PRO COMP SUSPENSION K3098B/K3098BFR/K3098BP 55747B/55747BFR/55747BP 2007-2014 6 inch 4WD Jeep Wrangler JK 4 Door Stage 3 Long Arm Lift Kit Fits w/ Automatic & Manual Trans. 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.
Box 1-PN 55747B-1 Part # Description Qty Illus. Page 91-5161 BELLY PAN 1 7 12 91-5164 CROSSMEMBER/ BELLY PAN BRACE : Drvr 1 6 11 91-5165 CROSSMEMBER/ BELLY PAN BRACE : Pass 1 6 11 90-3946 1/2 NUT PLATE 2 6 11 15-11309 FRONT BUMPSTOP 2 - - Box 2-PN 55747B-2 90-4291 KNUCKLE 1 - - 90-6529 HARDWARE PACK: Jeep Cam Kit 1 - - 73-01410940 14MM FLAT WASHER 1 9 13 72-01415008812 14MM- 1.5 NUT 1 9 13 90-3245 NOTCHED CAM 1 9 13 91-5166 FRONT TRACK BAR BRACKET 1 9 13 90-5169 NUT PLATE: Front Track Bar Bracket 1 9 13 90-6651 HARDWARE PACK: Front Track Bar Bracket 1 - - 70-0311001800 5/16 1 GR.8 HEX BOLT 2 9 13 73-0310830 5/16 SAE WASHER 2 9 13 90-2648 SLEEVE: Front Track Bar Bracket 1 9 13 91-2845 DRAG LINK 1 8 12 90-6644 HARDWARE PACK: 1 - - 90-4185 JAM NUT 1-18 2 8 12 90-4199 JEEP TIE ROD 1 8 12 Box 3-PN 55747B-3 7530 BRAKE LINE KIT 2 12 15 90-6645 HARDWARE PACK: Brake Line Bracket Front 1 - - 90-5170 JK FRONT BRAKE LINE BRACKET: Drvr 1 12 15 90-5171 JK FRONT BRAKE LINE BRACKET: Pass 1 12 15 90-6646 HARDWARE PACK: Brake Line Bracket Rear 1 - - 90-5172 JK REAR BRAKE LINE BRACKET: Drvr 1 25 24 90-5173 JK REAR BRAKE LINE BRACKET: Pass 1 25 24 91-8152 FRONT UPPER ARM 2 4,5 10,11 90-6553 HARDWARE PACK: Front Upper Arm 1 - - JMX12T 3/4 ROD END 2 4 10 SJNR12 3/4 STEEL R.H. JAM NUT 2 4 10 90-2449 HEIM SPACER 4 4 10 91-7167 FRONT UPPER ARM MOUNT: Drvr 1 3,4 10 2
Part # Description Qty Illus. Page 91-7171 FRONT UPPER ARM MOUNT: Pass 1 3,4 10 90-6632 HARDWARE PACK: Upper Arm Mount 1 - - 70-0501251800 1/2 X 1 1/4 HEX BOLT GR 8 2 3 10 70-0501501800 1/2 X 1 1/2 HEX BOLT GR 8 4 3 10 73-05000034 1/2 HARDENED FLAT WASHER 8 3 10 72-050100516 1/2 STOVER NUT GR. C 2 3 10 70-0563001800 9/16 X 3 HEX BOLTS GR 8 2 4 10 72-056100816 9/16 STOVER NUTS GR 8 2 4 10 73-05600830 9/16 SAE WASHERS GR 8 4 4 10 90-3719 REAR BUMPSTOP LOCK PLATE 2 22 22 90-6536 HARDWARE PACK: Rear Bump Stop Lock Plate 1 - - 70-05001751800 1/2" X 1 3/4" GR. 8 HEX BOLT 2 22 22 73-05000830 1/2" SAE FLAT WASHER 2 22 22 72-050100812 1/2" NYLOCK NUT 2 22 22 90-4149 REAR BUMPSTOP EXTENSIONS 2 22 22 91-2847 REAR SWAY BAR END LINK 2 24 23 90-6042 HARDWARE PACK: Front Sway Bar End Link 1 - - 45359 5/8 RUBBER HOURGLASS BUSHING 4 10 14 60859H 5/8 SLEEVE: OD X 12MM ID X 1.480 4 10 14 90-6660 HARDWARE PACK: Rear Sway Bar End Link/Extension 1 - - 90-2889 THREADED SLEEVE: Upper 2 22 24 90-6661 HARDWARE PACK: 1 - - 70-0501001409 1/2 X 1 BUTTON HEAD BOLT: Upper 4 22 24 73-05000839 1/2 AN GR. 8 FLAT WASHER: Upper 8 22 24 600026 3/4 BUSHING: Upper 2 - - 600006 5/8 BUSHING: Lower 2 22 24 60859H SLEEVE: 5/8"X 12MM X 1.480: Lower 2 22 24 91-7158 JEEP SWAY BAR END LINK: Front 2 10,11 14 90-6526 HARDWARE PACK: Sway Bar 1 - - 71-120601751000 12MM-1.75 X 60MM 10.9 HEX BOLT 4 - - 72-12175816 12MM-1.75 STOVER NUT 4 - - 73-01200030 12MM FLAT WASHER 8 - - 90-6547 HARDWARE PACK:Sway Bar Quick Disconnect 1 - - 90-2593 QUICK DISSCONNECT PIN 2 11 14 72-050200812 1/2"-20 NYLOCK NUT 2 11 14 73-05000034 1/2" SAE FLAT WASHER 2 11 14 73-06200034 5/8" SAE FLAT WASHER 2 11 14 90170A212 LOCKING PIN 2 11 14 90-6319 HARDWARE PACK: Zip Ties 1 - - 10999 ZIP TIE, 11", BLACK 12 - - 90-6681 HARDWARE PACK: Front Shock Relocation Brackets 1 - - 91-5385 SHOCK RELOCATION BRACKET-drvr 1 - - 91-5386 SHOCK RELOCATION BRACKET-pass 1 - - 90-2011 SPACER: 1 X 1/2 X 1 1/2 2 - - 3
Part # Description Qty Illus. Page 90-6682 HARDWARE PACK: Relocation Bracket 1 - - 70-0504501800 1/2 X 4 1/2 HEX BOLT GR 8 2 - - 72-050100816 1/2 STOVER NUT GR. C 2 - - 73-05000042 1/2 HARDENED FLAT WASHER 4 - - 70-0381251800 3/8 X 1 HEX BOLT GR 8 3 - - 72-038100816 3/8 STOVER NUT GR. C 3 - - 73-03800042 3/8 HARDENED FLAT WASHER 6 - - 70-0251001800 1/4-20 X 1 HEX BOLT GR 8 2 - - 72-025100816 1/4-20 STOVER NUT GR. C 2 - - 73-02500042 1/4-20 HARDENED FLAT WASHER 4 - - 90-3946 NUT PLATE: Front Upper Arm Mount 2 3 10 90-6502 HARDWARE PACK: Front Upper Arm Mount 1 - - 70-0501251800 1/2 X 1 1/4 HEX BOLT GR 8 2 3 10 73-05000830 1/2 GR 8 FLAT WASHER 2 3 10 Box 4-PN 55747B-4 91-5841 REAR TRACK BAR RELOCATION BRACKET 1 20 20 13-90496 U-BOLT: Rear Track Bar Relocation Bracket 1 20 20 72-050100816 1/2 STOVER NUT GR. C 2 20 20 73-05000034 1/2" SAE FLAT WASHER 2 20 20 90-6722 HARDWARE PACK: Rear Track Bar Bracket 1 - - 70-0563251800 9/16" X 3 1/4" GR. 8 HEX BOLT 1 20 20 72-056100816 9/16" GR. C STOVER NUT 1 20 20 73-05600830 9/16" SAE FLAT WASHER 2 20 20 70-0371001800 3/8" X 1" GR. 8 HEX BOLT 2 20 20 72-037100816 3/8" GR. C STOVER NUT 2 20 20 73-03700830 3/8" SAE FLAT WASHER 4 20 20 90-6529 HARDWARE PACK: Jeep Cam Kit 1 - - 73-01410940 14mm FLAT WASHER 1 20 20 72-01415008812 14mm- 1.5 NUT 1 20 20 90-3245 NOTCHED CAM 1 20 20 90-3718 CAM BOLT 1 20 20 90-2650 SPACER: Rear Track Bar Relocation Bracket 1 20 20 90-2867 SPACER: Rear Track Bar Drop Bracket 1 20 20 90-6524 HARDWARE PACK: Front Track Bar 1 - - 70-0311001800 5/16 X 1 GR. 8 HEX BOLT 3 9 13 72-031100816 5/16 STOVER NUT 3 9 13 73-03100830 5/16 SAE FLAT WASHER 6 9 13 91-5185 REAR TRACK BAR DROP BRACKET 1 21 21 90-6627 HARDWARE PACK: Track Bar Drop Rear 1 - - 70-0563001800 9/16 X 3 HEX BOLT GR 8 1 21 21 72-056100516 9/16 STOVER NUT GR. C 1 21 21 73-05600034 9/16 SAE HARDENED FLAT WASHER 2 21 21 70-0502251800 1/2 X 1 1/4 HEX BOLT GR 8 2 21 21 4
