THE FOLLOWING PARTS ARE USED IN CONJUNCTION WITH THIS KIT, AND MUST BE ORDERED SEPARATELY.
318514 ES3000 SHOCKS (FRONT) 2
326506 ES3000 SHOCKS (REAR) 2
‘86-’89 4-RUNNER
‘86-’95 PICKUP
-OR326513 ES3000 SHOCKS (REAR)
‘90-’95 4-RUNNER
ONE OF THE FOLLOWING REAR KITS WILL BE USED IN CONJUNCTION WITH THIS BASE KIT:
-OR57489 ‘90-’95 4-Runner
90-1204 Lower Link Relocating Bracket 2
90-1272 Upper Link Relocating Bracket 2
90-2130 Bump Stop Extension 2
90-1268 Trac Bar Relocating Bracket 1
90-2133 Sway Bar Extension 2
90-7210E Brake Hose 1
5242-1 Limiting Strap 2
PLEASE NOTE: ON SOME V6 MODELS, A HIGH MISALIGNMENT
DRIVESHAFT MAY BE REQUIRED IF THE ORIGINAL EQUIPMENT DRIVESHAFT BINDS AT THE CONSTANT VELOCITY JOINT AFTER THE LIFT KIT
IS INSTALLED.
3
57289
REVISED
2.1.06
Introduction:
♦ This installation requires a professional mechanic!
♦ We recommend that you have access to a factory service manual for your vehicle to assist in the
disassembly and reassembly of your vehicle. It contains a wealth of detailed information.
♦ Prior to installation, carefully inspect the vehicle’s steering and driveline systems paying close at-
tention to the tie rod ends, ball joints, wheel bearing preload, pitman and idler arm. Additionally,
check steering-to-frame and suspension-to-frame attaching points for stress cracks. The overall
vehicle must be in excellent working condition. Repair or replace all worn or damaged parts!
♦ Read the instructions carefully and study the illustrations before attempting installation! You may
save yourself a lot of extra work.
♦ Check the parts and hardware against the parts list to assure that your kit is complete. Separating
parts according to the areas where they will be used and placing the hardware with the brackets
before you begin will save installation time.
♦ Check the special equipment list and ensure the availability of these tools.
♦ Secure and properly block vehicle prior to beginning installation.
♦ ALWAYS wear safety glasses when using power tools or working under the vehicle!
♦ Use caution when cutting is required under the vehicle. The factory undercoating is flammable.
Take appropriate precautions. Have a fire extinguisher close at hand.
♦ Foot pound torque readings are listed on the Torque Specifications chart at the end of the instruc-
tions. These are to be used unless specifically directed otherwise. Apply thread lock
pound where specified.
retaining com-
♦ Please note that while every effort is made to ensure that the installation of your Pro
Comp lift kit is a positive experience, variations in construction and assembly in the
vehicle manufacturing process will virtually ensure that some parts may seem difficult to install. Additionally, the current trend in manufacturing of vehicles results in
a frame that is highly flexible and may shift slightly on disassembly prior to installation. The use of pry bars and tapered punches for alignment is considered normal
and usually does not indicate a faulty product. However, if you are uncertain about
some aspect of the installation process, please feel free to call our tech support department at the number listed on the cover page. We do not recommend that you
modify the Pro Comp parts in any way as this will void any warranty expressed or
implied by the Pro Comp Suspension company
.
Please Note:
• Front end and head light realignment is necessary!
• Speedometer and ABS recalibration will be necessary if larger tires (10% more than stock
diameter) are installed.
• Tire and wheel choice is crucial in assuring proper fit performance and the safety of your
Pro Comp equipped vehicle. For this application a wheel not to exceed 8 in width with a
maximum backspacing of 3.5 must be used. Diameter of wheel may be any of the following 3 choices, 15, 16, 17. Any other diameter, either smaller or larger, will not be endorsed
as acceptable by Pro Comp Suspension and will void any and all warranties, written or implied. In addition, a quality tire of radial design, not to exceed 33” tall x 12.5 wide is recommended.
4
INSTRUCTIONS:
57289
REVISED
2.1.06
PLEASE NOTE:
⇒ This is a mechanical change of 4”
in front, 3” in rear.
⇒ Front end alignment is needed after
installation, set to factory specs.
