4.0”

INSTALLATION INSTRUCTION

Part # FTS750201 / FTS750207 / FTS750208

4.0” Long Arm Suspension System

97-2005 Jeep Wrangler TJ / 2003-2005 Jeep Rubicon Read instructions from start to finish before installation of components

Version 3

Revised 08/2005

HARDWARE AND COMPONENTS LIST

CARTON 1 continued Qty

FTS750620 Master Hardware Box Kit

70-7535 Long Arm Hardware Kit JM-16T 1” x 1-1/4”-12 Male Rod End 41-1/4” Jam Nut 4

70-7539 High Mis-Alignment Spacer Kit50-750608-04 High Mis-Alignment Spacer 8

70-7583 Shock Bracket Kit 50-750616-01 Rear Shock Bracket, Lower 21/2” x 2.5 Gr.8 Bolt 21/2” Metal Lock Nut 21/2” Flat Washers 4SLE121 Sleeve 2

70-7563 Rear Support & V-Link Component Kit 3/4” x 4.5” Gr.5 Fine Thread Bolt 13/4” Flat Washer 250-750609-04 High Mis-Alignment Spacer 250-750612-04 Aluminum Spacer, RR Upper Mount 2

70-7560 Front Trac Bar Hardware KitKMX-12 3/4” Chromoly Rod End 150-750615-004 Mis-Alignment Spacers 2CA1018 Black Vecton Trac Bar Bushing 2SLE 151 Trac Bar Sleeve 13/4” Jam Nut 1

CARTON 1 Qty

SUSPENSION COMPONENTS50-750608 Front Lower Control Arm-Uni 250-750602 Control Arm Frame Support, Right 150-750603 Control Arm Frame Support, Left 150-750614 Upper Front Link Mount, Right 150-750614L Upper Front Link Mount, Left 1

CARTON 1 Qty

FTS750619 Master Hardware Box Kit

70-7562 Master Hardware Kit 3/8” x 1.0” NC Gr.8 Bolt 9 3/8” x 3.75 NC Gr.8 Bolt 63/8” Metal Lock Nuts 73/8” Flat Washers 163/8” Tek Screw 350-750616-02 Inner Frame Brake Line Tab 3 10mm x 1.5” x 35mm Long Bolt 410mm Lock Washer 410mm Small Flat Washer 41/2” x 3.75” NC Gr.8 Bolt 61/2” x 2.5” NC Gr.8 Bolt 11/2” x 1.5” NC Gr.8 Bolt 71/2” SAE Flat Washer 261/2” Metal Lock Nut 101/2” x 5” NC Gr.8 Bolt 29/16” x 2.5” NCC Gr.8 Bolt 19/16” Metal Lock Nut 19/16” SAE Flat Washer 2SLE153 Crush Sleeve, Frame 2SLE154 Crush Sleeve, Frame 6

70-7565 Brake Line Kit 16-F7506225 Brake Line, Front 216-R7506235 Brake Line, Rear 1 50-5002 Brake Line Brkt, Front L/R & Driver Rear 3Brake Line Retaining Clip 3

70-7566 Control Arm Greasable Bolt Kit 9/16” x 4” Gr.8 Bolt 69/16” x 4” Greasable Bolt 29/16” Metal Lock Nut 89/16” Flat Washer SAE 16

FTS3001 Pitman Arm 1

4.0”

CARTON 2 Qty

50-750610 Rear Lower Control Arm 250-750606 Upper Front Control Arm, Assembled 250-750204 Front Trac Bar Frame Cross Brace 150-750605 Front Adjustable Trac Bar 150-750207 Trac Bar Frame Mount Bracket 150-750612 Rear Upper “V” Link Support 1

50-750601-04 Compressor Mount Rubicon Only 11/4” X 3/4” Bolts & nuts 71/4” Metal Lock Nuts 71/4” Flat Washer 14

