Fabtech FTS24084BK Installation Instructions Manual Download

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Fabtech Motorsports

| 4331 Eucalyptus Ave. Chino, CA 91710

Tech Line:

909-597-7800 |

Fax:

909-597-7185 |

Web:

www.fabtechmotorsports.com

INSTALLATION INSTRUCTIONS

2007-15 JEEP JK

5’’ CRAWLER SYSTEM

FTS24094 / FTS24084BK / FTS24085BK

Summary of Contents for FTS24084BK

Page 1: ... Motorsports 4331 Eucalyptus Ave Chino CA 91710 Tech Line 909 597 7800 Fax 909 597 7185 Web www fabtechmotorsports com INSTALLATION INSTRUCTIONS 2007 15 JEEP JK 5 CRAWLER SYSTEM FTS24094 FTS24084BK FTS24085BK ...

Page 2: ...ar Dual Nut Tab Driver 1 FT50324 Rear Dual Nut Tab Pass 1 FT50360 Sway Bar Link Mount Driver 1 FT50361 Sway Bar Link Mount Pass 2 FT50295 Rear Brake Line Drop Bracket 1 FT50298 E Brake Drop Bracket 2 FT50327 Rear Shock Mount Dual Nut Tab 1 FT50362 RearTrac Bar Bracket Gusset 1 FT157 Rear Track Bar Bracket Sleeve 8 FT1003 Rear Upper Link Arm Bushings 4 FT7100 6 100 Rear Upper Link Arm Sleeves FTS24...

Page 3: ...hers 6 1 4 28 Grease Fitting 1 7 8 Lock Washer Pitman Arm FT50357 HARDWARE KIT Qty Description Location 7 1 2 13 x 1 1 4 Bolt Rear Link Pockets 1 1 2 13 C Lock Nuts 7 1 2 SAE Flat Washer 1 1 2 USS Flat Washer 4 1 2 Split Washer 4 7 16 14 x 1 Bolt Rear Shock Mount 4 7 16 SAE Flat Washer 4 7 16 Split Washer 2 1 2 13 x 2 3 4 Bolt Rear Shocks 2 1 2 13 C Lock Nut 4 1 2 SAE Flat Washers 4 9 16 12 x 4 1 ...

Page 4: ...tem with any other lift device or parts This suspension must be installed with Fabtech shock absorbers WARNING Installation of this system will alter the center of gravity of the vehicle and may increase roll over as compared to stock For technical assistance call 909 597 7800 or e mail info fabtechmotorsports com Fabtech replacement driveshafts are required with this system Due to the different s...

Page 5: ... the front axle Do not allow to hang freely 2 Remove the front crossmember driveshaft from the Jeep and set aside with the hardware 3 Working from the driver side of the truck unbolt the front brake line bracket from the frame and save the hardware Remove the ABS sensor wire from the C Clips on the front knuckle Remove and discard the sway bar end link save the hardware On Rubicon models only Unpl...

Page 6: ...rom the front of the mount cut 1 back and in and down to the axle This is just a starting point Each vehicle will need to be trimmed to fit due to variances from Jeep to Jeep SEE FIGURE 6 10 Locate FT50368 Trac Bar Bracket supplied 9 16 bolt washers nut and FT167 Trac Bar Sleeve Place a 9 16 flat washer on the outside of the bolt and put it through the new bracket and put another 9 16 flat washer ...

Page 7: ...FIGURE 8 FIGURE 9 FIGURE 10 FIGURE 11 FIGURE 12 FIGURE 13 7 of 31 WELD HERE WELD HERE WELD HERE WELD HERE ...

Page 8: ...ely cooled paint all bare metal areas SEE FIGURE 14 12 Remove the front upper lower link arms and save the factory hardware upper link arm bolt on the passenger side will need to be cut to be removed If you are installing the FTS94060 loop delete pipe for 2012 13 models complete steps 13 16 now 13 Locate the section of exhaust after the catalytic converter near the front driver side upper link arm...

Page 9: ...own in the photos cut will need to flush with the inside mount not the frame itself Use a sawz all or a die grinder with a cut off wheel and remove the outside of the pocket Use an angle grinder with a sanding disc to sand the cut area of the pocket Paint all bare metal areas SEE FIGURE 20 25 9 of 31 FIGURE 22 FIGURE 24 FIGURE 19 FIGURE 20 FIGURE 21 FIGURE 23 CUT THE POCKET FLUSH WITH THE OUTER MO...