⇒ Do not adjust torsion bars; leave at
factory specs.
BEFORE YOU BEGIN:
⇒ Read the instructions and study
the illustrations before attempting installation. Separating parts according
to the areas where they will be used
and placing the hardware with the
brackets before you begin will save
installation time.
⇒ Check the parts and hardware
against the parts list to assure that
your kit is complete.
⇒ Secure and properly block vehicle
prior to beginning installation.
⇒ Always wear safety glasses when
using power tools.
FRONT:
1) Place floor jack under front axle and
raise vehicle. Place jack stands under frame
to support vehicle. Set emergency brake
and block rear wheels, in front and behind
tires. Remove front wheels.
2) Remove clip from front of brake line
and bracket. Cut bracket to center of hole to
remove brake line of bracket. Install new
brake line drop down bracket to OEM
bracket and put 3/8” flat washer on top. Insert 3/8” x 1” hex bolt through both brackets
and tighten with 3/8” nyloc nut on bottom.
You may need to reform line slightly. Be
sure not kink or cause any interference of
line. Reinstall OEM brake line clip to hose at
bracket. See ILLUSTRATION 1.
3) Remove the shocks, sway bar, and
bump stops on each side (4 bump stops total). Remove eccentric bolt and nut front and
rear. Remove front crossmember from
mounting bracket. On passenger side only,
cut the mounting bracket tabs off of the exist-
ILLUSTRATION 1
FLAT
WASHER, 3/8”
BRAKE
LINE DROP
DOWN
BRACKET
90-55089-5
HEX BOLT,
3/8” X 1” LG.
ILLUSTRATION 2
NYLOC
NUT,
3/8”
EXISTING
OEM
BRACKET
BRAKE
LINE
CUT HERE FOR
DIFFERENTIAL CLEARANCE
5
57289
REVISED
2.1.06
ILLUSTRATION 3
LOCATING
SPACER
90-1301
LOCK NUT, 5/8”
EXISTING
EXISTING
ECCENTRIC
BOLT
HEX BOLT, 5/8”
X 4-1/2” LG.
NOTE: BOLT
MUST BE INSTALLED AS
SHOWN.
EXISTING
A-ARM
DROP
BRACKET
A-ARM
ILLUSTRATION 4
HEX BOLT,
7/16” X 1”
LG.
REAR CROSSMEMBER
90-1290
NYLOC
NUT,
7/16”
FLAT
WASHER
, 7/16”
FLAT
WASHER,
7/16”
FLAT
WASHER
, 7/16”
A-ARM
DROP
BRACKET
NYLOC
NUT, 7/16
FLAT
WASHER
, 7/16”
HEX
BOLT,
7/16” x
1” LG.
6
57289
REVISED
2.1.06
ing bracket between the bolt holes for differential clearance. See ILLUSTRATION 2.
4) Remove eccentric bolts (front and
rear) on front lower a-arm.
5) Install the 4 a-arm drop brackets into
OEM brackets. Use new 5/8” x 4-1/2” hex
bolts and 5/8” lock nuts, placing the a-arm
drop bracket locating spacers on the outside.
NOTE: Locating spacers will go in only
one way and all 8 spacers are the same.
Reinstall front crossmember with OEM bolts.
Hand tighten bolts until brackets are aligned.
See ILLUSTRATION 3.
6) Using a straight edge, line up bottom
bracket tabs with upper OEM tabs. Then
tighten bolts. Torque to 100 ft./lbs. (Not crossmember bolts yet). Install OEM bolts
and nut into front crossmember to front differential. Tighten bolts and then tighten
crossmember bolts.
7) Install new rear crossmember using
7/16” x 1” bolts, 7/16” flat washers and ny-
loc nuts. Torque to 45 ft./lbs. Using a
straight edge, align upper tabs with lower
tabs and tighten bolts. Torque to 100 ft./lbs.
See ILLUSTRATION 4.
8) Install lower a-arms into lower a-arm
brackets. Reinstall OEM eccentric bolts with
hole in OEM cam washers at bottom. Install
OEM nuts and tighten nuts. NOTE:
Tighten nut, not bolt because cam will not
turn inside of tabs. Torque to 103 ft./lbs.
Refer back to ILLUSTRATION 3, if necessary.
