Warrior 30841 LIFT KIT (1997 – 2006 Jeep TJ Wrangler) - Manual (Page 3)

Protecting Your Adventure Lifestyle
========================================================================================
QUALITY • INTEGRITY • INNOVATION • SERVICE
Warrior, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone: (888) 220-6861
Fax: (503) 692-0364
[email protected]
www.warriorproducts.com
a guide, drill a 3/8” hole and install the new bolt, washers and lock nuts. Install the new 12mm x 65mm bolt, washers and
nut in the track rod on the lower mount and tighten.
14. Assemble the boots on the front shock absorbers and install in the factory lower mounts. Install the upper stud bushings
and tighten the upper mounting point. Tighten the bar pin on the bottom of the shock with the stock hardware. Repeat
this on the opposite side of the vehicle. Install the tires, wheels and lug nuts. Lower the vehicle to the ground.
15. Install the sway bar conversion mount (u-strap shaped bracket) on the sway bar where the stock link was secured,
using the supplied 3/8” x 1.75” bolt, washer and nylon lock nut . Install the bushings and 12mm sleeves provided in Bag
# 2 on the bottom of the link at this time and use the factory hardware to install. The upper sway bar bushings are in Bag
# 3. These are installed on the top of the sway bar link with the 12mm sleeves. These bushings are a little thicker than the
lower sway bar bushings. Install the upper part of the new link in the hoop bracket with the 12mm bolts & hardware See
Figure #3.
16. Tighten the lower suspension arm to frame bracket nut and bolt to 130 ft. lbs. (both sides).
17. Align the reference marks on the adjustment cams and lower arm axle
brackets and tighten to 85 ft. lbs.
Note: Longer brake lines are not required in the front with this kit unless the
sway bar is disconnected. If disconnects are used, longer brake lines are
required.
18. Chock the front wheels. Jack up the rear of the vehicle and remove the
tires and wheels. Place jack stands on the frame rail to support the
vehicle. Place a floor jack under the differential. Remove the stock
shock absorbers and sway bar links. Retain the factory shock hardware it
will be reused.
19. On the rear of the vehicle unbolt the track rod from the axle and secure
out of the way.
20. Carefully lower the axle with the floor jack and remove the coil springs.
NOTE: It may be necessary to use a coil spring or strut compressor to remove the stock coil springs. Be careful not
to overextend the vent tube on the axle. It may be necessary to disconnect the hose during installation and reroute the
hose after installation.
21. Disconnect the track bar from the axle bracket and install the new track
bar relocation bracket in the stock location. See Figure #4 and 5. Secure
to the stock location using the 2-5/16” x 1” long bolts, washers and nuts
as shown in the picture. NOTE: It may be necessary to enlarge the
holes at these locations. If this is the case drill these holes to
accommodate the 5/16” bolts. Install the _” x 1 _” bolt washers and nut
in the stock track rod bolt location and tighten. Refer to the pictures to the
right.
Do not install the track rod in the new bracket at this time.
22. Remove and replace one suspension arm at a time. Remove the lower
arm axle and frame mount bolts. Remove the lower arm. Install new
lower arm to the frame and axle brackets. Use the original hardware but
do not tighten at this time. Then repeat these steps on the other side.
Note: The part of the arm with the slight bend in it will install on the axle
mount
23. Install the new coil springs making sure that the rubber damper is
positioned in the upper mount. It will be necessary to use a coil spring
compressor to install the new coil springs. Jack up the axle to compress
the coil spring and to align the track rod with the new mounting point and
install the stock mounting hardware. See Figure 4 & 5 above.
24. Assemble shock with the shock bushings and sleeves in the shock bag on
the larger barrel end. Install the shocks on the vehicle with the factory
hardware.
25. Reinstall the wheels, tires. Lower the vehicle to the ground and tighten
the lug nuts to the factory torque specifications (80-110 ft-lbs.)
Figure 5
Figure 6
Figure
4