Warrior 30641 ’87-’96 Economy LIFT KIT (1987 – 1996 Jeep YJ Wrangler) - Manual (Page 2)

Protecting Your Adventure Lifestyle
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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
7. Prior to installation of new springs and shackles (#801490 Front - #801500 Rear), thoroughly lubricate the new spring
poly eye bushings and sleeves with “water resistant” lithium based grease. Loosely attach the spring (front spring
#800019) to its hangers, snug up but do not completely tighten yet. Make sure spring centering pin aligns and seas into
spring perch hole.
8. While re-installing your u-bolts, put one bump stop extension snubber on top of axle tubes. (Figure 1 shows how the
bump-stops are captured by the u-bolts). Tighten u-bolts to 65 ft. lbs. of torque. Tighten spring pivot bolts to 35ft. lbs. on
both frame mounts and shackle mounts.
9. Assemble and install new front shock absorbers Part #60501 (Boot installation and poly hourglass bushing installation
can made easier with the use of rubbing alcohol sprayed on the poly as a lubricant.). Tighten upper stem type mounts
only until bushings swell slightly, then torque lower mounts to 45 ft lbs.
10. Install tires/ wheels, remove jack stands and lower vehicle to floor. Tighten the front spring’s shackle to 95 ft. lbs. and
the stationary end to 105 ft. lbs. (If kit includes pitman arm, you may want to read the pitman arm instructions and install
the pitman arm before proceeding to rear of vehicle)
11. Once again as on the front (following same basic steps). Place safety (jack) stands under rear frame rails.
12. Install rear shackles.
13. Install new springs (#800020) with shims. (torque u-bolts 65 ft. lbs.) Remember to install the bump stop extension
snubber on as you did on the front. When installing the springs, the thick part of shim goes toward front of Jeep. Re-
attach tracking bar.
14. Assemble the rear shock absorbers (Part# 60502) with loop bushings and corresponding sleeves and install shocks.
Torque upper and lower mounts to 45-ft. lbs. On some models there may not be adequate clearance between the shock
body and the axle tube. In this situation your only option is to relocate the shock bracket.
15. Install tires, remove jack stands and lower vehicle to floor. Tighten the shackle to 95 ft. lbs. and the frame end to
105ftlbs.
16. Install Transfer Case Spacer Kit following instructions packaged with part #800006.
Figure 1