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Summary of Contents for Fabtech FTS24094
- Page 1 INSTALLATION INSTRUCTIONS 2007-15 JEEP JK 5’’ CRAWLER SYSTEM FTS24094 / FTS24084BK / FTS24085BK Fabtech Motorsports | 4331 Eucalyptus Ave. Chino, CA 91710 Tech Line: 909-597-7800 | Fax: 909-597-7185 | Web: www.fabtechmotorsports.com...
- Page 2 - PARTS LIST - FTS24094 COMPONENT BOX 1 FT50372 HARDWARE SUB-ASSEMBLY FT50390BK Front Crossmember FT167 Frt Trac Bar Bkt Sleeve FT50368 Front Trac Bar Bracket FT50089 Sleeve 4 Pack FT50318BK Frt. Skid Plate FT50048 5/8" Hourglass Bushing 4 Pack FT50294...
- Page 3 - PARTS LIST - FT50356 HARDWARE KIT FT50357 HARDWARE KIT Qty. Description Location Qty. Description Location 1/2"-13 x 1 1/2" Bolt Front Crossmember 1/2"-13 x 1 1/4" Bolt Rear Link Pockets 1/2"-13 C-Lock Nut ---------------- 1/2"-13 C-Lock Nuts ---------------- 1/2" SAE Flat Washer ---------------- 1/2"...
- Page 4 - PRE-INSTALLATION NOTES - Read this before you begin installation- Check all parts to the parts list above before beginning installation. If any parts are missing contact Fabtech at 909-597-7800 and a replacement part will be sent to you immediately.
- Page 5 - INSTRUCTIONS - 7. Remove and save the trac bar and hardware. Use a pickle fork and separate the draglink from the pitman arm, save hardware. Use a pitman arm puller and remove the stock FRONT SUSPENSION pitman arm. Discard the arm and save the nut and washer. Locate the FT50294 pitman arm and supplied 7/8”...
- Page 6 Use a drill with a ½” bit and drill the new hole to new bracket is to be installed. The inside front corner of mount the new Fabtech spacer. (DO NOT INSTALL AT the coil spring mount will need to be cut / trimmed. From the front of the mount, cut 1 ¼”...
- Page 7 WELD HERE FIGURE 8 FIGURE 11 WELD HERE FIGURE 9 FIGURE 12 WELD HERE WELD HERE FIGURE 10 FIGURE 13 7 of 31...
- Page 8 11. Once gusset kit has completely cooled, paint all bare metal areas. SEE FIGURE 14. TRAC BAR SHOWN INSTALLED (FOR PHOTO ONLY) FIGURE 16 FIGURE 14 14. Locate the flange at rear of the pipe just cut. Remove mounting bolts at the flange and discard this section of 12.
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Page 9: Table Of Contents
CUT THE POCKET FLUSH WITH THE OUTER MOUNT FIGURE 19 FIGURE 23 16. Rotate the rear of the pipe with the two bolt flange up to the factory flange and install the hardware. Torque the two bolt flange and clamp to 37 ft-lbs. SEE FIGURE 19. CUT THE POCKET FLUSH WITH THE OUTER MOUNT 17. -
Page 10: The Frame And Attach** With The 1/2" Hardware
FIGURE 25 FIGURE 28 18. Locate FT50390BK Crossmember, FT50314 & FT50315 19. Mark & drill the bottom frame for the rear hole on the new Nut Tabs, and the supplied 1/2” & 12mm hardware. crossmember. Use a small drill bit first and follow with a Attach ** the front tabs of the crossmember to the factory 1/2”... -
Page 11: Figure
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. -
Page 12: Figure
24. Install the assembled link arm to the axle with the 25. Attach the assembled upper link arm to the lower link arm supplied alignment cam bolt and washers first, then that is already installed on the Jeep using the supplied attach the other end of the link to the pocket in the new 7/16”... -
Page 13: Figure
MAKE SURE FACTORY UPPER COIL ISOLATOR IS INSTALLED BEFORE INSTALLING COIL SPRINGS FIGURE 43 27. Locate the Fabtech shock FTS7188 (Not included in the kit), the supplied ½” x 2 ½” bolts, USS and SAE Flat Washers, and C-Lock Nuts. Use the supplied lower bushings and sleeves (FT402087 Sleeve) from the kit (discard lower bushings &... -
Page 14: Figure
28. Re-install the ABS lines, differential vent tube, and on Rubicon models, the electrical connection for front locker (use WD-40 on the mounts on the ABS lines to adjust for re-connection 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. -
Page 15: Figure
30. Locate FT50360 drv. & FT50361 pass. Sway Bar Link Mounts, FT50261 Front Sway Bar Endlinks, FT50048 & FT50089 bushing and sleeve kits. Press one bushing and one sleeve from the supplied bushing kit into each end of the end link. Attach the link mount brackets to the factory sway bar mount on the axle with the supplied ½”x1 ½’... -
