front shocks, steering stabilizer, steering linkage from the knuckles, pitman arm, front trac bar, and front sway bar links. Do not remove the D bushings or the front sway bar from the frame. 5. Remove the front brake line bracket from the frame to allow the axle to drop down far enough to remove the front coil springs. New brake lines will be installed later during this installation. Remove both lower front control arms. Fig.3 Leave the upper control arms attached at this time. 4.

7 Installing the Full-Traction Trac-Bar Bracket Fig.3 1a. To install, two (2) holes will be drilled. Drill out factory tapered hole in the large cast iron trac-bar mount to 9/16 as shown in Fig.4 Insert the trac bar bracket guide rod into the frame hole in the bottom side of the frame. Fig.5 Install 9/16 x 2.5 bolt, nut and washer and torque to 90lbs/ft. The 9/16 bolt will hold the new bracket in place while the next hole is drilled in the frame. 1b. Insert the drill bit into the trac bar guide rod and drill hole out through the top side panel of frame to 1/2 as shown in Fig.6 install 1/2 x5 bolt, nut and washer. Torque to 75lbs. Fig.4 Fig.5 2. Install frame brace to trac bar bracket using ½ x 1.5 bolt as shown in Fig.8 On the Right side frame rail, locate the factory hole and drill a 1/2 hole through the top of the frame rail and install a ½ x 5 bolt through the frame. Fig. 7a, Fig.7b & Fig.8 3. At this time, mount the new adjustable Trac Bar to only the axle Fig.7b Fig.6 Fig.7a end. Enlarge hole in axle bracket Fig.9 to 1/2. Install KMX-12 3/4 Chromoly Rod End and # Mis-Alignment Spacers using 1/2 x 2.5 bolt, nut, and washers. Fig 9 NOTE: The new adjustable front Trac Bar will be attached to the new Trac Bar bracket last after the suspension install is complete and the vehicle is ready to be returned to level pavement. The axle must be centered under the vehicle before the Trac Bar is attached to the new bracket. Fig.8 4. Install new steering pitman arm. Refer to factory service manual for torque specifications. Fig.9 5. Install factory steering system back to vehicle. 5.

8 Installing Full-Traction Upper Front Control Arms 1. Remove front lower control arm frame mount. Using an electric grinder, make an incision grind mark to use as a guide to grind off the factory weld. Fig.10,11 & 12 Grind both inside and outside frame surfaces. Finish frame smooth with a dual action sander and paint with semi-gloss black spray paint. Grind Here Fig.10 Fig.11 Fig New Full-Traction upper control arm support brackets are Left and Right. Position the new FTS upper control arm support bracket on the frame by measuring the distance from a factory frame reference hole or similar reference. Fig.13 Using the support bracket as a template, mark and center-punch the frame for the 3 smaller holes and for the larger access hole which will be used for the greasable control arm bolt. Drill the 3 smaller holes using a 7/16 through both sides of the frame surface. Drill a 1/4 pilot hole to serve as a guide for the holesaw. Using a 1-1/8 hole-saw drill bit, drill the large access hole for the greasable control arm bolt as shown in Fig.14. Drill the inside hole for the greasable bolt to 9/16 Mount the control arm support bracket(s) to the frame using 3/8 x 3.5 bolts, washers, and metal lock nuts. Install 3/8 bolts from the backside of the frame with the thread of the bolts facing toward the outside of the frame as shown in Fig.15 Fig.15 Fig.13 Fig.14 Right/Passenger Side 7. IMPORTANT! Holesaw through the outside surface of the frame only. DO NOT holesaw through the inside surface of the frame. Refer to Fig.14. The inside hole opposite the 1-1/8 holesaw must be 9/16 Fig.10 6.

