Warrior 30841 LIFT KIT (1997 – 2006 Jeep TJ 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
Figure 3
Bolt
Size Grade 5 Grade 8 Bolt Size Class 9.8 Class 10.9 Class 12.9
5/16 15 Ft – Lbs 20 Ft – Lbs M 6 5 Ft – Lbs 9 Ft – Lbs 12 Ft – Lbs
3/8 30 Ft – Lbs 35 Ft – Lbs M 8 18 Ft – Lbs 23 Ft – Lbs 27 Ft – Lbs
7/16 45 Ft – Lbs 60 Ft – Lbs M10 32 Ft – Lbs 45 Ft – Lbs 50 Ft – Lbs
_ 65 Ft – Lbs 90 Ft – Lbs M12 55 Ft – Lbs 75 Ft – Lbs 90 Ft – Lbs
9/16 95 Ft – Lbs 130 Ft – Lbs M14 85 Ft – Lbs 120 Ft – Lbs 145 Ft – Lbs
5/8 135 Ft – Lbs 175 Ft – Lbs M16 130 Ft – Lbs 165 Ft – Lbs 210 Ft – Lbs
_ 185 Ft – Lbs 280 Ft – Lbs M18 170 Ft – Lbs 240 Ft – Lbs 290 Ft – Lbs
NOTICE TO DEALER AND VEHICLE OWNER
Any vehicle equipped with any Warrior should have a “Warning to Driver”
decal installed on the inside of the windshield or on the vehicle’s dash. The
decal should act as a constant reminder for whoever is operating the vehicle of
its unique handling characteristics.
INSTALLING DEALER - it is your responsibility to install the warning decal
and forward these installation instructions on to the vehicle owner for review.
These instructions should be kept in the vehicle for its service
INSTALLATION INSTRUCTIONS
1. Place the vehicle on a level surface. Set the parking brake. Center front
wheels and chock rear wheels. From inside the engine compartment,
remove the upper stud nut, retainer and grommet form both of the front
shocks Jack up the vehicle and place jack stands on the frame rail behind
the lower control arm mount on the frame. Installation is done one end at a
2. time. The front-end components are installed first.
3. Remove the front tires and wheels.
4. Place a floor jack underneath the axle for support and complete the
removal of the front shock absorbers (DO NOT REUSE THE
ORIGINAL SHOCK ABSORBERS).
5. Remove the track rod from the axle housing and secure out of the way.
Save the bolt and flag nut they will be reused in a later step. Remove
both of the front sway bar end links.
6. Remove the brake calipers and secure out of the way.
7. Mark the position of the lower control arm cam bolt and axle brackets for
installation reference. (See Figure #1) If equipped with ABS brakes,
Remove the sensor wires and clamps for the inside of the lower arms and
save clamps for re-use.
8. Remove the coil spring clip located on the bottom coil seat on both sides
of the vehicle. Lower the axle and remove the coil spring. A coil spring
or strut compressor may be needed to remove the stock coil spring.
9. Remove the stock lower control arm by removing the nut, cam, and cam
bolt from the axle bracket and then removing the nut and bolt from the frame bracket. Install the new bushings and
sleeves in the Warrior, Inc control arm and install on the vehicle using factory hardware – do not tighten at this time.
Note: The part of the arm with the slight bend in it will install on the axle mount.
10. If applicable, drill a 23/64” hole into each lower link and reinstall the ABS sensor wires. Use the original clamps.
11. Install the coil spring. A coil spring or strut compressor will be needed for the new coil spring installation.
Compress the new coil spring to 16” in length. Install the new spring into the upper and lower spring pockets and
carefully remove the compressor. Make sure the coil is seated properly in the coil seat by rotating the spring so the pig
tail end fits in the spring pocket. Install the coil spring clamp and torque the spring clip bolt to 16ft.-lbs.
12. Repeat steps on other side.
13. Install the WARRIOR, INC. track rod extension bracket in the factory location as shown in Figure #2. Slide the bracket
all the way up to the flange in the stock bracket. Install the stock bolt in the upper hole and tighten. Using the bracket as
Figure 2