Warrior 30641 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

30641 ’87-’96 Economy 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
Warrior, 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. Make sure the vehicle cannot roll.

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 tracking bar from the housing on the axle and then tie the bar up and out of the way.

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

side at a time.)

6. 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 front spring U-bolts and frame bolts, and the shackle bolts on the
leaf spring. Repeat on the other side.

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

7. Prior to installation of new springs and shackles (#801490 Front - #801500 Rear), thoroughly lubricate the new spring

poly eye bushings and sleeves with “water resistant” lithium based grease. Loosely attach the spring (front spring
#800019) to its hangers, snug up but do not completely tighten yet. Make sure spring centering pin aligns and seas into
spring perch hole.

8. While re-installing your u-bolts, put one bump stop extension snubber on top of axle tubes. (Figure 1 shows how the

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

9. Assemble and install new front shock absorbers Part #60501 (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.

10. Install 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 read the pitman arm instructions and install
the pitman arm before proceeding to rear of vehicle)

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

12. Install rear shackles.

13. 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. Re­attach tracking bar.

14. Assemble the rear shock absorbers (Part# 60502) 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.

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

105ftlbs.

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

Figure 1