50-750612-06 Dana 35 Diff Reinforcement Plate 150-750612-07 Dana 44 Diff Reinforcement Plate 150-750612-08 Upper Reinforcement Plate w/nut 1B516X1 5/6” X 1” Bolts 3N516MLN 3FW516 Flat Washer 3

70-7561 Rear Sway Bar Link Kit Rear Sway Bar Link Kit Assembled 1

FTS306057 Front Sway Bar Link kit Assembled 150-750619 Sway Bar Link Relocation Brackets 2 (Weld-On)

70-7537 Bushing & Sleeve Kit MO3515 Lower Control Arm Bushings 8MO2825 Upper Rear V-Bar Bushings 4SLE10091 Control Arm Sleeve 4SLE 155 Upper Rear V-Bar Sleeve 2

70-7564 Bump Stop Hardware Kit 10mm x 1.50 x 70mm Gr.5 Bolt 43/8” x 2” Self Tapping Bolt 4CA1014 Lower Bump Stop, Front & Rear, 3”x 1.75” 4CA1004 Upper Bump Stop, Front & Rear, 2”x2” 4

CARTON 3 Qty50-7501 Coil Spring, Front 4” TJ 97-05 250-7502 Coil Spring, Rear 4” TJ 97-05 2

CARTON 4 Qty50-750609 Upper Rear V-Link, Partial Assembled 1WSSX-16T 1” Spherical Bearing Assembled 1 WHM-212 Retaining Ring Assembled 1

CARTON 5 Qty50-750601 Center Skid Plate 6” TJ 97-05 1

INSTALLATION INSTRUCTIONS 1

HARDWARE AND COMPONENTS LIST

IMPORTANT NOTES

WARNING: This suspension system will enhance the off-road performance of your vehicle. It will handle differently, both on and off-road, from a factory equipped passenger car or truck. Extreme care must be used to prevent loss of control or vehicle rollover during abrupt maneuvers. Failure to drive this vehicle safely may result in serious injury or death to the driver and passengers. ALWAYS WEAR your seat belts. Reduce your speed, and AVOID sharp turns and other abrupt maneuvers.

Before installing this system, have the vehicle’s alignment checked by a certified technician. The alignment must be within factory specifications and the frame of the vehicle must be sound (no cracks, damage or corrosion).

Do not chrome, cad or zinc plate any of the components in this system. Changing the coated surface of components will void the warranty of your Full Traction Suspension.

This suspension system was developed using the following tire & wheel combination: 35” x12.50 tire, 15 x 8 wheel with 4.5 inches of wheel backspacing. Before installing any other combination, consult your local tire and wheel specialist.

Mandatory Requirements

97-2004 Jeep TJ *Slip Yoke Eliminator

*Rear CV Drive Shaft Replacement *Exhaust Modification - See Pg.4

2003-2004 Jeep Rubicon *Rear CV Drive Shaft Replacement *Exhaust Modification - See Pg.4

See Pg.13 for basic specifications.

The required installation time for this system is approximately 12-15 hours. Installation time will vary. Allow time for transfer case and exhaust modifications.

Thank you for purchasing the best suspension system available. For the best installed system, follow these instructions. If you do not have the tools or are unsure of your abilities, have this system installed by a certified technician.

FULL TRACTION SUSPENSION IS NOT RESPONSIBLE FOR DAMAGE OR FAILURE RESULTING FROM AN IMPROPER OR

MODIFIED INSTALLATION.

ADDITIONAL INFORMATION

Congratulations on your purchase of the highest quality suspension system available for the Jeep TJ. Some of the service procedures require the use of special tools designed for specific procedures. The following tools and supplies are recommended for proper installation of this system.