Part # Description Qty Illus. Page 72-043100816 1/2 STOVER NUT GR. C 2 21 21 73-05000034 1/2 HARDENED FLAT WASHER 4 21 21 91-5189 REAR UPPER SHOCK MOUNTS 2 24 23 90-6629 HARDWARE PACK: Rear Upper Shock Mount 1 - - 70-0502751800 1/2 X 2 3/4 HEX BOLT GR 8 2 24 23 72-050100516 1/2 STOVER NUT GR. C 2 24 23 73-05000838 1/2 HARDENED AN FLAT WASHER 4 24 23 90-6628 HARDWARE PACK: Emergency Brake Drop 1 - - 70-0504001800 7/16 X 4 HEX BOLT GR 8 1 26 24 72-043100816 7/16 STOVER NUT GR. C 1 26 24 73-0430830 7/16 SAE FLATWASHER 2 26 24 90-5193 EMERGENCY BRAKE RELOCATION BRACKET 1 26 24 90-3946 NUT PLATE: (3) Rear Lower Arm Mount/ (4) Front Upper Arm Mount 7 3,16,18 10,18,19 90-5194 NUT PLATE DUAL: Rear Lower Arm Mount 2 16,18 18,19 91-5195 REAR LOWER ARM MOUNT: Drvr 1 17,18 18,19 91-5198 REAR LOWER ARM MOUNT: Pass 1 16 18 90-6633 HARDWARE PACK: Lower Arm Mount 1 - - 70-0501501800 1/2 X 1 1/2 HEX BOLT GR 8 5 16,18 18,19 73-05000034 1/2 HARDENED FLAT WASHER 5 16,18 18,19 70-0564001800 9/16 X 4 HEX BOLT GR 8 2 16,18,19 18,19 73-05600830 9/16 SAE WASHER GR 8 2 16,18,19 18,19 91-2868 REAR UPPER ARM 2 15 17 90-6647 HARDWARE PACK: Rear Upper Arm 1 - - JMX-12T HEIM 2 15 17 SJNR12 3/4 STEEL R.H. JAM NUT 2 15 17 90-4187 ROD END SPACER: Rear Upper Control Arm 4 15 17 90-6648 HARDWARE PACK: Rear Upper Arm 1 - - 15-11325 BUSHING 4 15 17 90-2871 SLEEVE 2 15 17 91-5201 REAR LOWER ARM: Drvr 1 18,19 19 91-5207 REAR LOWER ARM: Pass 1 16,19 18,19 90-6649 HARDWARE PACK: Rear Lower Arm 1 - - JMX-14T 7/8 ROD END 2 19 19 90-4153 HIGH MISALIGNMENT SPACER 4 19 19 90-6544 HARDWARE PACK: Rear Lower Arm 1 - - 15-10979 BUSHING 4 19 19 90-2665 SLEEVE 2 19 19 90-6552 HARDWARE PACK: Lower Control Arm Pinch Clamp 1 - - 70-0311751800 5/16" X 1 3/4" GR.8 HEX BOLT 4 19 19 72-031100816 5/16" GR. C STOVER NUT 4 19 19 5
Part # Description Qty Illus. Page 73-03100830 5/16" SAE WASHERS 8 19 19 90-6630 HARDWARE PACK: Rear Sway Bar Extension Brackets 1 - - 71-120701751000 12mm-1.75 X 70mm HEX BOLT GR 10.9 Not Used 2 - - 71-120401751000 12mm-1.75 X 40mm HEX BOLT GR 10.9: Top 2 23 23 73-01200030 12mm SAE FLAT WASHER ZINC (4) Not Used 8 23 23 72-12175816 12mm-1.75 STOVER NUT GR. C (2) Not Used 4 23 23 90-6652 HARDWARE PACK: Rear Sway Bar Extension Brackets 1 - - 90-5229 SWAY BAR ADAPTER INNER BRACKET 2 23 23 90-5230 SWAY BAR ADAPTER OUTER BRACKET 2 23 23 90-5231 SWAY BAR ADAPTER BRACKET SPACER 2 23 23 Box 5-PN 55747B-5 91-7786 TRANSMISSION CROSSMEMBER 1 1 9 20-65227 HARDWARE PACK: Front Lower Arm Cam s 1 - - 73-01410940 12mm-1.75 FLAT WASHER 4 4 10 72-1415008812 12mm-1.75 NYLOC NUT 2 4 10 90-3245 NOTCHED CAM 2 4 10 90-3881 CAM BOLT 2 4 10 90-6631 HARDWARE PACK: Belly Pan 1 - - 70-0501251806 1/2 X 1 1/4 GR. 8 COUNTER SUNK BOLTS 10 6,7 11,12 70-0563751800 9/16 X 3 3/4 HEX BOLTS GR 8 2 4 10 72-056100816 9/16 STOVER NUTS GR 8 2 4 10 73-05600830 9/16 SAE WASHERS GR 8 4 4 10 91-5220 FRONT LOWER ARM: Drvr 1 4,5 10,11 91-5226 FRONT LOWER ARM: Pass 1 4,5 10,11 90-6544 HARDWARE PACK: Lower Arm 1 - - 15-10979 BUSHING 4 5 11 90-2665 SLEEVE 2 5 11 90-6649 HARDWARE PACK: Lower Arm 1 - - JMX-14T 7/8 ROD END 2 4 10 90-4153 MISALIGNMENT SPACER 4 4 10 FOLLOWING PARTS ARE USED IN CONJUNCTION WITH THIS KIT. THEY ARE PACKAGED AND MUST BE ORDERED SEPARATELY. SPRING & SHOCK OPTIONS: 55617 JEEP JK FRONT 6 COIL SPRING 1 - - 55417 JEEP JK REAR 4 COIL SPRING 1 - - 929511 ES9000 SERIES FRONT SHOCK 2 - - 929504 ES9000 SERIES REAR SHOCK 2 24 23 OR 55577 FOX FRONT AND REAR SHOCK BOX 1 24 23 JTB402 FRONT ADJUSTABLE TRACK BAR 1 9,13 13,15 DRIVESHAFT OPTIONS: 55837B CV FRONT DRIVE SHAFT (2 & 4 DOOR) 6 1 - - 55767B NON CV REAR DRIVE SHAFT (4 DOOR) 1 - -
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-toframe 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 and 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 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. PLEASE NOTE: Due to differences in manufacturing, dimensions and inflated measurements, tire and wheel combinations should be test fit prior to installation. Tire and wheel choice is crucial in assuring proper fit, performance, and the safety of your Pro Comp equipped vehicle. For this application, we recommend a minimum of a 17 wheel not to exceed 10 in width with a minimum backspacing of 4 1/2 must be used. Additionally, quality tire of radial design, not exceeding 35 tall X 12.50 wide is also recommended. Please note that the use of a 37 X 12.50 tire may require wheel well modification. Violation of these recommendations will not be endorsed as acceptable by Pro Comp Suspension and will void any and all warranties either written or implied. Optional Equipment Available from your Pro Comp Distributor! JK LIGHT BAR: 237000 STEERING STABILIZER KIT: 222580 DUAL STEERING STABILIZER KIT: 222586 Also, check out our outstanding 7 selection of Pro Comp tires to compliment your new installation!
1. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or 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: FRONT INSTALLATION: LR: RF: RR: 3. Place the vehicle in neutral. Place your floor jack under the front axle and raise the vehicle. Place jack stands under 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 the front track bar and remove it from the vehicle. Save the hardware for reinstallation. 6. Using the appropriate tool, remove the outer tie rod end nut. Separate using the appropriate tool. Save nut for reinstallation. 7. Loosen the drag link adjustment collar and unthread the drag link from the collar. 8. Unbolt and remove the front sway bar end links from the vehicle. Save the hardware for reuse. 9. Unbolt and remove the front sway bar from the vehicle. Save the hardware for reinstallation. 10. 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. 11. Unbolt the ABS mounting clips from the vehicle. 12. Remove the OE bump stops from the bump stop mounting cup. Unplug the ABS wires at the frame. 13. 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. COMPLETE STEPS 14 THROUGH 25 ON THE PASSENGER SIDE ONLY! 14. Unbolt the brake caliper from the knuckle and secure it clear from the work area. DO NOT let the caliper hang by the brake line or damage may result. 15. Remove the front rotor from the front hub. 16. Unbolt the three uni-bearing retaining bolts from the back of the knuckle. 17. Unbolt the ABS sensor from the hub. 18. Carefully remove the hub, axle and dust cover assembly from the front axle. 19. Remove the cotter pin from the upper and lower ball joints. Loosen the upper and lower ball joint retaining nuts. Separate the ball joints using the appropriate tool and remove the retaining nuts. Save the nuts for reuse. 20. Remove the knuckle from the front axle. This parts will not be reused. 21. Raise the new Pro Comp knuckle (90-4291) into place and secure it in place to the upper and lower ball joints using the OE nuts. 22. Torque the ball joint nuts to factory specifications. 23. Reinstall the OE hub, ABS sensor, axle and dust cover into the front axle. Secure the unibearing to the knuckle using the previously removed retaining bolts. Torque the unibearing bolts to 75 ft./lbs and the ABS sensor to 34-50 ft./lbs.. NOTE: The ABS sensor must be reinstalled to the hub before the hub is installed into the knuckle. 24. Install the front rotor on to the front hub. 8
Frame Front lower Control Arm Mount Illustration 2 Front Control Arm Mount Cutting OE s Transmission Crossmember 91-7786 Front Upper Control Arm Mount Illustration 1 Transmission Crossmember Install OE s 9 25. Reinstall the brake calipers to the new knuckle using the previously removed OE bolts. Torque to the bolts to 125 ft./lbs. 26. Remove the (2) front bolts that secure the gas tank skid plate to the vehicle. 27. Support the transmission and transfer case with a jack and remove the (3) transmission mount nuts. Unbolt the (4) bolts holding the crossmember in place and remove it from the vehicle. Save the hardware for reinstallation. 28. Temporarily raise the crossmember (91-7786) into place and secure with the previously removed OE bolts. See ILLUSTRATION 1. Carefully bend the gas tank skid plate out of the way, where it contacts the crossmember. Mark or use the bend as a guide to trim the gas tank skid plate. 29. Unbolt and remove the crossmember (91-7786). Using a suitable cutting tool, (abrasive cutoff wheel, Sawz-all, etc.) trim the gas tank skid plate according to the previously applied marks. After cutting, sand the area smooth. Clean the area thoroughly and paint the exposed metal with a good quality paint. IMPORTANT!: Be very careful not to cut into the gas tank or any fuel or brake lines. IMPORTANT!: DO NOT trim off the gas tank skid plate forward mounting bolt points. 30. Install the new transmission crossmember (91-7786), into the original transmission crossmember position, using the previously removed OE bolts and hardware. See IL- LUSTRATION 1. Torque to 90 ft./lbs. 31. Secure the transmission to the crossmember using the (3) previously removed OE nuts. Torque to 15 ft./lbs. 32. On the passenger side, with the axle supported, remove the passenger side upper and lower control arm from the vehicle. NOTE: Be sure to leave the driver side
Front Upper Control Arm Bracket 91-7167 and 91-7171 pass Nut Plate 90-3946 90-3245 Cam 90-3881 Cam Transmission Crossmember 91-7786 5/16 X 1 3/4 Pinch Clamp Front Upper Control Arm Bracket 91-7167 and 91-7171 pass Illustration 4 Front Control Arm Install Front Upper Control Arm Mount (2) 90-2449 Misalignment Spacer 1/2 X 1 1/4 1/2 X 1 1/2 Illustration 3 Front Upper Control Arm Mount JMX12T Rod End 1/2 X 1 1/4 (2) 90-4153 Misalignment Spacer JMX14T Rod End Lower Control Arm 91-5220 drvr and 91-5226 pass 9/16 X 3 s Upper Control Arm 91-8152 10 control arms in place to keep the front axle from rolling over 33. Using a suitable cutting tool, (abrasive cutoff wheel, Sawz-all, etc.) cut off the front lower arm mounting pocket as shown in ILLUS- TRATION 2. After cutting the lower arm mounting pockets, sand the frame smooth. Clean the area thoroughly and paint the exposed metal with a good quality paint. IMPORTANT!: Be sure not to cut into fuel or brake lines. DO NOT cut into the frame rail. This will weaken the frame structure considerably. NOTE: The lower mount is made of multiple pieces laminated to the frame. All of the lower mount needs to be removed to expose the bare frame. 34. Using a suitable cutting tool, (abrasive cutoff wheel, Sawz-all, etc.) trim off a portion of the front upper control arm mounting pocket as shown in ILLUSTRATION 2. After trimming the upper control arm mounting pocket, sand the cut area smooth. Clean the area thoroughly and paint the exposed metal with a good quality paint. IMPORTANT!: Be sure not to cut into fuel or brake lines. DO NOT cut into the frame rail. This will weaken the frame structure considerably. 35. Install the upper control arm mount bracket (91-7167 drvr and 91-7171 pass) to the existing (previously modified) upper control arm bracket. Secure to the OE mount using the supplied 1/2 X 1 1/4 bolt and hardware in the front hole. See ILLUSTRATION 3. 36. Secure the rear of the bracket in place using the supplied (2) 1/2 X 1 1/2 bolts, (2) 1/2 X 1 1/4 bolts, hardware and (3) nut plates (90-3946) in the existing holes in the frame. See ILLUSTRATION 3. 37. Install the rod end (JMX12T) into the end of the front upper arms (91-8152) with the jam nut (SJNR12) as shown in ILLUSTRATION 4. Adjust the arm length according to the arm