9) Lower differential (keep steady so not
to pull out front driveshaft). Install center differential bracket (90-1277) at rear of front
differential as shown in ILLUSTRATION 5.
a) Install the 1/4” spacer tube at rear
lower mounting between differential and
ILLUSTRATION 5
HEX BOLT,
1/2” X 2-1/2”
LG.
FLAT
WASHER,
1/2”
SPACER
90-2022
CENTER
DIFFERENTIAL
BRACKET 90-1277
NYLOC
NUT, 1/2”
SPACER
90-2014
ILLUSTRATION 6
HEX BOLT,
1/2” X 11/4” LG.
EXISTING OEM
BOLT
(USE LOCTITE)
HEX BOLT,
1/2” X 2-1/4”
LG.
F
O
T
N
O
R
F
PASSENGER SIDE
DIFFERENTIAL
DROP BRACKET
90-1282
NYLOC
NUT, 1/2”
O
T
N
O
R
F
SPACER
90-2136
EXISTING
L
C
I
H
E
V
FLAT
WASHER
, 1/2”
C
I
H
E
V
F
E
E
L
7
57289
REVISED
2.1.06
bracket. Install existing OEM bolts
through bracket, spacer and into the two
bottom holes (with loctite). Torque to 70
ft./lbs.
b) Install 1-1/8” spacer tube at rear
of upper OEM rubber mount with 1/2” x 2-1/2” hex bolt, 1/2” flat washer and 1/2”
nyloc nut. Torque to 70 ft./lbs.
c) Install 3/4” spacer tube at rear of
upper OEM rubber mount with 1/2” x 2-1/4” bolt, 1/2” flat washer and 1/2” nyloc
nut. Torque to 70 ft./lbs.
10) Install passenger side differential
drop bracket using 1/2” x 1-1/4” hex bolt
with 1/2” flat washer and nyloc nut into
upper hole of OEM rubber mount. Wide
part of bracket should be at bottom with
hole towards front, as shown in ILLUSTRATION 6. Reinstall OEM bolt through
bracket and into side of differential (using
loctite). Torque to 70 ft./lbs.
11) Install driver side differential
drop bracket using OEM bolts in two
bottom holes (using loctite). Use 1/2” x
1-1/4” hex bolts, 1/2” flat washers and
1/2” nyloc nuts in two upper holes.
Torque to 70 ft./lbs. See ILLUSTRATION 7.
12) Remove tie rods from steering
knuckles. Remove two bolts on back
side of spindle which hold the metal
bracket for the brake hose.
13) Support lower a-arm with floor
jack and separate upper ball joint from
spindle. Using file, file corners off of
spindle to contour with bottom of new
spindle adapter so that the bottom of
the new spindle seat surface is in contour with OEM spindle top surface.
Clean out hole on top of steering
knuckle (spindle).
NYLOC NUT, 1/2”
EXISTING
ILLUSTRATION 8
EXISTING
TAPERED
SPINDLE
SLEEVE
96-4026
HEX
BOLT, 5/8”
X 2-1/2”
E
L
C
I
H
E
V
F
O
T
N
O
R
F
EXISTING
(USE LOCTITE)
FLAT WASHER, 1/2”
PASSENGER SIDE SHOWN
ILLUSTRATION 7
DRIVER SIDE
DIFFERENTIAL
DROP BRACKET
90-1283
FLAT
WASHER, 1/2”
HEX BOLT,
1/2” X 1
1/4” LG.
UPPER
BALL
JOINT
LOCK
NUT, 5/8”
ADAPTER
SPINDLE
90-4010
90-4009
EXISTING
(USE
LOCTITE)
8
57289
REVISED
2.1.06
14) Insert tapered spindle sleeve with
small end going downward, install 5/8” x 2-1/2” hex bolt and 5/8” lock nut as shown in
ILLUSTRATION 8. Torque to 100 ft./lbs.
15) Referring again to ILLUSTRATION 8,
reinstall brake hose bracket to new spindle
with OEM bolts (using loctite). Torque to
120 ft./lbs. Insert spindle into upper ball
joint; tighten. Torque to 105 ft./lbs. Reinstall
the rod. Torque to 67 ft./lbs. Reinstall all
cotter pins.
16) File down front bump stop lip on each
side of front for shock clearance. Install new
long shocks and tighten.