- Jeep Factory Service Manual - Pitman Arm Puller Tool - Coil Spring Compressor - Universal Steering Linkage Puller - Ball Joint Separator - Prevailing Torque Nuts (for steering linkage)- Die Grinder - Drill Motor - Assorted Drills: 1/8” & larger - Tie Down Strap - Torque Wrench - 1/2” drive Ratchet and Sockets - Assorted Combination Wrenches- Heavy Duty Jack Stands - Wheel Chocks or Blocks - Hydraulic Floor Jacks - Center Punch - File- Large “C” Clamps, Bench Vise and Adjustable Straps.- Hammer - Hole Saw - Wire Brush ( to clean mounting surfaces)- White Lithium Silicone Spray Lubricant- Grease Gun with Assembly Lube - Tape measure - Safety Glasses ( wear safety glasses at all times)- Semi Gloss Black Spray Paint

2.

Part # FTS750201

97-05 Jeep TJ Wrangler / 2003-2005 Jeep Rubicon

4.0” Long Arm Suspension System

3.Full-Traction prides itself on continual quality improvements,

therefore there might be slight variations in product appearance than those shown here.

IMPORTANT

READ BEFORE YOU BEGIN INSTALLATION

The installer of this system should be prepared to modify the exhaust system as shown in Fig.1 The new suspension system cannot be installed around the stock exhaust, therefore the vehicle is disabled without the exhaust. A rear slip yoke eliminator conversion (97-04 models) & CV type drive shaft is required to complete the installation. On 97-04 models, no change in the front drive shaft is required. Check the parts and hardware against the parts list to assure that your kit is complete. Refer to page #2 of these instructions for a list of tools and supplies needed to perform the installation. Use these instructions as a guide, however experienced installers may want to change the order of installation procedures to suit their needs.

General Disassembly 1. Raise and support the vehicle frame with jack stands. Support the front axle with a floor jack. Remove all wheels. Place reference marks on the front driveshaft and axle. Disconnect and remove the front driveshaft from the axle.

2. Remove the rear driveshaft. Support the Yoke of the driveshaft and support the transfer case with a stand or a tie down strap. Fig.2 Remove the center factory transfer case skid plate from the vehicle. Save factory bolts.

3. Cut the exhaust as shown in Fig.1 Remove the entire remaining exhaust system from the vehicle. The exhaust may also be unbolted from the “B” pipe flange next to the engine block. ** It is the installers decision how to do the exhaust.

4. With the front axle supported, remove the front shocks, steering stabilizer, steering linkage from the knuckles, pitman arm, front trac bar, and front sway bar links. Do not remove the “D”bushings or the front sway bar from the frame.

5. move

both lower front control arms. Fig.3 Leave the upper control arms attached at this time.

Remove the front brake line bracket from the frame to allow the axle to drop down far enough to remove the front coil springs. New brake lines will be installed later during this installation. Re

Fig.1

Fig.2

Fig.3

4.

NOTE: For 2003-2004 Rubicon models only -

After removing the factory transfer case skid plate, support the transfer case with a stand. Using a jack, lift the transfer case into the confined area all the way to indent the area to be relieved. Next lower the transfer case down to allow the hammer to make an impression in the floor. Make a large enough impression so that the transfer case does not hit the floor after the new skid plate is installed.

Due to the factory oversized NP241 transfer case, the floor pan in the area of the transfer case must be relieved with the aid of a ball peen hammer.

Installing the Full-Traction Trac-Bar Bracket Fig.3

1a. To install, two (2) holes will be drilled. Drill out factory tapered hole in the large cast iron trac-bar mount to 9/16” as shown in Fig.4 Insert the trac bar bracket guide rod into the frame hole in the bottom side of the frame. Fig.5 Install 9/16” x 2.5” bolt, nut and washer and torque to 90lbs/ft. The 9/16” bolt will hold the new bracket in place while the next hole is drilled in the frame.

1b. Insert the drill bit into the trac bar guide rod and drill hole out through the top side panel of frame to 1/2” as shown in Fig.6 install 1/2”x5” bolt, nut and washer. Torque to 75lbs.