OE Axle Illustration 5 Front Control Arm Install Upper Control Arm 91-8152 OE OE 90-2665 Sleeve 15-10979 Bushings length chart on page 26 and tighten the jam nut. 38. Insert the spacers (90-2449) into the rod end. See ILLUSTRATION 4. 39. Install the clevis end of the upper arm to the bushings on the front axle using the previously removed OE hardware. See ILLUS- TRATION 5. 40. Install the rod end of the upper arm to Transmission Crossmember 91-7786 Lower Control Arm 91-5220 drvr and 91-5226 pass Illustration 6 Crossmember/Belly Pan Brace Install the mounting pockets on the frame using the supplied 9/16 X 3 bolts and hardware. See ILLUSTRATION 4. 41. Torque the OE upper control arm mounting bolts to 75 ft./lbs. and the supplied 9/16 bolts to 130 ft./lbs. 42. Insert the bushings (15-10979) and sleeve (90-2665), using a thin layer of lubricant, into the new front lower control arms (91-5220 drvr and 91-5226 pass) as shown in ILLUS- TRATION 4. 43. Install the rod ends (JMX14T) into the pinch clamp end of the lower arms. Install the pinch clamp 5/16 X 1 3/4 bolts and hardware. See ILLUSTRATION 4. Adjust the arm length according to the arm length chart on page 26 and tighten the jam nut. 44. Insert the (2) misalignment spacers per arm (90-4153) into the rod end. See ILLUSTRA- TION 4. 45. Install the rod end of the lower arm to the mounting pockets on the transmission crossmember (91-7160) using the supplied cam bolts (90-3881), cams (90-3245) and 12mm Transmission Crossmember 91-7786 1/2 X 1 1/4 Countersunk s Belly Pan Brace Plate 91-5164 and 91-5165 pass 1/2 X 1 1/4 Countersunk s 90-3946 Nut Plate 1/2 Drill Bit OE Belly Pan Brace Plate 91-5164 and 91-5165 pass OE 11
1/2 X 1 1/4 Countersunk s Illustration 8 Drag Link Assembly 90-4199 Tie Rod End 91-2845 Drag Link Transmission Crossmember 91-7786 91-5161 Belly Pan 90-4185 Lock Nut OE OE Hardware 90-4180 Knuckle OE Lock Collar Illustration 7 Belly Pan Install OE Tie Rod End Pitman Arm hardware from pack (20-65227). Be sure to install the cam bolts with the heads toward the inside of the vehicle. See ILLUSTRA- TION 4. NOTE: The cam assemblies have been provided for easier alignment of the lower control arms in the transmission crossmember. If your JK has a build date of 2010 or newer, rotate the cams toward the rear of the vehicle. This will be a good place to start for proper alignment. 46. Install the bushing end of the lower arms to the mounting pockets on the axle using the supplied OE bolts and hardware. See IL- LUSTRATION 5. 47. Torque the lower control arm OE mounting bolts to 125 ft./lbs. and the supplied cam bolts (90-3881) to 130 ft./lbs. 48. Repeat steps 32 through 47 on the remaining side of the vehicle. 49. Unbolt and remove the front driveshaft from the vehicle. Save the hardware for reinstallation. 50. Install the Pro Comp slip yoke front driveshaft kit (55837) into the vehicle. See enclosed driveshaft and yoke kit instruction manuals for reinstallation. 51. On the driver side, raise the crossmember/ belly pan brace into place (91-5164 drvr and 91-5165 pass) and secure with the previously removed OE lower bolt and the (2) supplied 1/2 X 1 1/4 countersunk bolts in the crossmember holes. See ILLUSTRATION 6. 52. Use the remaining hole in the brace as a guide to drill 1/2 holes in the frame. See ILLUS- TRATION 6. 53. Finish securing the brace to the frame using the 1/2 X 1 1/4 countersunk bolt and nut plate (90-3946). See ILLUSTRATION 6. 54. Repeat steps 51 Through 53 on the remaining side of the vehicle. 55. Raise the belly pan (91-5161) into place on 12
Illustration 9 Front Track Bar Relocation Bracket 5/16 X 1 Front Track Bar Cam Hardware 91-5166 Front Track Bar Relocation Bracket OE Track Bar Nut 90-5169 Nut Plate Support Arm Install Drill (2) Holes Using 5/16 Drill Bit Upper Control Arm Mount 5/16 X 1 90-3245 Cam OE track Bar Front Axle Front Track Bar Spacer 90-2648 the transmission crossmember. Secure the front of the belly pan using the (4) 1/2 X 1 1/4 countersunk bolts and hardware. See ILLUSTRATION 7. 56. Secure the rear of the belly pan (91-5161) using the (2) previously removed OE bolts. The passenger side rear mount will be secured by the fuel tank skid plate retaining bolt. See ILLUSTRATION 7. 57. Thread the supplied jam nut (90-4185) onto the tie rod until it is fully engaged. Thread the new tie rod (90-4199) into the new drag link (91-2845). See ILLUSTRATION 8. NOTE: There should be minimal threads showing when the tie rod is threaded in properly. 58. Thread the OE tie rod end and adjustment collar onto the remaining end of the drag link. See ILLUSTRATION 8. OE Track Bar Mount Pocket 59. Use the adjustment collar to adjust the length of the tie rod/drag link assembly. The entire tie rod/drag link assembly should measure 42 3/8 end to end. Lock the tie rods place with the supplied jam nut (90-4185) and by tightening the adjustment collar. See ILLUSTRA- TION 8. This will be a good start to be able to bring the vehicle to a qualified alignment shop. 60. Secure the OE tie rod end of the drag link assembly to the pitman arm using the previously removed retaining nut. Torque the nut to 77 ft./lbs. 61. Secure the supplied tie rod end of the drag link assembly to the knuckle using the previously removed nut. Torque the nut to 55 ft./ lbs. 62. Install the front track bar relocation bracket (91-5166) into the original track bar mount- 13
