Warrior 30640 User Manual

Protecting Your Adventure Lifestyle

========================================================================================

QUALITY • INTEGRITY • INNOVATION • SERVICE

Warrior, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone: [phone]
Fax: [phone]

[e-mail]
www.warriorproducts.com

30640 YJ 4” LIFT KIT

INSTALLATION INSTRUCTIONS

Warrior recommends this system be installed by a certified technician. In addition to these instructions, professional
knowledge of disassembly and reassembly procedures as well as post installation checks must be known. Attempts to install
this system without this knowledge and expertise may jeopardize the integrity and/or operating safety of the vehicle.

Please read instructions before beginning installation. Check the kit hardware against the parts diagram. Be sure
you have all needed parts and know where they go.

With the installation of all lift kits and larger tires it is important to check the condition of your steering stabilizer. If the
stabilizer is worn or is leaking it should be replaced. Steering stabilizers are designed to restrain “bump steering” and front
end vibration, giving added life to tires, ball joints, and other steering components. A large bore off-road stabilizer kit is

highly recommended for vehicles equipped with larger tires.

PRODUCT USE INFORMATION

As a general rule, the taller a vehicle is, the easier it will roll. Offset, as much as possible, what is lost in rollover resistance
by increasing tire track width. In other words, go "wide" as you go "tall". Many sportsmen remove their mud tires after
hunting season and install ones more appropriate for street driving; always use as wide a tire and wheel combination as
possible to enhance vehicle stability.

We strongly recommend, because of rollover possibility, that the vehicle be equipped with a functional roll-bar and cage
system. Seat belts and shoulder harnesses should be worn at all times. Avoid situations where a side rollover may occur
Generally, braking performance and capability are decreased when significantly larger/heavier tires and wheels are used.
Take this into consideration while driving.

Do not add, alter, or fabricate any factory or after-market parts to increase vehicle height over the intended height of the
Rough Country product purchased. Mixing component brands is not recommended.

Warrior makes no claims regarding lifting devices and excludes any and all implied claims. We will not be responsible for
any product that is altered.

If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products.

NOTICE TO DEALER AND VEHICLE OWNER

Any vehicle equipped with Warrior Suspension System products 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 life.

INSTALLATION INSTRUCTIONS

1. Raise the front of the vehicle and support with safety stands.

2. Remove the front wheels and tires. Remove stock shocks.

3. Support the front axle housing with a floor jack (you must have stands under frame supporting vehicle weight).

4. Unbolt track bar from the housing on the axle and then tie the bar up and out of the way (see figure 3 for relative

location).

5. The upper end of the front brake hoses attach to the top of each frame rail with one bolt located directly behind the

shock towers (see figure 2). Remove the bolts (access is gained through the engine compartment).

Protecting Your Adventure Lifestyle

========================================================================================

QUALITY • INTEGRITY • INNOVATION • SERVICE

Warrior, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone: [phone]
Fax: [phone]

[e-mail]
www.warriorproducts.com

6. Remove the four front spring to axle u-bolts. (The remainder of the spring removal and installation is performed one

side at a time.)

7. On the driver side position a floor jack beneath the axle tube, just inside of the leaf spring. Raise the jack until the axle

just separates from the spring. Now remove the frame bolts and the shackle bolts on the leaf spring. Repeat on the
other side.

8. Prior to installation of new springs, thoroughly lubricate the new spring poly eye bushings and sleeves with “water

resistant” lithium based grease. Loosely attach the spring to its hangers, snug up but do not completely tighten yet.
Make sure spring centering pin aligns and sets into spring perch hole.

9. While installing new u-bolts, put one bump stop extension snubber on top of axle tubes. (figure 1 shows how the bump-

stops are capture by the u-bolt. Tighten u-bolts to 65 ft. lbs. of torque. Tighten spring pivot bolts to 35ft. lbs. on both
frame mounts and shackle mounts.

10. To install new track bar bracket onto front axle housing, refer to instructions with Front Trac Arm Bracket.

11. Assemble and install new front shock absorbers (Boot installation and poly hourglass bushing installation can made

easier with the use of rubbing alcohol sprayed on the poly as a lubricant.). Tighten upper stem type mounts only until
bushings swell slightly, then torque lower mounts to 45 ft lbs.

12. Install new front brake line relocating brackets (#700021) in stock holes reusing the bolts on the frame rail. Pull steel line

out from the frame rail (Use caution when rerouting the steel line so you do not kink the line). Mount the line to the
bracket using the 5/16” x 1” bolts, washers and flange lock nut. Note: There is a driver side and a passenger side bracket
as shown in figure 2.

13. Reinstall tires/wheels, remove jack stands and lower vehicle to floor. Tighten the front spring’s shackle to 95 ft. lbs. and

the stationary end to 105 ft. lbs. (If kit includes pitman arm, you may want to do pitman arm instructions before
proceeding to rear of vehicle)

14. Once again as on the front (following same basic steps). Place safety (jack) stands under rear frame rails.

15. Remove the retainer clip that attaches the stock rubber brake hose to its upper mount bracket. This is where the rubber

hose ends and the metal line starts. Insert the new “Z” brackets in between the stock mounting bracket and the hose end.
The 5/16” x 1” bolt and flanged lock nut are used to attach the bracket to the bracket end. Position the hose/line through
the slot and into the hole on the “Z” bracket’s opposite end and then reinstall clip (See figure 5).

16. Disconnect tracking bar from frame rail. Install new drop down tracking bar mounting bracket (#800005) on housing as

shown in figure 4 using provided hardware.

17. Install new springs (#800020) with shims. (torque u-bolts 65 ft. lbs.) Remember to install the bump stop extension

snubber on as you did on the front. When installing the springs the thick part of shim goes toward front of jeep. Attach
tracking bar to drop down bracket using original 12mm bolt and flange-nut. (torque to 45 ft. lbs.)

18. Assemble the rear shock absorbers with loop bushings and corresponding sleeves and install shocks. Torque upper and

lower mounts to 45-ft. lbs. On some models there may not be adequate clearance between the shock body and the axle
tube. In this situation your only option is to relocate the shock bracket.

19. Install tires, remove jack stands, and lower vehicle to floor. Tighten the shackle to 95 ft. lbs. and the frame end to

105ftlbs.

20. Install Transfer Case Spacer Kit following instructions packaged with part #800006.

21. Install Pitman Arm Kit following instructions packaged with part #800016

Figure 2 - Brake line bracket

Figure 1