2. Install frame brace to trac bar bracket using ½” x 1.5 bolt as shown in Fig.8 On the Right side frame rail, locate the factory hole and drill a 1/2” hole through the top of the frame rail and install a ½” x 5” bolt through the frame. Fig. 7a, Fig.7b & Fig.8

3. At this time, mount the new adjustable Trac Bar to only the axle

end. Enlarge hole in axle bracket to 1/2”. Install KMX-12 3/4” Chromoly Rod End and #50-750608-04 Mis-Alignment Spacers using 1/2” x 2.5” bolt, nut, and washers. Fig 9 NOTE: The new adjustable front Trac Bar will be attached to the new Trac Bar bracket last after the suspension install is complete and the vehicle is ready to be returned to level pavement. The axle must be centered under the vehicle before the Trac Bar is attached to the new bracket.

4. Install new steering pitman arm. Refer to factory service manual for torque specifications. Fig.9 5. Install factory steering system back to vehicle.

Fig.4

Fig.5

Fig.6

Fig.7a

Fig.8

5.

Fig.7b

Fig.9

Installing Full-Traction Upper Front Control Arms

1. Remove front lower control arm frame mount. Using an electric grinder, make an incision grind mark to use as a guide to grind off the factory weld. Fig.10,11 & 12 Grind both inside and outside frame surfaces. Finish frame smooth with a dual action sander and paint with semi-gloss black spray paint.

2. New Full-Traction upper control arm support brackets are Left and Right. Position the new FTS upper control arm support bracket on the frame by measuring the distance from a factory frame reference hole or similar reference. Fig.13 Using the support bracket as a template, mark and center-punch the frame for the 3 smaller holes and for the larger access hole which will be used for the greasable control arm bolt. Drill the 3 smaller holes using a 7/16” through both sides of the frame surface. Drill a 1/4” pilot hole to serve as a guide for the holesaw. Using a 1-1/8” hole-saw drill bit, drill the large access hole for the greasable control arm bolt as shown in Fig.14. Drill the inside hole for the greasable bolt to 9/16”

Mount the control arm support bracket(s) to the frame using 3/8” x 3.5” bolts, washers, and metal lock nuts. Install 3/8” bolts from the backside of the frame with the thread of the bolts facing toward the outside of the frame as shown in Fig.15

7. IMPORTANT ! Holesaw through the outside surface of the frame only. DO NOT holesaw through the inside surface of the frame. Refer to Fig.14. The inside hole opposite the 1-1/8” holesaw must be 9/16”

Fig.10

Fig.13 Fig.14

Fig.15

Fig.10

Fig.11 Fig.12

Right/Passenger Side

Grind Here

6.

Installing Full-Traction Upper Front Control Arms

5. The Upper front arms are shipped pre-assembled, however arms must be adjusted for length to correct the pinion angle. Install upper front control arms using 9/16” x 4” greasable bolts as shown in Fig.16 Torque greasable bolts to 85lbs/ft. Install the axle end of the upper arms using factory bolts and nuts. Fig.17 The upper arms have the joint welded on an angle. The joints will be angled inward when mounted on the axle. Refer to factory service manual for torque specs on factory bolts.

Installing Side Skid Brackets & Center Skid Plate to Frame

Note: A 90 degree side angle type drill is required to install the side skid bracket properly on the inside frame surface.

1. Side Skid brackets are left and right. Starting on the left side of the vehicle, line up the factory holes in the bottom of the frame with the holes in the side skid bracket. 97-04 model TJ will use the three forward holes in the bracket. Wrangler 2003-2004 X, Sport & Rubicon models use the reward set of holes as shown in Fig.18

2. Unclip the brake lines attached to the frame next to the transfer case. Mount three 50-750616-02 Inner frame brake line standoff tabs to the inside edge of the frame using 3/8” x 1” Tek self tapping screw. Fig.19

4. Before removing the factory upper control arms, support axle so it does not rotate or pivot. Remove factory upper arms. Save factory bolts to be reused on new FTS control arms.