Illustration 10 Front Sway Bar End Link Assembly (Front) Sway Bar Link 91-7158 ing pocket using the OE bolt and supplied spacer (90-2648). See ILLUSTRATION 9. 63. Secure the track bar relocation bracket to the axle mounting pocket using the supplied 5/16 X 1 bolts and hardware. See ILLUS- TRATION 9. 64. Use the (2) holes in the support leg of the track bar bracket as a guide to center punch and drill the mounting holes in the axle upper control arm mount. Drill the holes using a 5/16 drill bit. See ILLUSTRATION 9. 65. the support leg of the track bar bracket to the upper control arm mount using the supplied 5/16 X 1 bolts, washers and nut plate Illustration 11 Lower Sway Bar Disconnect Install Sway Bar End Link 91-7158 Quick Disconnect Pin 90-2593 1/2 Hardware Lower Axle Mount Bushing 45359 Sleeve 60859 Lower Locking Pin 90170A212 Finished Lower Mount Inside of Vehicle 14 (90-5169). See ILLUSTRATION 9. 66. Torque the 5/16 hardware according to the torque chart on page 26 and the OE bolt to 125 ft./lbs. 67. Install the supplied front bump stops (15-11309) into the OE bump stop mounting cup. NOTE: To properly seat the newly installed bump stops, carefully lower the weight of the vehicle onto the bump stops. 68. Carefully lower the front axle to ease in the new coil spring installation. Using the factory isolators install the Pro Comp coil springs (55617) into the spring buckets and raise the front axle into place. Make sure the coil spring seats properly on the lower spring perch. 69. Assemble the front sway bar end links (91-7158) using the supplied bushings (45359) and sleeves (60859) from hardware pack (90-6042). See ILLUSTRATION 10. 70. On the driver side only, secure the quick disconnect pins (90-2593) to the factory lower sway bar mount location and the sway bar using the supplied 1/2 washers and 1/2 nylock nuts. See ILLUSTRATION 11. IMPORTANT: The sway bar mounted pin must face toward the outside of the vehicle and the axle mounted pin must face toward the inside of the vehicle. NOTE: The mounting hole on the sway bar may need to be drilled out to 1/2. 71. Slide the sway bar end link (91-7158) onto the quick disconnect pins and secure with the (2) locking pin 90170A212 and 5/8 washers. See ILLUSTRATION 11. 72. On the passenger side, install the front sway bar end link (91-7158) into original mounting bracket on the axle using the passenger side OE lower mounting bolt and hardware. 73. the remaining end of the sway bar end link to the front sway bar using the driver side OE lower sway bar mounting bolt. Torque the supplied hardware according to the torque
Brake Line Hardware OE Illustration 12 Front Brake Line Bracket Assembly chart on page 26 and the OE hardware to 75 ft./lbs. 74. Install the shock relocation brackets from hardware pack (90-6681) using the enclosed instruction manual. 75. Install the new Pro Comp front shocks (929511 w/shaft end up or FX6503 w/shaft end down) using the OE hardware on the top and the supplied 1/2 X 4 1/2 bolt, spacer (90-2011) and hardware from pack (90-6681) on the bottom. Torque the upper mounting Illustration 13 Track Bar Assembly (2) Bushing 15-11080 OE Metal Brake Line Frame Brake Line 7530 Front Brake Line Bracket 90-5170 drvr and 90-5171 pass Track Bar 91-2658 Sleeve 90-2443 Rod End JMX12T Jam Nut SJNR12 (2) Mono Ball Spacer 90-2449 OE Front Track Bar 15 hardware to 20 ft./lbs. and the lower hardware to 65 ft./lbs. 76. At the driver side, unbolt the brake line bracket from the frame rail. locate the rubber brake hose that runs from caliper to frame and detach it from the caliper and factory metal line. Plug or cover the caliper opening and remove the brake line from the vehicle. 77. Secure the supplied 90 degree brake line mounting bracket (90-5170 drvr and 90-5171 pass) to the frame using the previously removed OE bolt. Position the bracket so it is below the mounting bolt. See ILLUSTRA- TION 12. 78. Thoroughly clean all mating surfaces. At the upper end of the brake line (7530), insert the threaded end of the brake line from the bottom through the brake line mounting bracket (90-5170 drvr and 90-5171 pass). Install the supplied jam nut to the threaded end of the brake line and tighten the nut, securing it to the brake line bracket. Connect the new brake line (7530) to the existing frame metal brake line and tighten. See ILLUSTRATION 12. Install the brake line to the caliper using the factory banjo bolt and new crush washer. Torque the banjo bolt to 23 ft./lbs. Position the line so it doesn t make contact with any other parts. Make sure brake lines are clean and dry of any material before ABS brake bleeding. 79. Repeat on the remaining side of vehicle. BLEEDING OF THE BRAKE SYSTEM SHOULD BE DONE ACCORDING TO A JEEP FACTORY SERVICE MANUAL. IMPORTANT: BE VERY CAREFUL NOT TO LET THE MASTER CYLINDER RUN DRY! WITH ABS BRAKES THIS SITUATION WILL DAMAGE THE SYSTEM! IMPORTANT: Move the control arm assembly up and down to its limits several times to check for binding and to ensure that there are no interference or pinching problems with the brake lines and/or ABS wiring.