9 Installing Full-Traction Upper Front Control Arms Greasable Bolts Fig.16 Fig Before removing the factory upper control arms, support axle so it does not rotate or pivot. Remove factory upper arms. Save factory bolts to be reused on new FTS control arms. 5. The Upper front arms are shipped pre-assembled, however arms must be adjusted for length to correct the pinion angle. Install upper front control arms using 9/16 x 4 greasable bolts as shown in Fig.16 Torque greasable bolts to 85lbs/ft. Install the axle end of the upper arms using factory bolts and nuts. Fig.17 The upper arms have the joint welded on an angle. The joints will be angled inward when mounted on the axle. Refer to factory service manual for torque specs on factory bolts. Installing Side Skid Brackets & Center Skid Plate to Frame Note: A 90 degree side angle type drill is required to install the side skid bracket properly on the inside frame surface. 1. Side Skid brackets are left and right. Starting on the left side of the vehicle, line up the factory holes in the bottom of the frame with the holes in the side skid bracket model TJ will use the three forward holes in the bracket. Wrangler X, Sport & Rubicon models use the reward set of holes as shown in Fig.18 Fig.18 Fig Unclip the brake lines attached to the frame next to the transfer case. Mount three Inner frame brake line standoff tabs to the inside edge of the frame using 3/8 x 1 Tek self tapping screw. Fig.19 7.

10 Installing Side Skid Brackets & Center Skid Plate to Frame 3. Install factory bolts in the bottom of the frame to hold the side skid bracket in place. Using the bracket as a template, mark & centerpunch for the new holes to be drilled. Drill 1/4 pilot holes. Fig.20 Next, mark & centerpunch the holes on the inside frame rail. Drill holes to 9/16 using 90 degree side angle drill. Note: Do not attempt to drill through both sides of the frame at the same time. This will cause holes to become mis-aligned. Next, remove the factory bolts and the side skid from the frame. On the outside holes only, using a 3/4 holesaw, enlarge the holes to 3/4 diameter. (Outside holes only). Insert crush sleeve SLE154 into the frame holes as shown in Fig.21,22 Again, position side skid bracket in place and install ½ x 3.5 bolts, nuts, and washers and torque to 75lbs./ft. Repeat same for the right side of the vehicle. Fig.21 Fig.20 Left Side/Driver Fig.22 Installing Center Skid Plate 1. There are eight (8) holes in the center of the skid plate. (Two sets of 4 holes each) The forward set of holes are used on TJ automatic models and the rear set of holes is for spd and See Fig.23 Align the bolt studs from the Transfer case mount with the holes in the center skid plate. Next, align the bolt holes in the Side Skid brackets with the holes in the skid plate. Install 3/8 dia x 1 bolts and flat washers into the Full-Traction pre-installed nutserts. 2. Install the factory nuts on the four (4) Transfer case mount studs and secure tight. For TJ Rubicon models only Mount the small air compressor skid plate on the left rear section of the center skid plate to hold the factory air compressor in place Fig.24 Air lines & wiring may need to be re-routed to have enough slack. Fig.24 Fig.23 8.