17) Install stock bump stop as shown in
ILLUSTRATION 9 using the 3/8” x 1” hex
bolt, 3/8” flat washer and 3/8” nyloc nut.
Repeat on other three bump stops.
18) Reinstall sway bar with the two sway
bar drop down brackets using OEM bolts
and nuts in top holes, adding a 5/16” flat
washer to the OEM flat washers; tighten.
Install sway bar to bottom of drop down
bracket using 5/16” x 1” hex bolts, 5/16” flat
washers and 5/16” nyloc nuts; tighten. See
ILLUSTRATION 10. (Driver side, use first
forward round hole and rear slotted hole with
slant downward, open side inward. Passenger side, use first slotted hole and rear round
hole with slant downward, open side inward).
Tighten sway bar bracket bolts and sway bar
pins in a-arm.
19) Install lower end of the compression
strut into the tabs located on the a-arm drop
brackets using the bushings and hardware
provided. Install the upper compression strut
mount, as shown in ILLUSTRATION 11. Using existing hardware.
20) Install the front wheel and lower the
vehicle.
ILLUSTRATION 9
FLAT
WASHER,
3/8”
EXISTING
NUT
STOCK
BUMP
STOP
ILLUSTRATION 9
EXISTING
FLAT
WASHER,
5/16”
HEX BOLT,
3/8” X 1”
LG.
FLAT
WASHER
, 3/8”
NYLOC
NUT, 3/8”
A-ARM
DROP
BRACKET
EXISTING
NYLOC
NUT, 5/16”
SWAY BAR DROP
DOWN BRACKET 901279 (DRIVER)
90-1278 (PASSENGER)
SWAY BAR
HEX BOLT,
5/16” X 1”
LG.
9
A-ARM
DROP
BRACKET
FLAT
WASHER,
1/2”
57289
REVISED
2.1.06
ILLUSTRATION 11
NYLOC
NUT, 1/2”
COMPRESSION STRUT
90-2155 (PASS.)
90-2154 (DRVR).
SLEEVE
90-2109
HEX BOLT,
1/2” X 4” LG.
BUSHING
15-11148
NOTE:
⇒ Measure from center of eccentric
adjustment bolt to ground to ensure
proper height.
⇒ On alignment, both sides inner and
outer tie rods may need to be pulled
out of adjusting sleeve and cut 1/2” off
tie rod ends so proper adjustment can
be achieved.
⇒ After installation is complete, dou-
ble check that all nuts and bolts are
tight. (Do not retighten nuts and bolts
where loctite was used). Recheck periodically.
F
PASSENGER SIDE
R
O
N
T
O
F
V
E
H
I
C
L
E
10
REAR INSTALLATION:
REAR: 86-89 4-Runner
86-95 Pickup
1) Place floor jack under rear axle and
raise vehicle. Place jack stands under frame
to support vehicle. Set emergency brake and
block front wheels, in front and behind tires.
Remove wheels and shocks.
2) Pull out brake line clip at rear brake
hose bracket. Bolt rear brake line drop down
bracket to existing bracket using 3/8” x 1”
hex bolt, 3/8” flat washer and 3/8” nyloc nut;
tighten. Install brake line into lower bracket
hole and reinstall OEM brake line clip. Refer
to ILLUSTRATION 12.
3) Unbolt brake equalizer arm bracket
from axle. Install rear brake cable extension
to axle with OEM bolts and tighten. Mount
equalized cable bracket to top of extension
using 5/16” x 1” hex bolts and 5/16” nyloc
nuts and tighten. See ILLUSTRATION 13.
4) Loosen emergency cables by removing
cotter pin, pulling pin out from back side of
brake backing plate at adjuster.
5) Remove u-bolts, lower axle and install
3 1/2” tapered blocks with tapered end towards transmission, as shown in ILLUSTRATION 14. Install new u-bolts, washers and
nuts and tighten. Reinstall emergency brake
cable, keeping cable under spring.
6) Install new longer shock absorbers.
7) Install the rear wheels and lower the
vehicle.
NOTE:
⇒ After installation is complete, dou-
ble check that all nuts and bolts are
tight. (Do not retighten nuts and bolts
where loctite was used).
ILLUSTRATION 12
NYLOC
NUT, 3/8”
REAR BRAKE LINE
DROP DOWN
BRACKET 90-1280
BRAKE LINE
⇒ Recheck periodically.