80. On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component. At full droop, cycle the steering from lock to lock while observing the reaction of these components. Reposition them if needed. 81. Reinstall the front wheels and lower the vehicle to the ground. Torque the lug nuts according to the wheel manufacturers recommendations. 82. Assemble the track bar (91-2658 from box JTB402) using bushings (15-11080) and sleeve (90-2443) into the track bar (91-2658). See ILLUSTRATION 13. 83. Loosely install the rod end (JMX12T) into the track bar with the jam nut (SJNR12) as shown in ILLUSTRATION 13. Adjust the arm length according to the arm length chart on page 26 and tighten the jam nut. 84. Insert the mono ball spacers (90-2449) into the rod end. See ILLUSTRATION 13. NOTE: The spacers are a tight fit. A press might be needed to fit the spacers into the rod end. 85. Install the bushing end of the track bar assembly into the passenger side axle track bar bracket (91-5166) using the supplied cam bolt (90-3245) and hardware. Torque this bolt to 103 ft. lbs. See ILLUSTRATION 9. 86. With the vehicle fully on the ground and the driver side of the track bar NOT attached, center the front differential to the vehicle chassis by measuring the clearance between each tire and inner fender. This is easier done with assistance. When the axle is centered, screw the rod end in or out until the OE bolt fits through bracket and rod end with ease. Install the bolt and nut plate. Torque the bolt to 125 ft./lbs. See ILLUSTRATION 13. 87. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or asphalt). 88. 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. 89. Unlock the ignition key and loosen the drag link adjustment collar. 90. Center the steering wheel by rotating the drag link counter clockwise until the steering wheel is centered. Re-torque the drag link adjustment collar to 26 ft./lbs. IMPORTANT!: If the steering wheel is not centered properly it will trigger the antilock brake and traction control warning lights. NOTES: On completion of the installation, have the suspension and headlights re-aligned. After 100 miles recheck for proper torque on all newly installed hardware. Recheck all hardware for tightness after off road use. 16
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 and remove it from the vehicle. Save the bar and 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. 5. Unbolt and remove the rear sway bar end links from the vehicle. 6. Unbolt and remove the rear driveshaft from the vehicle. Save the hardware for reinstallation. 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. Using a twisting motion remove the rear bump stops from the factory mounts. Save for reinstallation. 9. Unhook the emergency brake cables from the rear brake assembly. 10. Unclip from the underside of the vehicle and Illustration 14 Upper Control Arm Installation OE reroute the emergency brake cables so they run under the frame crossmember. NOTE: Pull the emergency brake and then clamp the cable in order to get enough slack. Release the emergency brake. Unclamp the cable and reinstall to the brake assemblies. 11. Work on one side of the vehicle at a time. 12. Unbolt the upper control arm and remove it from the vehicle. Save the hardware for reinstall. 13. Assemble the rear upper control arms (91-2868) using bushings (15-11325) and sleeves (90-2871). See ILLUSTRATION 14. 14. Install the rod end (JMX12T) into the remaining end of the rear upper arms (91-2868) with the jam nut (SJNR12) as shown in ILLUSTRA- TION 14. Adjust the arm length according to the arm length chart on page 26 and tighten the jam nut. 15. Insert the spacers (90-4187) into the rod end. See ILLUSTRATION 14. 16. Install the bushing end of the upper arm to the mounting pockets on the rear axle using the previously removed OE hardware. See ILLUS- TRATION 14. 17. Install the rod end of the upper arm to the mounting pockets on the frame Illustration 15 Lower Control Arm Mount Removal OE Nut Plate 90-4187 Spacers Frame Frame 91-2868 Upper Control Arm 15-11325 Bushings OE SJNR12 Jam Nut JMX12T Rod End Clean, Grind and Paint Frame Rear Lower Control Arm Mount 90-2871 Sleeve OE Nut 91-2868 Upper Control Arm 17
Illustration 16 Pass Rear Lower Control Arm Bracket Install 1/2 Drill Bit Frame Rear Lower Arm Bracket 91-5198 9/16 Drill Bit Fuel Tank Skid Plate OE Rear Lower Arm Bracket 91-5198 1/2 Drill Bit Hole in Frame Hole in Frame 1/2 X 1 1/2 Nut Plate 90-3946 1/2 X 1 1/2 Nut Plate 90-5194 91-5207 pass Lower Control Arm 9/16 X 4 Illustration 17 Drvr Rear Lower Control Arm Bracket Install 1/2 Drill Bit 11 1/8 11 1/8 9/16 Drill Bit Rear Lower Arm Bracket 91-5195 Access hole on Bottom of Frame 11 1/8 1/2 Drill Bit Rear Lower Arm Bracket 91-5195 18
Rear Lower Arm Bracket 91-5195 Illustration 18 Drvr Rear Lower Control Arm Bracket Install Hole in Frame 1/2 X 1 1/2 Hole in Frame Nut Plate 90-3946 9/16 X 4 1/2 X 1 1/2 91-5201 drvr Lower Control Arm 1/2 X 1 1/2 Nut Plate 90-5194 using the previously removed OE bolt and hardware. See ILLUSTRATION 14. 18. Torque the OE upper control arm mounting bolts according to 125 ft./lbs. 19. Starting on the passenger side, with the rear axle fully supported, unbolt and remove the rear lower arm from the vehicle. Save the hardware for reuse. Illustration 19 Rear Lower Control Arm Install OE 91-5202 drvr and 91-5207 pass Lower Control Arm 15-10979 Bushings 90-2665 Sleeve For Maximum Travel Measure up 1 and Trim Pocket 90-4153 Spacers 5/16 X 1 3/4 Pinch Clamp 9/16 X 4 JMX14T Rod End 20. Using a suitable cutting tool, (abrasive cutoff wheel, Sawz-all, etc.) cut off the front lower arm mounting pocket as shown in ILLUSTRA- TION 15. After cutting the lower arm mounting pockets, sand the frame smooth. Clean the area thoroughly and paint the exposed metal with a good quality paint. NOTE: For maximum travel, it may be necessary to trim 1 off the rear body mounts. See ILLUSTRATION 19. IMPORTANT!: Be sure not to cut into fuel or brake lines. DO NOT cut into the frame rail. This will weaken the frame structure considerably. 21. Unbolt the rear outer retaining bolt that secures the fuel tank skid plate to the frame. See IL- LUSTRATION 16. Save bolt for reinstallation. 22. Raise the pass side rear lower control arm mount bracket (91-5198) into place and secure to the frame using the previously removed OE skid plate retaining bolt. Clamp the bracket firmly in place against the frame. See ILLUS- TRATION 16. 23. Using the mounting holes in the bracket as a guide, drill the center control arm mounting bolt hole using a 9/16 drill bit. See ILLUSTRA- TION 16. 24. Drill the upper and front lower holes using a 1/2 drill bit. See ILLUSTRATION 16. 19
Illustration 20 Rear Track Bar Relocation Bracket Rear Track Bar Cam Hardware 13-90496 U- 91-5841 Rear Track Bar Relocation Bracket Rear Axle 90-3245 Cam 3/8 X 1 s OE Track Bar Mount Pocket Rear Track Bar Spacer 90-2650 9/16 X 3 1/4 1/2 U- Hardware 25. Secure the bracket to the frame using the 1/2 X 1 1/2 bolt, 9/16 X 4 bolt and the supplied dual nut plate (90-5194). Do not tighten the 9/16 bolt at this time. See ILLUSTRATION 16. 26. Secure the front lower bracket mounting hole to the frame using the supplied 1/2 X 1 1/2 bolt and nut plate (90-3946). See ILLUSTRATION 16. 27. On the driver side the bracket will be located on the frame by measuring 11 1/8 forward from the small square hole near the rear upper control arm mounting bolt. See ILLUSTRATION 17. NOTE: The bracket is contoured to fit perfectly against the overlap in the frame. 28. Raise the driver side rear lower control arm mount bracket (91-5195) into place and secure to the frame using C-clamps. See ILLUSTRA- TION 17. 29. Using the mounting holes in the bracket as a guide, drill the center control arm mounting bolt hole using a 9/16 drill bit. See ILLUSTRA- TION 17. 30. Drill the (1) upper and (2) lower holes using a 20 1/2 drill bit. See ILLUSTRATION 17. 31. Secure the bracket to the frame using the supplied 1/2 X 1 1/2 bolt, 9/16 X 4 bolts and the dual nut plate (90-5194). Do not tighten the 9/16 bolt at this time. See ILLUSTRATION 18. 32. Secure the (2) lower bracket mounting holes to the frame using the (2) supplied 1/2 X 1 1/2 bolts and (2) nut plate (90-3946). See ILLUS- TRATION 18. 33. Insert the bushings (15-10979) and sleeve (90-2665), using a thin layer of lubricant, into the new lower control arms (91-5201 rear drvr and 91-5207 rear pass) as shown in ILLUSTRA- TION 19. 34. Install the rod ends (JMX14T) into the pinch clamp end of the rear lower arms. Install the pinch clamp 5/16 X 1 3/4 bolts and hardware. See ILLUSTRATION 19. Adjust the arm length according to the arm length chart on page 26 and tighten the jam nut. 35. Insert the (2) misalignment spacers per arm(90-4153) into the rod end. See ILLUSTRATION 19.