Fig.16 Fig.17

Fig.18 Fig.19

7.

Installing Side Skid Brackets & Center Skid Plate to Frame

3. On 97-02 models, install new ½ x 1.5” bolts in the bottom of the frame to hold the side skid bracket in place. (On 2003-2004, reuse factory bolts). Using the bracket as a template, mark & centerpunch for the new holes to be drilled. Drill 1/4” pilot holes.Fig.20 Next, mark & centerpunch the holes on the inside frame rail. Drill holes to 9/16” using 90 degree side angle drill.

Note: Do not attempt to drill through both sides of the frame at the same time. This will cause holes to become mis-aligned.

Next, remove the factory bolts and the side skid from the frame. On the outside holes only, using a 3/4” holesaw, enlarge the holes to 3/4” diameter. (Outside holes only). Insert crush sleeve SLE154 into the frame holes as shown in Fig.21,22 Again, position side skid bracket in place and install ½ x 3.5” bolts, nuts, and washers and torque to 75lbs./ft. Repeat same for the right side of the vehicle.

Installing Center Skid Plate

1. There are eight (8) holes in the center of the skid plate. (Two sets of 4 holes each) The forward set of holes is used on 97-04 TJ automatic models and the rear set of holes is for 97-04 5-spd and 2003-2004 See Fig.23 Align the bolt studs from the Transfer case mount with the holes in the center skid plate. Next, align the bolt holes in the Side Skid brackets with the holes in the skid plate. Install using 3/8” dia x 1” bolts, flange nuts and washers.

2. Install the factory nuts on the four (4) Transfer case mount studs and secure tight.

For 2003-2004 TJ Rubicon models only Mount the small air compressor skid plate on the left rear section of the center skid plate to hold the factory air compressor in place Fig.24 Air lines & wiring may need to be re-routed to have enough slack.

Left Side/Driver

Fig.22

Fig.23Fig.24

Fig.21

Fig.20

8.

Installing Upper Rear Differential “V” Link Support

1. Support rear axle with stands. Pinch off the factory rubber brake line so it doesn’t leak brake fluid. Remove the bolt holding the rear brake line to the rear axle. Not shown.2. Remove factory rear shocks. 3. Remove rear coil springs. 4. Remove the rear sway bar and save all hardware to be reused. 5. Disconnect the parking brake cable attached to the rear upper control arms. Remove the factory rear upper and lower control arms.

6. Position the Full-Traction Upper “V” Link Support over axle. Fig.25 Insert 50-750612-04 billet aluminum spacer and secure using the factory control arm bolt as shown in Fig.26 Align holes in the new upper link support bracket with the holes in the frame from the sway bar bracket. To secure the new “V” link bracket, install factory sway bar “D” shaped brackets using new 10mm 1.5 x 35mm bolts and washers. Secure all hardware.

Installing Upper Rear “V” Link

1. Insert #MO2825 bushings & sleeve # SLE155 into eyelets of “V” Link. Bushings must be greased liberally with lithium grease or similar type assembly lube. Failure to lube bushings prior to assembly will result in suspension squeaks and premature wear of the bushings. The “V” Link comes pre-assembled with #WSSX-16T 1” Spherical Bearing and the retaining ring in place.

2. The Full-Traction Logo on the “V” link must be facing in the upright position. Align the eyelets of the “V” link to the upper side skid bracket mounting point. Install 9/16” x 4” Greasable bolts, nuts and washers. Leave bolts and nuts hand tight.

