Warrior 30741 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

30741 TJ 4” ECONOMY LIFT KIT

INSTALLATION INSTRUCTIONS

Warrior recommends this system be installed by a certified technician. In
addition to these instructions, professional knowledge of
disassemble/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 layout and list found on the last page of these
instructions. 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 multiple stabilizer kit is recommended for vehicles equipped with a winch or larger tires

PRODUCT USE INFORMATION

1. 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.

2. 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

3. Generally, braking performance and capability are decreased when significantly larger/heavier tires and wheels are used.

Take this into consideration while driving.

4. 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.

5. 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.

6. The required installation time for this system is approximately 8 hours.

7. This suspension system was developed using a 33 x 12.50R – 15 tire, on a 8” wheel. Before installing other

combinations, please consult your local tire and wheel specialist.

8. The following tools and supplies are recommended for proper installation of this kit.

a. Spring Compressor

b. Pitman Arm Puller
c. Silicone Spray

d. Drill Motor
e. Drill Assortment (1/8” to 1/2")

f. Torque Wrench (250 ft lbs. Capacity)
g. Hammer

h. _” Drive Ratchet and Sockets
i. Combination Wrenches

j. Allen Wrenches
k. Torx Key Socket

l. Hacksaw
m. File

n. Large “C” Clamps and/or Bench Vise
o. Hydraulic Floor Jacks

p. Heavy Duty Jack Stands
q. Wheel Chocks (Wooden Blocks)

r. Molybdenum Grease or Anti Seize Compound
s. Safety Glasses – Wear safety glasses at all times

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

FIGURE 1

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

STANDARD BOLT TORQUE SPECIFICATIONS

INCH SYSTEM

METRIC SYSTEM
Bolt
Size

Grade 5

Grade 8

Bolt Size

Class 9.8

Class 10.9

Class 12.9

5/16

15 Ft – Lbs

20 Ft – Lbs

M 6

5 Ft – Lbs

9 Ft – Lbs

12 Ft – Lbs

3/8

30 Ft – Lbs

35 Ft – Lbs

M 8

18 Ft – Lbs

23 Ft – Lbs

27 Ft – Lbs
7/16

45 Ft – Lbs

60 Ft – Lbs

M10

32 Ft – Lbs

45 Ft – Lbs

50 Ft – Lbs

_

65 Ft – Lbs

90 Ft – Lbs

M12

55 Ft – Lbs

75 Ft – Lbs

90 Ft – Lbs
9/16

95 Ft – Lbs

130 Ft – Lbs

M14

85 Ft – Lbs

120 Ft – Lbs

145 Ft – Lbs

5/8

135 Ft – Lbs

175 Ft – Lbs

M16

130 Ft – Lbs

165 Ft – Lbs

210 Ft – Lbs

_

185 Ft – Lbs

280 Ft – Lbs

M18

170 Ft – Lbs

240 Ft – Lbs

290 Ft – Lbs

NOTICE TO DEALER AND VEHICLE OWNER

Any vehicle equipped with any Warrior product 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

INSTALLATION INSTRUCTIONS

1. The front-end components are installed first.

2. Place the vehicle on a level surface. Set the parking brake. Center front wheels and chock rear wheels. From inside the

engine compartment, remove the upper stud nut, retainer and grommet form both of the front shocks Jack up the vehicle
and place jack stands on the frame rail behind the lower control arm mount on the frame. Installation is done one end at a
time.

3. Remove the front tires and wheels.

4. Place a floor jack underneath the axle for support and complete the removal of the front shock absorbers (DO NOT

REUSE THE ORIGINAL SHOCK ABSORBERS).

5. Remove the track rod from the axle housing and secure out of the way. Save the bolt and flag nut they will be reused in a

later step. Remove both of the front sway bar end links.

6. Remove the brake calipers and secure out of the way.

7. Mark the position of the lower control arm cam bolt and axle brackets for installation reference. (See Figure #1) If

equipped with ABS brakes, Remove the sensor wires and clamps for the inside of the lower arms and save clamps for re­use.

8. Remove the coil spring clip located on the bottom coil seat on both sides of the vehicle. Lower the axle and remove the

coil spring. A coil spring or strut compressor may be needed to remove the stock coil spring.

9. Install the coil spring. A coil spring or strut compressor will be needed for the new coil spring installation.

Compress the new coil spring to 16” in length. Install the new spring into the upper and lower spring pockets and
carefully remove the compressor. Make sure the coil is seated properly in the coil seat by rotating the spring so the pig
tail end fits in the spring pocket. Install the coil spring clamp and torque the spring clip bolt to 16ft.-lbs.