11 Installing Upper Rear Differential V Link Support 1. Support rear axle with stands. Pinch off the factory rubber brake line so it doesn t leak brake fluid. Remove the bolt holding the rear brake line to the rear axle. Not shown. 2. Remove rear trac bar from axle and discard. Remove factory rear shocks. Remove rear coil springs. Discard these items. 3. Save Factory Shock Bolts to be reused. 4. Remove the rear sway bar and save all hardware to be reused. 5. Disconnect the parking brake cable attached to the rear upper control arms. Remove the factory rear upper and lower control arms. 6. Position the Full-Traction Upper V Link Support over axle. Fig.25 Insert billet aluminum spacer and secure using the factory control arm bolt as shown in Fig.26 Align holes in the new upper link support bracket with the holes in the frame from the sway bar bracket. To secure the new V link bracket, install factory sway bar D shaped brackets using new 10mm 1.5 x 35mm bolts and washers. Secure all hardware. Installing Upper Rear V Link Fig.25 Fig.26 Fig Insert #MO2825 bushings & sleeve # SLE155 into eyelets of V Link. Bushings must be greased liberally with lithium grease or similar type assembly lube. Failure to lube bushings prior to assembly will result in suspension squeaks and premature wear of the bushings. The V Link comes preassembled with #WSSX-16T 1 Spherical Bearing and the retaining ring in place. 2. The Full-Traction Logo on the V link must be facing in the upright position. Align the eyelets of the V link to the upper side skid bracket mounting point. Install 9/16 x 4 Greasable bolts, nuts and washers. Leave bolts and nuts hand tight. 3. Insert # high mis-alignment spacers on both sides of the spherical bearing. To install the V link to axle, tilt (pivot) the rear axle backwards to align bearing with bolt hole in upper V link support. Carefully guide the assembly into the Well of the support. Insert 3/4 x 4.5 bolt, washers and 3/4 metal lock nut under the support and torque to 150 lbs./ft. Fig.27 Fig Included in carton #2 are # Dana 44 and # Dana 35 differential reinforcement plate and upper reinforcement plate. Install reinforcement plate using V-Link ¾ x 4.5 bolt. Install the differential plate using the factory bolts from the rear differential inspection cover. Drill 3/8 holes into upper reinforcement using holes in differential plate as a template. Install 3/8 bolts provided. Draining oil from rear differential is not necessary. Fig.28 9.

12 Installing Rear Components. 1. Install rear sway bar links using factory hardware. Fig.29 Fig Drill a 5/16 hole into the coil spring base cup. Install the rear Lower CA x2 aluminum bump stop extensions using the 3/8 x 2 self tapping bolts. Screw the bolts into the spring seat as shown in Fig.30 Note: Rear 3 x2 lower extensions must be installed after the rear coil springs are installed as the opening of the coil will not allow the extension to pass through it. 3. Install the rear Upper CA x2 aluminum bump stop extensions using the 10mm x 65mm Bolts. To install, remove the factory upper foam bump stop. Remove the bell shaped factory mount. Install the 2 x2 bump stop extension and re-install factory foam bump stop as shown in Fig.31 NOTE: Failure to install ALL upper and lower bump stop extensions will void the warranty of your Full- Traction Suspension system. Fig.30 Fig.31 Upper and Lower Assembly Upper Assembly 4. Repeat steps #3 and #4 for the front bump stops extensions. Upper and Lower aluminum extension are installed in the same manner as the rear extensions. Installing Rear Coil Springs. Shock absorbers are required to complete the installation of this suspension system. Fig Using 1/2 x 2.75 bolt provided, bolt on part # rear lower shock extension brackets to the axle. Secure the bracket with a 3/8 x 1 bolt on the front side of the bracket. Fig.32 After mandatory bump stop extensions are installed, install the rear coil springs one at a time. Check to see that the upper factory rubber insulator is in place on top of the coil prior to assembly. Assemble rear bar pin into upper shock eyelet and install the shocks on the vehicle. 10.

13 Installing Rear Lower Control Arms & Adjustments 1. The rear lower control arms measure approximately 30 inches in length and are shorter than the front lower control arms. Insert MO3515 bushings and SLE10091 sleeves into large eyelet of control arms. Grease zerks are pre-installed to allow lubrication to the bushings. Prior to installing the rod ends, apply anti-seize or similar lubricant to the threads of JM-16T 1 x 1-1/4 Male rod end. Install 1-1/4 Jam nut onto rod end. Install male rod end all the way inside the threaded end of each control arm. Check for damage on threads of rod end and clean or file as necessary to ensure smooth rotation/adjustment of the rod end prior to assembly. Fig Rotate the Male rod end counterclockwise to expose approx 1/8 of threads prior to installing control arm on vehicle. Final length adjustments of the control arm will need to be made after vehicle is road tested. Insert # High Mis-Alignment spacers on both side of rod end opening as shown in Fig.33 Install rear lower control arms to the axle using the factory hardware at the axle. Install control arm to the side skid mounting point using 9/16 x 4 Gr.8 bolts. Fig.34 After all adjustments are performed, apply final torque to the 1-1/4 jam nuts. Installing New Rear Brake Line 1. Remove factory brake line support bracket from the frame and replace with # brake line bracket using factory bolt. Install #16-R rear brake line. Insert brake line through hole in bracket and secure with new Brake line retaining clip. Clip must be lightly tapped into place with a small ball peen hammer. Fig.34 Installing Front Coil Springs Shock absorbers are required to complete the installation of this suspension system. Fig With front axle supported and front bump stop extensions in place, install front coils springs. The top of the coil has a smaller opening than the bottom of the coil. Rotate the coil spring until it rests in the coil cup properly. Install front shock absorbers. Fig.35 Fig.35A Automatic only: Install front skid plate as shown. Factory frame nutserts are reused to attach skidplate to frame. Secure small skid to main skidplate using hardware provided. Fig.35A Front Coil Springs with bump stop extensions correctly installed. 11.