3. Insert # 50-750609-04 high mis-alignment spacers on both sides of the spherical bearing. To install the “V” link to axle, tilt (pivot) the rear axle backwards to align bearing with bolt hole in upper “V” link support. Carefully guide the assembly into the Well of the support. Insert 3/4”x 4.5” bolt, washers and 3/4” metal lock nut under the support and torque to 150 lbs./ft. Fig.27 The V-Link is shown in place Fig.28

4. Included in Carton 2 but not shown are #50-750612-07 Dana 44 and #50-750612-06 Dana 35 differential reinforcement plate and 50-750612-08 Upper reinforcement plate. Install reinforcement plate using V-Link 3/4” x 4.5” Bolt. Install the Differential plate using the factory bolts from the rear differential inspection cover. Drill 3/8” holes to into upper reinforcement using holes in differential plate as a template. Install 3/8” bolts provided. Draining oil from rear differential is not necessary.

Fig.25

Fig.26

Fig.27

Fig.28

9.

Installing Rear Components.

1. Install rear sway bar links using factory hardware. Fig.29

2. Drill a 5/16” hole into the coil spring base cup. Install the rear Lower CA1014 3”x2” aluminum bump stop extensions using the 3/8 x 2” self tapping bolts. Screw the bolts into the spring seat as shown in Fig.30 Note: Rear 3”x2” lower extensions must be installed after the rear coil springs are installed as the opening of the coil will not allow the extension to pass through it.

3. Install the rear Upper CA1004 2”x2” aluminum bump stop extensions using the 10mm x 65mm Bolts. To install, remove the factory upper foam bump stop. Remove the bell shaped factory mount. Install the 2”x2” bump stop extension and re-install factory foam bump stop as shown in Fig.31

NOTE: Failure to install ALL upper and lower bump stop extensions will void the warranty of your Full-Traction Suspension system.

4. Repeat steps #3 and #4 for the front bump stops extensions.Upper and Lower aluminum extension are installed in the same manner as the rear extensions.

Installing Rear Coil Springs. Shock absorbers are required to complete the

installation of this suspension system.

1. Using 1/2” x 2.75” bolt provided, bolt on part # 50-750616-01 rear lower shock extension brackets to the axle. Secure the bracket with a 3/8” x 1” bolt on the front side of the bracket. Fig.32 After mandatory bump stop extensions are installed, install the rear coil springs one at a time. Check to see that the upper factory rubber insulator is in place on top of the coil prior to assembly. Assemble rear bar pin into upper shock eyelet and install the shocks on the vehicle.

Upper AssemblyUpper and Lower Assembly

Fig.29

Fig.30 Fig.31

10.

Fig.32

Installing Rear Lower Control Arms & Adjustments

1. The rear lower control arms measure approximately 30 inches in length and are shorter than the front lower control arms. Insert MO3515 bushings and SLE10091 sleeves into large eyelet of control arms. Prior to installing the rod ends, apply anti-seize or similar lubricant to the threads of JM-16T 1” x 1-1/4” Male rod end. Install 1-1/4” Jam nut onto rod end. Install male rod end all the way inside the threaded end of each control arm. Check for damage on threads of rod end and clean or file as necessary to ensure smooth rotation/adjustment of the rod end prior to assembly.

2. Rotate the Male rod end counterclockwise to expose approx 1/8” of threads prior to installing control arm on vehicle. Final length adjustments of the control arm will need to be made after vehicle is road tested. Insert #50-750608-04 High Mis-Alignment spacers on both side of rod end opening as shown in Fig.33 Install rear lower control arms to the axle using the factory hardware at the axle. Install control arm to the side skid mounting point using 9/16” x 4” greasable bolts. After all adjustments are performed, apply final torque to the 1-1/4” jam nuts.

Installing New Rear Brake Line

1. Remove factory brake line support bracket from the frame and replace with #50-5003 brake line bracket using factory bolt. Install #16-R7506235 rear brake line. Insert brake line through hole in bracket and secure with new Brake line retaining clip. Clip must be lightly tapped into place with a small ball peen hammer. Fig.34

Installing Front Coil Springs

Shock absorbers are required to complete the installation of this suspension system.