FLAT
WASHER
, 3/8”
ILLUSTRATION 13
NYLOC
NUT, 5/16”
EXISTING
HEX BOLTS
57289
REVISED
2.1.06
HEX
BOLT,
3/8” X 1”
LG.
HEX BOLT,
5/16” X 1” LG.
REAR
BRAKE
CABLE
EXTENSION
90-1276
11
57289
REVISED
2.1.06
TORQUE SPECIFICATIONS:
A-Arm Drop Bracket Bolts............... 100
ft./lbs.
Crossmember Bolts........................ 45
ft./lbs.
Eccentric Bolts.............................. 103
ft./lbs
Center Differential Bolts................ 70
ft./lbs.
Pass. Differential Brkt. Bolt........... 70
ft./lbs.
ILLUSTRATION 14
Drvr. Differential Brkt. Bolt........... 70
ft./lbs.
Tapered Spindle Sleeve Bolt........... 100
ft./lbs.
Brake Hose Brkt. to Spindle........... 120
ft./lbs.
Spindle to Upper Ball Joint............. 105
ft./lbs.
Tie Rod......................................... 67
Vehicles that have been enhanced for off-road performance often have unique handling characteristics due to the
higher center of gravity and larger tires. This vehicle may handle, react and stop differently than many passenger cars or
unmodified vehicles, both on and off–road. You must drive your vehicle safely! Extreme care should always be taken to
prevent vehicle rollover or loss of control, which can result in serious injury or even death. Always avoid sudden sharp turns
or abrupt maneuvers and allow more time and distance for braking! Pro Comp reminds you to fasten your seat belts at all
times and reduce speed! We will gladly answer any questions concerning the design, function, maintenance and correct use
of our products.
Please make sure your Dealer/Installer explains and delivers all warning notices, warranty forms and
instruction sheets included with Pro Comp product.
Application listings in this catalog have been carefully fit checked for each model and year denoted. However, Pro
Comp reserves the right to update as necessary, without notice, and will not be held responsible for misprints, changes or
variations made by vehicle manufacturers. Please call when in question regarding new model year, vehicles not listed by
specific body or chassis styles or vehicles not originally distributed in the USA.
Please note that certain mechanical aspects of any suspension lift product may accelerate ordinary
wear of original equipment components.
factory warranty as it pertains to certain covered parts; it is the consumer’s responsibility to check with their local dealer for
warranty coverage before installation of the lift.
Further, installation of certain Pro Comp products may void the vehicle’s
Warranty and Return policy:
Pro Comp warranties its full line of products to be free from defects in workmanship and materials. Pro Comp’s obligation under this warranty is limited to repair or replacement, at Pro Comp’s option, of the defective product. Any and all
costs of removal, installation, freight or incidental or consequential damages are expressly excluded from this warranty. Pro
Comp is not responsible for damages and / or warranty of other vehicle parts related or non-related to the installation of Pro
Comp product. A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will
assume all risk and responsibility for potential damages incurred as a result of their chosen modifications. Warranty coverage does not include consumer opinions regarding ride comfort, fitment and design. Warranty claims can be made directly
with Pro Comp or at any factory authorized Pro Comp dealer.
IMPORTANT! To validate the warranty on this purchase please be sure to mail in the warranty card.
Claims not covered under warranty-
• Parts subject to normal wear, this includes bushings, bump stops, ball joints, tie rod ends and heim joints
• Discontinued products at Pro Comp’s discretion
• Bent or dented product
• Finish after 90 days
• Leaf or coil springs used without proper bump stops
• Light bulbs
• Products with evident damage caused by abrasion or contact with other items
• Damage caused as a result of not following recommendations or requirements called out in the
installation manuals
• Products used in applications other than listed in Pro Comp’s catalog
• Components or accessories used in conjunction with other manufacturer’s systems
• Tire & Wheel Warranty as per Pro Competition Tire Company policy
• Warranty claims without “Proof of Purchase”
• Pro Comp Pro Runner coil over shocks are considered a serviceable shock with a one-year
warranty against leakage only. Rebuild service and replacement parts will be available and sold
separately by Pro Comp. Contact Pro Comp for specific service charges.
• Pro Comp accepts no responsibility for any altered product, improper installation, lack of or
improper maintenance, or improper use of our products.