14 Installing Front Lower Control Arms & Adjustments 1. The front lower control arms measure approximately 35 inches in length and are longer than the rear lower control arms. Prior to assembly, apply anti-seize or similar lubricant to the threads of JM-16T 1 x 1-1/4 Male rod end. Install 1-1/4 Jam nut onto rod end. Install male rod end all the way inside the threaded end of each control arm. Check for damage on threads of rod end and clean or file as necessary to ensure smooth rotation/adjustment of the rod end prior to assembly. Insert MO3515 bushings and SLE10091 sleeves into large eyelet of control arms. Grease zerks are pre-installed to allow lubrication to the bushings. Fig Rotate the Male rod end counterclockwise to expose approx 1/8 of threads prior to installing control arm on vehicle. Final length adjustments of the control arm will need to be made after vehicle is road tested. Insert # High Mis-Alignment spacers on both side of rod end opening. Install front lower control arms to the axle using the factory hardware at the axle. Install control arm to the front side skid mounting point using 9/16 x 4 Gr.8 bolts. After all adjustments are performed, apply final torque to the 1-1/4 jam nuts. Fig.36 Install front drive shaft. Installing New Front Brake Lines 1. Remove factory brake bracket from the frame and replace with new FTS brake line brackets. Install # Front Right & Left (same as Left Rear) Brackets. Fig.37 Insert brake line through hole in bracket and secure with new Brake line retaining clip. Clip must be lightly tapped into place with a small ball peen hammer. Installing New Front Sway Bar Quick Disconnect Links & Track Bar 1. Sway bar disconnect links are pre-assembled. Remove CA1005 upper bracket and install onto the sway bar as shown in Fig.38 Rotate bracket and secure button head bolt using an allen wrench. Install disconnect links to bracket and secure to lower factory bracket using factory hardware. Return vehicle to flat level pavement and attach front adjustable Trac Bar to the frame. Axle must be centered under the vehicle for easy installation of the Track Bar. Install using 1/2 x 3.5 Bolt, nut, and washers. Torque Track bar bolt to 75lb./ft. Fig.38 Fig.37 IMPORTANT: Optional weld-on front sway bar link extensions are included in this system. Fig.38 shows the optional weld-on sway bar link extensions in place. To install, trim factory brackets approx 50% in half. Weld new extensions In place. Extensions move the location of the sway bar link and allow full steering mobility. See photo on next page