1. With front axle supported and front bump stop extensions in place, install front coils springs. The top of the coil has a smaller opening than the bottom of the coil. Rotate the coil spring until it rests in the coil cup properly. Install front shock absorbers. Fig.35

Fig.33

Fig.35

Front Coil Springs with bump stop extensions correctly installed.

11.

Fig.34

Installing Front Lower Control Arms & Adjustments

1. The front lower control arms measure approximately 35 inches in length and are longer than the rear lower control arms. Prior to assembly, apply anti-seize or similar lubricant to the threads of JM-16T 1” x 1-1/4” Male rod end. Install 1-1/4” Jam nut onto rod end. Install male rod end all the way inside the threaded end of each control arm. Check for damage on threads of rod end and clean or file as necessary to ensure smooth rotation/adjustment of the rod end prior to assembly.

2. Rotate the Male rod end counterclockwise to expose approx 1/8” of threads prior to installing control arm on vehicle. Final length adjustments of the control arm will need to be made after vehicle is road tested. Insert #50-750608-04 High Mis-Alignment spacers on both side of rod end opening. Install front lower control arms to the axle using the factory hardware at the axle. Install control arm to the front side skid mounting point using 9/16” x 4” greasable bolts. After all adjustments are performed, apply final torque to the 1-1/4” jam nuts. Fig.36 Install front drive shaft.

Installing New Front Brake Lines

1. Remove factory brake bracket from the frame and replace with new FTS brake line brackets. Install #50-5002 Front Right & Left (same as Left Rear) Brackets. Fig.37 Insert brake line through hole in bracket and secure with new Brake line retaining clip. Clip must be lightly tapped into place with a small ball peen hammer.

Installing New Front Sway Bar Quick Disconnect Links

1. Sway bar disconnect links are pre-assembled. Remove CA1005 upper bracket and install onto the sway bar as shown in Fig.38 Rotate bracket and secure button head bolt using an allen wrench. Install disconnect links to bracket and secure to lower factory bracket using factory hardware. Return vehicle to flat level pavement and attach front adjustable Trac Bar to the frame. Axle must be centered under the vehicle for easy installation of the Track Bar. Install using 1/2” x 3.5” Bolt, nut, and washers. Torque Track bar bolt to 75lb./ft.

NOTE: Optional weld-on front sway bar link extensions are included in this system. Fig. 38 shows the optional weld-on sway bar link extensions in place. To install, align new bracket on outside of OEM bracket & trim OEM bracket as shown. Extensions move the location of the sway bar link and allow full steering mobility.

Fig.36

12.

Fig.37

Fig.38

13.

Basic Specifications Chart

Rear CV Drive Shaft & Slip Yoke Eliminator

97-05 Jeep TJ After installation of this system, the installer must measure for the correct length rear CV drive shaft. A short shaft adapter (SYE) is required for all Jeep TJ’s equipped with a factory NP231transfer case. There is NO front drive shaft modification required on 97-04 models.

Diameter Reduction modification to factory drive shaft may be required. Jeep uses at least 3 different diameter front drive shafts for the TJ. Length of front shaft with 6” lift does not change. To eliminate front drive shaft from hitting the skid plate, maximum outside diameter (O.D.) of the front drive shaft should not exceed 1.5 inches.

Grease Zerks

Exhaust Modification

Custom fabricated type required. Exhaust must be custom built to allow proper clearance of all suspension components during articulation. Small catalytic converters and turbo type mufflers are available from major manufacturers. Exhaust may exit out either the left or right rear area.

Shock Absorbers

NOTE: Length of all shocks is critical. There are NO EXCEPTIONS to extended length allowed from the listed shock sizes. Full-Traction Suspension is not responsible for breakage, damage or abuse to any installed component due to improper installation or misapplication of components.