Page 10: ...e frame and attach with the supplied 12mm bolts with flat split washer SEE FIGURES 26 28 19 Mark drill the bottom frame for the rear hole on the new crossmember Use a small drill bit first and follow with a 1 2 bit Locate FT50314 FT50315 Nut Tabs 1 2 x 1 1 2 bolts with flat split washers Insert the nut tab into the frame and attach with the 1 2 hardware SEE FIGURES 29 32 FIGURE 26 FIGURE 29 FIGURE...

Page 11: ... MEASUREMENTS ARE JUST A STARTING POINT YOU MAY HAVE TO ADJUST THEM BASED ON YOUR JEEP BOTH FRONT LINKS MUST BE ADJUSTED EQUALLY FROM SIDE TO SIDE FOR PROPER VEHICLE ALIGNMENT Locate the new Fabtech front lower link arms FT50144 and install one of the previously assembled large pivot joints into each end of the link SEE FIGURE 33 22 Locate two FT50124 Small Pivot Joints Assemble one of the supplie...

Page 12: ...ent cam bolt and washers first then attach the other end of the link to the pocket in the new crossmember using the supplied 9 16 hardware When attaching the lower link to the Jeep the pivot end on the frame mount will need to have the grease fittings facing down and the pivot end on the axle will need the grease fitting facing down after the joints are installed on the Jeep Tighten the cam bolts ...

Page 13: ...ers and C Lock Nuts Use the supplied lower bushings and sleeves FT402087 Sleeve from the kit discard lower bushings sleeves provided with the shocks Attach the bottom of the shock to the stock lower shock mount Use two flat washers on the outside of the mount and two large USS washers on each side of the shock bushing on the inside of the mount Use the upper bushings provided with the shock for th...

Page 14: ... into the mounts The clips that hold the diff vent hose will need to be repositioned on the hose for proper fitment back onto the coil bucket Re attach the brake line bracket to the frame with the factory hardware Carefully adjust bend the hard line of the brake line for proper fitment and clearance SEE FIGURE 46 52 FIGURE 46 FIGURE 47 FIGURE 48 FIGURE 49 FIGURE 50 FIGURE 51 14 of 31 ...

Page 15: ...nk mount brackets to the factory sway bar mount on the axle with the supplied x1 bolts and hardware Torque to 127 ft lbs With the supplied x 2 bolts hardware connect the new end link to the sway bar factory hole in sway bar may need to be enlarged with a die grinder out to Mount the bolt with the head of the bolt facing outward towards the tire Then using the FT42 Sway Bar Pin FT45 Key Ring FT9003...

Page 16: ...the factory hardware 9 16 hardware to 184 ft lbs SEE FIGURES 58 59 33 Torque the pivot bolts in all the front link arms to 85 ft lbs 31 Install front tires and wheels Torque lug nuts to wheel manufacturer s specifications Turn wheels left to right to check for proper clearance of brake lines ABS lines and fenders FIGURE 56 FIGURE 57 FIGURE 58 FIGURE 59 MAKE SURE THE 1 2 BOLT IS MOUNTED WITH THE HE...

Page 17: ... the supplied x 1 hardware Disconnect the sway bar from the lower axle mounts Rotate the sway bar end links up toward the coil bucket and attach the retainers to the end links Position the retainer bracket to the coil bucket and mark the bucket for the retainers Mark the two holes from the retainer to the bucket Lower the retainers and drill the two new holes to 1 4 Attach the retainer to the coil...

Page 18: ...the hardware Remove the rear sway bar end links and save with the hardware SEE FIGURE 66 37 Remove the brake line brackets from the frame and save the hardware Remove the plastic clips that hold the ABS lines to the frame and at the rear upper link arm pockets Do not damage the clips they will be reused Remove the top differential cover bolt and remove the ABS line clamp Save the bolt Remove the t...

Page 19: ...r side ONLY the outer mount on the passenger side DO NOT REMOVE the inner mount on the passenger side Attempting to remove the inner mount could result in damaging the fuel tank Sand grind off the rest of the weld and cut areas smooth to the frame Paint all bare metal areas SEE FIGURES 70 78 FIGURE 70 FIGURE 71 FIGURE 72 FIGURE 73 FIGURE 74 FIGURE 75 19 of 31 ...