10. Repeat steps on other side.

11. Assemble the boots on the front shock absorbers, part #60506 and install in the factory lower mounts. Install the upper

stud bushings and tighten the upper mounting point. Tighten the bar pin on the bottom of the shock with the stock
hardware. Repeat this on the opposite side of the vehicle. Install the tires, wheels and lug nuts. Lower the vehicle to the
ground.

12. Align the reference marks on the adjustment cams and lower arm axle brackets and tighten to 85 ft. lbs.
Note: Longer brake lines are not required in the front with this kit unless the sway bar is disconnected. If disconnects are

used, longer brake lines are required. Install tires and wheels.

13. Chock the front wheels. Jack up the rear of the vehicle and remove the tires and wheels. Place jack stands on the frame

rail to support the vehicle. Place a floor jack under the differential. Remove the stock shock absorbers and sway bar

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

links. Retain the factory shock hardware it will be reused.

14. On the rear of the vehicle unbolt the track rod from the axle and secure out of the way.

15. Carefully lower the axle with the floor jack and remove the coil springs. NOTE: It may be necessary to use a coil

spring or strut compressor to remove the stock coil springs. Be careful not to overextend the vent tube on the axle. It
may be necessary to disconnect the hose during installation and reroute the hose after installation.

16. Install the new Warrior coil springs making sure that the rubber damper is positioned in the upper mount. It will be

necessary to use a coil spring or strut compressor to install the new coil springs. Jack up the axle to compress the coil
spring and to align the track rod with the new mounting point and install the stock mounting hardware.

17. Assemble shock # 60507 with the shock bushings and sleeves in the shock bag on the larger barrel end. Install the

shocks on the vehicle with the factory hardware.

18. Reinstall the wheels, tires. Lower the vehicle to the ground and tighten the lug nuts to the factory torque specifications

(80-110 ft-lbs.)

19. Tighten lower arm pivot bolts to 130 ft. lbs and the track bar mounting bolts to 74 ft. lbs.

20. A brake line bracket is supplied with this kit for the rear of the vehicle. Remove the brake line at the frame mount. Do

not remove the rubber line from the steel line. This will cause the brakes not to function properly unless the lines are
bled. Mount the bracket to the factory location with the supplied hardware and tighten. Place the factory line at the other
end of the bracket in the slotted hole.

21. To install the transfer case, place the transmission in neutral and place a floor jack under the transmission mount skid

plate to support it.

22. Slightly loosen the bolts on the transfer case skid plate on both sides to allow for some movement. Do not remove the

bolts.

23. Proceed to other side. NOTE: Do not attempt to take out the bolts on both sides simultaneously. Installation is done one

side at a time. Remove the three bolts holding the transfer case skid plate to the frame rail.

24. Using the floor jack, slightly lower the skid plate and insert the six transfer case spacers.

25. Using the bolts and conical washers supplied with the kit slightly tighten the bolts. Do not fully tighten to allow for
some movement for the opposite side. Conical end of the washer must fit over the mounting hole in the cross-member.

26. After installing both sides, tighten bolts to 45ft lbs.

27. Center the steering wheel and mark the position of the original pitman arm. Remove the nut and washer from the
steering gear box.

28. Remove the pitman arm from the steering gear with a pitman arm puller.

29. Align and install new pitman arm on the steering gear shaft. Install the washer and nut. Tighten to 185 ft. lbs.

30. Install the drag link ball stud to the pitman arm. Install the nut and tighten to 60 ft lbs. Install a new cotter pin.

POST INSTALLATION INSTRUCTIONS

1. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all

rotating, mobile, fixed and heated members. Check steering gear for interference and proper
working order. Test brake system.

2. Readjust headlamps. Have the vehicle aligned to the following specifications:

Adjustment

Preferred

Range

Caster7°± 1°

Camber

- 0.25°

± .63°

Toe In (each

wheel)

0.15°

± .15°

Thrust Angle

0°

± .15°

3. Perform steering sweep. Check to ensure brake hoses have sufficient slack and will not contact

rotating, mobile, or fixed members, adjust lines/brackets to eliminate interference and maintain
proper working order. Failure to perform inspections may result in component failure.

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

4. Re torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during

routine vehicle service.

MAINTENANCE INFORMATION

It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 100
miles and then every

1000 miles. Wheel alignment, steering system, suspension and driveline systems must be inspected by a qualified professional mechanic at least every 3000
miles.

PARTS LIST

FRONT COIL SPRINGS

TRANSFER CASE

SPACER KIT

FRONT SHOCK

Black Shock Boots
(4)

800001

800029

60506 (2)

Boot Ties (4)
Installation
Instructions