Page 16: Figure
32. Locate the factory trac bar and upper hardware and the lower factory trac bar bolt and nut tab. Position the trac bar into the new mount on the axle and attach with the factory bolt and nut tab. Then attach the trac bar to the factory upper mount with the factory hardware. -
Page 17: Figure
34. Locate FT50359 Sway Bar Retainer and the supplied ¼”x 1¼” 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. -
Page 18: Figure
36. Remove the factory shocks and discard, save the hardware. Remove the rear sway bar end links and save with the hardware. SEE FIGURE 66. FIGURE 68 FIGURE 66 37. Remove the brake line brackets from the frame and save the hardware. -
Page 19: Metal Areas. See Figure
40. Mark the lower link arm pockets & body mounts as shown in the photos below. You will be removing the inner and outer link arm mount from the frame on the driver side & ONLY the outer mount on the passenger side. DO NOT REMOVE the inner mount on the passenger side. -
Page 20: Figure
41. Mark and cut the rear lower shock mounts as shown in the photos below. Locate FT50325BK / FT50326BK Lower Shock Mounts & supplied 9/16” x 4 1/4” bolts. Attach the new mounts with the 9/16” hardware to ensure that the factory mount has been trimmed enough. -
Page 21: Figure
FIGURE 82 FIGURE 85 FIGURE 83 FIGURE 86 FIGURE 84 FIGURE 87 21 of 31... -
Page 22: Figure
FIGURE 88 FIGURE 91 43. Mark and cut the same body mount on the passenger side of the Jeep as done on the passenger side. There is a factory hole in the frame on the passenger side, so you will not need to make the 1 1/2” hole on this side. 44. -
Page 23: See Figure
46. Locate FT50309 & FT50324 Dual Nut Tab, and the supplied 1/2” & 9/16” hardware. 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”... -
Page 24: Figure
50. Locate FT50362 Gusset, position it onto the axle and the factory trac bar mount as shown in photo. Weld the gusset on the two sides. SEE FIGURE 102. WELD HERE FIGURE 99 48. FT503014 & FT503015 Rear Pocket Nut Tabs & insert into TRAC BAR INSTALLED FOR PHOTO ONLY, IT the tab into the hole just below the body mount. -
Page 25: Figure
FACTORY BOLT AND NUT TAB WELD HERE FIGURE 104 FIGURE 107 TRAC BAR INSTALLED FOR PHOTO ONLY, IT MUST BE REMOVED PRIOR TO INSTALLATION. WELD HERE FIGURE 105 FIGURE 108 TRAC BAR INSTALLED FOR PHOTO ONLY, IT MUST BE REMOVED PRIOR TO INSTALLATION. -
Page 26: Figure
53. Locate FT50346BK Rear Lower Links, (8) FT1003 Bushings, (2) FT7100-6-100 Sleeves, (4) FT50123 Large Adjustable Joints, and (4) large jam nuts. Install the jam nuts onto the joints and insert the joints into the arms. Adjust the joints so the link is 32 1/2” center to center of the joints (Make sure there is an equal amount of threads on both ends. -
Page 27: Figure
FIGURE 115 FIGURE 118 FIGURE 116 FIGURE 119 FIGURE 117 FIGURE 120 56. Remove & discard the factory rear driveshaft & hardware. Locate the correct (FTS94051 2 Door or FTS94052 4 door) new rear driveshaft and install at this time. 27 of 31... -
Page 28: See Figure
58. Locate FT50298 E-Brake Bracket and supplied ¼” hardware. Position the bracket to the factory mounting position and attach with the factory hardware. Attach the factory bracket to the new Fabtech bracket with the ¼” hardware. Torque to 10 lbs. SEE FIGURE 122. FIGURE 124 60. -
Page 29: Figure
61. Install the Fabtech shock FTS6002 (Not included in the 62. Locate FT50295 Rear Brake Line Drop Bracket, supplied kit) Use the factory upper hardware to mount the bar bin 1/4” hardware, and factory rear brake line hardware. and the supplied ½” x 2 ½” bolt, large USS washers, and Attach the drop bracket to the factory mount with the hardware. -
Page 30: Figure
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... - Page 31 Fabtech products are not designed nor intended to be installed on vehicles used in race applications or for racing purposes or for similar activities. (A “RACE” is defined as any contest between two or more vehicles, or any contest of one or more vehicle against the clock, whether or not such contest is for a prize).
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