Page 20: ...ardware to ensure that the factory mount has been trimmed enough Remove the bracket sand grind off the rest of the weld and cut areas smooth to the frame Drill out the two factory holes out to 7 16 Paint all bare metal areas SEE FIGURES 79 89 FIGURE 76 FIGURE 77 FIGURE 78 FIGURE 79 FIGURE 80 FIGURE 81 DO NOT CUT OR REMOVE THE INNER MOUNT DO NOT CUT OR REMOVE THE INNER MOUNT 20 of 31 ...

Page 21: ...FIGURE 82 FIGURE 83 FIGURE 84 FIGURE 85 FIGURE 86 FIGURE 87 21 of 31 ...

Page 22: ... you will not need to make the 1 1 2 hole on this side 44 Locate FT50312BK FT50313BK Rear Frame Pockets Position the bracket onto the bottom of the frame 2 forward of the previously trimmed body mount Mark the holes in the bracket onto the frame Remove the bracket from the frame and drill the holes only into the face of the frame DO NOT drill into the back of the frame The two bottom holes and two...

Page 23: ...e Insert the dual nut tab into the new hole dr side factory hole pass side and attach with a 1 2 x 1 1 4 bolt flat split washer the 9 16 x 4 1 4 bolt Leave loose SEE FIGURES 96 97 47 Locate FT50308 Long Nut Tab insert into the tab into the new hole Insert the 1 2 bolt with the split flat washer with the supplied thread locking compound Leave loose SEE FIGURES 98 99 FIGURE 93 FIGURE 94 FIGURE 95 FI...

Page 24: ...shown in photo Weld the gusset on the two sides SEE FIGURE 102 51 Locate FT50342 Rear Trac Bar Bracket position it onto the top of the axle and trac bar mount Use the supplied 9 16 bolt to align the new bracket to the original mount Use a punch and mark the factory mount through the two holes in the new bracket Use a drill with a 3 8 bit and drill the two new holes Locate and install the supplied ...

Page 25: ...IGURE 108 FIGURE 106 FIGURE 109 FACTORY BOLT AND NUT TAB WELD HERE WELD HERE WELD HERE TRAC BAR INSTALLED FOR PHOTO ONLY IT MUST BE REMOVED PRIOR TO INSTALLATION TRAC BAR INSTALLED FOR PHOTO ONLY IT MUST BE REMOVED PRIOR TO INSTALLATION VIEW OF FRONT SIDE OF AXLE LOOKING TO THE REAR OF THE JEEP 25 of 31 ...

Page 26: ... mounts on the axle with the factory hardware Then attach the links to the original frame mounts with the factory hardware here also Torque the bolts to 135 ft lbs SEE FIGURE 111 113 55 Remove the 9 16 bolt from the frame pocket and install the assembled lower link arm with the zerk fitting facing downward Torque to 184 ft lbs Insert the bottom of the link into the lower shock mount zerc fitting f...

Page 27: ...card the factory rear driveshaft hardware Locate the correct FTS94051 2 Door or FTS94052 4 door new rear driveshaft and install at this time FIGURE 115 FIGURE 118 FIGURE 116 FIGURE 119 FIGURE 117 FIGURE 120 27 of 31 ...

Page 28: ...2 59 Locate install FT50303 Rear 5 Coil Spring with the factory isolators on the top into the upper mount first then onto the factory coil perch on the axle make sure upper isolator is fully seated into the upper pocket mount SEE FIGURES 123 124 60 Position the trac bar into the new trac bar bracket and attach with the factory hardware Remove the 9 16 bolt and install the provided FT157 Sleeve in ...

Page 29: ...ttach the drop bracket to the factory mount with the factory hardware Attach the factory brake line bracket to the new drop bracket with the hardware Torque to 10 lbs SEE FIGURE 128 63 Reconnect the factory ABS mount to the rear differential and torque to 20 lbs 64 Locate the factory end links and hardware Attach the links to the outside of the sway bar with the studded end of the link Attach the ...

Page 30: ... resetting the fluid level with the new position of the differential s 70 Install Driver Warning Decal Complete product registration card and mail to Fabtech in order to receive future safety and technical bulletins on this suspension Vehicles that will receive oversized tires should check ball joints and all steering components every 2500 5000 miles for wear and replace as required RETORQUE ALL N...

Page 31: ...Wheel sizes listed in Fabtech s website are only a guideline for street driving with noted fender trimming Fabtech is not responsible for damages to the vehicle s body or tires Fabtech is not responsible for premature wear of factory components due to the installation of oversized tires and wheels Fabtech s obligation under this warranty is limited to the repair or replacement at Fabtech option of...

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