15 Basic Specifications Chart Rear CV Drive Shaft & Slip Yoke Eliminator Jeep TJ After installation of this system, the installer must measure for the correct length rear CV drive shaft. A short shaft adapter (SYE) is required for all Jeep TJ s equipped with a factory NP231transfer case. There is NO front drive shaft modification required on models. Front Drive Shaft Diameter Reduction modification to factory drive shaft may be required. Jeep uses at least 3 different diameter front drive shafts for the TJ. Length of front shaft with 6 lift does not change. To eliminate front drive shaft from hitting the skid plate, maximum outside diameter (O.D.) of the front drive shaft should not exceed 1.5 inches. Typical Rear CV Drive Shaft & Slip Yoke Eliminator Grease Zerks Grease all zerk fittings on the control arms and rear upper v-link prior to driving vehicle. Periodically grease the zerks after each hard use. Most squeaks coming from the suspension is a sign of dry bushings. Typical Exhaust Routing Exhaust Modification Custom fabricated type required. Exhaust must be custom built to allow proper clearance of all suspension components during articulation. Small catalytic converters and turbo type mufflers are available from major manufacturers. Exhaust may exit out either the left or right rear area. Shock Absorbers 6 Full-Traction Long Arm Suspension Optional Weld-on Bracket Shock Absorber Length Chart Vehicle Length Axle Jeep TJ Front Extended Dana Jeep TJ Rear Extended Dana Rubicon Front Extended Dana Rubicon Rear Extended Dana 44 NOTE: Length of all shocks is critical. There are NO EXCEPTIONS to extended length allowed from the listed shock sizes. Full-Traction Suspension is not responsible for breakage, damage or abuse to any installed component due to improper installation or misapplication of components. 13.

16 Full Traction Limited Warranty Place Warranty Sticker Here WARRANTY About our warranty Full Traction components may have minor finish damage to powder coated or plated surfaces which may occur during shipping and is not covered under warranty. Full Traction Suspension warrants each new Full Traction Component against factory defects in material and workmanship for 1 year after date of purchase. Full Traction Suspension systems are sold as complete systems and must be installed as such per Full-Traction installation instructions. Any substitutions of other manufacturers components or exemptions of required components will immediately void the warranty. Full-Traction suspension guarantees that all of its products are of the finest quality and free from manufacturing defects. Any product that has been manufactured incorrectly or is of a defective nature will be repaired or replaced at the discretion of Full-Traction Suspension. Returns: Only after written or verbal approval, send such part(s) and proof of purchase, via prepaid freight with an RGA (Return Goods Authorization) number to: Full-Traction Suspension 6951 McDivitt Dr. Bakersfield Ca USA. Shipments without an RGA number clearly designated on the outside of all containers or collect shipments will be refused. To obtain RGA(s) call 661/ What is not covered Suspension and steel fabricated components: Limited (12) month warranty excluding the following items: Tie rod ends, bushings, hardware, brake lines, heim joints. These parts are subject to wear and are not considered defective when worn. They are warranted for 90 days from the date of purchase for defects in workmanship. Shock absorbers are covered under our limited warranty. Products or components installed on vehicles other than those specifically indicated in the Full-Traction Suspension catalog or website. Products or components which have been subjected to abuse, accident, alteration, modification, improper installation, tampering, negligence, misuse, or products installed on a vehicle used in sanctioned racing events. A race is defined as any contest between two or more vehicles, or any contest of one or more vehicles against the clock, whether or not such contest is for a prize. This warranty does not include vehicles used for government or commercial purposes. Full Traction does not warrant any product not manufactured by Full Traction Suspension. Full Traction Suspension products are not covered under warranty outside the United States of America. Full Traction Suspension shall not be liable for any loss, damage, or injury, whether ordinary, direct, special, incidental or consequential damages, arising from the manufacture, sale, installation, re-sale, delivery, possession, handling or use of its products. Full Traction Suspension is not responsible for typographical errors either in pricing or in content. Warranties, policies, and prices subject to change without notice. Installer s Safety Warning Full-Traction Suspension recommends our products to be installed by certified technicians only. These recommendations pertain only to Full-Traction Manufactured Products. Efforts to install our system without experience and knowledge may jeopardize the operating safety of the vehicle. Detach and mail or fax to the address below Name Phone Number ( ) WARRANTY FORM Address City State Zip Products Purchased from: Date Purchased Installed By Date Installed Vehicle make Model Year Installation Comments Product Part Number Description: FTS JEEP TJ 6in Long Arm Suspension System WARRANTY FORM Mail or Fax To: Full Traction Suspension 6951 McDivitt Dr Bakersfield Ca Warranty Registration Number Fax: Printed in U.S.A. Full-Traction Suspension 2005