OE 36. Install the rod end of the lower arms into the mounting pockets on the new rear lower arm bracket (91-5195 drvr and 91-5198 pass) using the supplied 9/16 X 4 bolts and hardware. See ILLUSTRATION 19. 37. Install the bushing end of the lower arms to the mounting pockets on the axle using the supplied OE bolts and hardware. See ILLUSTRATION 19. 38. Torque all OE lower control arm mounting bracket and arm mounting bolts to 125 ft./lbs. and the supplied 9/16 bolts to 130 ft./lbs. 39. Install the driver side rear track bar relocation bracket (91-5841) into the original track bar mounting pocket using the supplied 9/16 X 3 1/4 bolt and supplied spacer (90-2650). See ILLUSTRATION 20 40. 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 20. 41. Tighten the previously installed 9/16 and 3/8 hardware. 42. Install the U-bolt around the rear end axle tube and secure to the rear track bar relocation bracket (91-5841) using the supplied 1/2 washer and nut. See ILLUSTRATION 20 1/2 X 1 1/4 Rear Track Bar Illustration 21 Rear Track Bar Drop Install Track Bar OE Frame Mount 9/16 X 3 91-5185 Rear Track Bar Drop Bracket 21 43. Torque the 3/8, 1/2 U-bolt and 9/16 track bar hardware according to the torque chart on page 26. 44. Install the passenger side track bar drop bracket (91-5185) into the upper track bar mounting position using the previously removed OE bolt, hardware and sleeve (90-2867). See ILLUS- TRATION 21. 45. Secure the passenger side track bar drop bracket (91-5185) to the frame using the (2) supplied 1/2 X 1 1/4 bolts. See ILLUSTRATION 21. 46. Torque the 1/2 track bar drop hardware according to the torque chart on page 26 and the OE bolt to 125 ft./lbs. 47. Slide the 1/2 X 1 3/4 bolt through the center of the bump stop lock plate (90-3719). Install the lock plate assembly to the original bump stop frame mounting bracket. Secure using a 1/4 turn clockwise. See ILLUSTRATION 22. 48. Slide the rear bump stop extensions (90-4149) over the mounted lock plate assembly and secure using the supplied 1/2 hardware from pack (90-6536). Torque hardware to 35 ft./lbs. See ILLUSTRATION 22. 49. Reinstall the OE bump stop to the newly installed bump stop drop brackets. 50. Carefully lower the rear axle to ease in the new coil spring installation. Using the factory isolators install the Pro Comp coil springs (55417) into the spring buckets and raise the rear axle into place. Make sure the coil spring seats properly on the lower spring perch. NOTE: Be sure to reinstall the factory isolators before raising the springs into place. 51. Assemble the rear sway bar end links (91-2847) using the supplied bushings (600006 lower and 600026 upper) and sleeves (60859H lower and threaded sleeve 90-2889 upper) from hardware pack (90-6660). See ILLUSTRATION 23. 52. Install the rear sway bar end link (91-2847) into original mounting bracket on the axle using the supplied OE bolts. Torque to 75 ft./lbs. 53. Install the sway bar extension brackets (90-5229 inner and 90-5230 outer) to the sway bar using
Illustration 22 Rear Bump Stop Lock Plate Assembly 90-4149 Rear Bump Stop Extension 90-3719 Bump Stop Lock Plate Bump Stop Frame Mount Cup OE Bump Stop 1/2 X 1 3/4 1/2 Hardware the supplied square adapter spacer (90-5231) on the outside of the bracket, 12mm X 40mm bolt and hardware. See ILLUSTRATION 23. 54. the remaining end of the sway bar extension brackets to the sway bar end link (91-2847) using the supplied 1/2 X 1 button head bolts and 1/2 AN flat washer. Thread the 1/2 button head bolts and hardware into the threaded sleeve (90-2889). See ILLUSTRATION 23. 55. Torque the sway bar extension bracket hardware according to the torque chart on page 26. 56. Install the cross pin eliminator brackets (91-5189) into the upper shock mounting pocket using the previously removed OE bolts and hardware. Torque the upper mounting hardware to 37 ft./lbs. See ILLUSTRATION 24. 57. Install your new Pro Comp rear shocks (929504 w/shaft end up or FX6504 w/shaft end down) using the supplied 1/2 X 2 3/4 bolt and hardware in the upper mount and the OE bolt and hardware in the lower mount. Torque the upper mounting hardware according to chart on page 26 and the lower to 56 ft./lbs. 58. At the driver side, unbolt the brake line bracket from the frame rail. locate the rubber brake hose that runs from caliper to frame and detach it from the caliper and factory metal line. Plug or cover the caliper opening and remove the brake line from the vehicle. 59. Secure the supplied 90 degree brake line mounting bracket (90-5172 drvr and 90-5173 pass) to the frame using the previously removed OE bolt. Position the bracket so it is above the mounting bolt. See ILLUSTRATION 25. 60. Thoroughly clean all mating surfaces. At the upper end of the brake line (7530), insert the threaded end of the brake line from the bottom through the brake line mounting bracket (90-5172 drvr and 90-5173 pass). Install the supplied jam nut to the threaded end of the brake line and tighten the nut, securing it to the brake line bracket. Connect the new brake line (7530) to the existing frame metal brake line and tighten. See ILLUSTRATION 26. Install the brake line to the caliper using the factory banjo bolt and new crush washer. Torque the banjo bolt to 23 ft./lbs. Position the line so it doesn t make contact with any other parts. Make sure brake lines are clean and dry of any material before ABS brake bleeding. 61. Repeat on the remaining side of vehicle. BLEEDING OF THE BRAKE SYSTEM SHOULD BE DONE ACCORDING TO A JEEP FACTORY SERVICE MANUAL. 22