Front Drive Shaft

Grease all zerk fittings on the control arms and rear upper v-link prior to driving vehicle. Periodically grease the zerks after each hard use. Most squeaks coming from the suspension is a sign of dry bushings.

Typical Rear CV Drive Shaft & Slip Yoke Eliminator

Optional Weld-on Bracket

Optional Exhaust System Part # FTS750650

4.0” Full-Traction Long Arm Suspension

Shock Absorber Length Chart

Vehicle Length Axle97-05 Jeep TJ Front 24.50 Extended Dana 3097-05 Jeep TJ Rear 24.50 Extended Dana 35 2003-2005 Rubicon Front 24.50 Extended Dana 442003-2005 Rubicon Rear 24.50 Extended Dana 44

Full Traction Limited Warranty

About our warranty Full Traction components may have minor finish damage to powder coated or plated surfaces which may occur during shipping and is not covered under warranty. Full Traction Suspension warrants each new Full Traction Component against factory defects in material and workmanship for 1 year after date of purchase. Full Traction Suspension systems are sold as complete systems and must be installed as such per Full-Traction installation instructions. Any substitutions of other manufacturers components or exemptions of required components will immediately void the warranty. Full-Traction suspension guarantees that all of its products are of the finest quality and free from manufacturing defects. Any product that has been manufactured incorrectly or is of a defective nature will be repaired or replaced at the discretion of Full-Traction Suspension. Returns: Only after written or verbal approval, send such part(s) and proof of purchase, via prepaid freight with an RGA (Return Goods Authorization) number to: Full-Traction Suspension 6951 McDivitt Dr. Bakersfield Ca 93313 USA. Shipments without an RGA number clearly designated on the outside of all containers or collect shipments will be refused. To obtain RGA(s) call 661/398-9585

What is not coveredSuspension and steel fabricated components: Limited (12) month warranty excluding the following items: Tie rod ends, bushings, hardware, brake lines, heim joints. These parts are subject to wear and are not considered defective when worn. They are warranted for 90 days from the date of purchase for defects in workmanship. Shock absorbers are covered under our limited warranty. Products or components installed on vehicles other than those specifically indicated in the Full-Traction Suspension catalog or website. Products or components which have been subjected to abuse, accident, alteration, modification, improper installation, tampering, negligence, misuse, or products installed on a vehicle used in sanctioned racing events. A race is defined as any contest between two or more vehicles, or any contest of one or more vehicles against the clock, whether or not such contest is for a prize. This warranty does not include vehicles used for government or commercial purposes. Full Traction does not warrant any product not manufactured by Full Traction Suspension. Full Traction Suspension products are not covered under warranty outside the United States of America. Full Traction Suspension shall not be liable for any loss, damage, or injury, whether ordinary, direct, special, incidental or consequential damages, arising from the manufacture, sale, installation, re-sale, delivery, possession, handling or use of its products. Full Traction Suspension is not responsible for typographical errors either in pricing or in content. Warranties, policies, and prices subject to change without notice.

Installer’s Safety WarningFull-Traction Suspension recommends our products to be installed by certified technicians only. These recommendations pertain only to Full-Traction Manufactured Products. Efforts to install our system without experience and knowledge may jeopardize the operating safety of the vehicle.

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Address__________________________City______________________State________Zip________________

Products Purchased from:_____________________________________Date Purchased_________________

Installed By________________________________________ Date Installed___________________________

Vehicle make____________________________________Model_____________________Year___________

Installation Comments______________________________________________________________________

Product Part Number________________Description:___________________________________________

Warranty Registration Number____________________________________

WARRANTY

Detach and mail or fax to the address below

Mail or Fax To: Full Traction Suspension

6951 McDivitt Dr Bakersfield Ca 93313

Fax: 661-398-9555

Place Warranty Sticker Here

Printed in U.S.A. Full-Traction Suspension 2005

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FTS750201 JEEP TJ 4.0” Long Arm Suspension System