90-5231 Sway Bar Adapter Square Washer 90-5230 Sway Bar Adapter Outer Bracket Rear Sway Bar 90-5229 Sway Bar Adapter Inner Bracket Illustration 23 Rear Sway Bar Adapter Assembly 12mm X 40mm 1/2 X 1 Button Head 1/2 AN Washer 1/2 AN Washer 1/2 X 1 Button Head 91-2847 Rear Sway Bar End Link 600026 Bushing 90-2889 Threaded Sleeve IMPORTANT: BE VERY CAREFUL NOT TO LET THE MASTER CYLINDER RUN DRY! WITH ABS BRAKES THIS SITUATION WILL DAMAGE THE SYSTEM! IMPORTANT: Move the control arm assembly up and down to its limits several times to check for binding and to ensure that there are no interference or pinching problems with the brake lines and/or ABS wiring. Illustration 24 Cross Pin Eliminator Bracket Install Upper shock brackets Shock Install 91-5189 Cross Pin Eliminator Bracket 62. On both sides of the vehicle, check the routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component. Use the supplied zip ties and Adel clamps to secure these lines out of the way and to keep from contacting any moving parts. Reposition lines if needed. 63. Install the Pro Comp slip yoke rear driveshaft kit (55767) into the vehicle using the previously removed OE hardware. See enclosed driveshaft and yoke kit instruction manuals for reinstallation. 64. Install the assembled emergency brake line bracket (91-5193) and 7/16 X 4 bolt and hardware from pack (90-6628) through the existing hole in the rear crossmember. See IL- LUSTRATION 26. 65. Secure the emergency brake cables between the emergency brake line bracket (90-5193) and the rear crossmember. Do not over tighten this bolt. See ILLUSTRATION 26. 1/2 X 2 3/4 Shock OE s 66. Reinstall the rear wheels and lower the vehicle to the ground. Torque the lug nuts according to the wheel manufacturers recommendations. 23
Brake Line Hardware OE Metal Brake Line Illustration 25 Rear Brake Line Bracket Assembly 7/16 Hardware Illustration 26 Emergency Brake Line Bracket Install Frame Existing Hole Rear Crossmember OE Brake Line 7530 Rear Brake Line Bracket 90-5172 drvr and 90-5173 pass Emergency Brake Lines 91-5193 Emergency Brake Line Bracket 67. Install the OE rear track bar to the rear axle relocation bracket (91-5841) using the supplied adjustable cam bolt (90-3718) and hardware from hardware pack (90-6529). See ILLUS- TRATION 20. 68. Install the OE rear track bar to the rear frame relocation bracket (91-5185) using the supplied adjustable 9/16 X 3 bolt and hardware. Torque the 9/16 bolt according to the torque chart on page 26. See ILLUSTRATION 21. 69. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or asphalt). 70. Rotate the track bar cam bolt until the wheels are centered under the vehicle. 71. Torque the cam bolt to 103 ft./lbs. 72. 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. NOTES: On completion of the installation, have the suspension and headlights re-aligned. After 100 miles recheck for proper torque on all newly installed hardware. Recheck all hardware for tightness after off road use. 7/16 X 4 Final Install 24
SUGGESTED CONTROL ARM/TRACK BAR MEASUREMENT CHART Front Upper Arms 24 1/2 Lower Arms: 38.72 Upper Front Control Arm 90-8152 19 7/8 Rear Lower Control Arm 90-5201 drvr 90-5207 pass 37 7/8 Upper Rear Control Arm 90-2868 NOTE: When the arms are properly adjusted there will be 3-4 threads showing on the rod ends. Front Lower Control Arm 90-5220 drvr 90-5226 pass Front Track Bar 34.70 Front Track Bar (90-2658) 25
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REVISION PAGE: 3.29.11: Changed the part number for the transmission crossmember in box 5 from (91-5213) to (91-7160). Also added lower arm cam pack (20-65227) to box 5. 5.5.11: Changed the part numbers in box 3 for the front sway bar end link from (91-2008) to (91-7158). Changed the front upper arm mounts from (91-5175 drvr and 91-5179) to (91-7167 drvr and 91-7171) pass. Changed the front upper arm from (91-2864) to (91-8152). Changed Ill #25 to show the new upper arm and dimension. Removed (91-5182) and hardware pack (90-6340) from box 3 permanently. Changed all text and illustrations accordingly. Added Cam bolt note after step #45. Added (2) nut plates (90-3946) and hardware pack (90-6502) to box 3 BOM, installation text and illustration #3. 6.9.11: Updated Illustrations 10 &11 with the correct sway bar image (91-7158) 12.22.11: Updated kit fitment to include years up to 2011. Updated front transmission crossmember part number to (91-7786) in BOM box-5, text and illustrations. Removed notes and steps a-d after front install step 30. 8.30.12: Added (90-3718) cam bolt into hardware pack (90-6529) in BOM box-4. 4.12.14: Updated front install step 80 and rear install step 62. 8.18.14: Updated kit fitment box. 27
The PRO COMP PROMISE WARRANTY At Pro Comp, we know you have many choices when selecting products to personalize your vehicle. You should demand nothing but the highest quality available and have total confidence that the products you selected are the best in the industry. It is for these reasons that Pro Comp Suspension products are backed by the best warranty in the industry...the Pro Comp Promise! Pro Comp promises that its products will last a lifetime or we will replace it free of charge. It s that simple! Because of our commitment to quality and manufacturing excellence, we are able to stand behind our products. FOREVER. It is Pro Comp s Promise that if one of our suspension products breaks not due to misuse, neglect or vandalism, we will replace it. Whether you are the original purchaser or not, you can be assured that we will make it right. The Pro Comp Promise covers all suspension products including shocks and steering stabilizers. Buy Pro Comp Suspension today and enjoy it for the rest of your life! That s our Pro Comp Promise! 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. 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 that the Dealer / Installer explains and delivers all warning notices, warranty forms and instruction sheets included with Pro Comp product. Warranty and Return Policy: Pro Comp warranties its full line of products to be free from defects in workmanship and materials for the life of the product. 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 assume 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 * Parts subject to normal wear; this includes bushings, bump stops, ball joints, tie rod ends and heim joints. * Finish after 90 days. * Damage caused as a result of not following recommendations or requirements called out in the installation manuals. Pro Comp MX Series 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.