Warrior 30841 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

30840 / 30841 TJ 4” LIFT KIT

INSTALLATION INSTRUCTIONS

Warrior recommends installation of this kit by a certified technician. In addition to these
instructions, professional knowledge of disassemble/re-assembly 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.

A multiple stabilizer kit is recommended for vehicles equipped with a snow plow, winch,
or larger tires.

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. We recommend no larger than a 33x12.50” tire. Consult your local wheel & tire shop for backspacing and wheel size

recommendations.

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. Torq 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.

STANDARD BOLT TORQUE SPECIFICATIONS

INCH SYSTEM

METRIC SYSTEM

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

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 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. 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

2. time. The front-end components are installed first.

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 re-use.

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. Remove the stock lower control arm by removing the nut, cam, and cam

bolt from the axle bracket and then removing the nut and bolt from the frame bracket. Install the new bushings and
sleeves in the Warrior, Inc control arm and install on the vehicle using factory hardware – do not tighten at this time.
Note: The part of the arm with the slight bend in it will install on the axle mount.

10. If applicable, drill a 23/64” hole into each lower link and reinstall the ABS sensor wires. Use the original clamps.

11. 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.

12. Repeat steps on other side.

13. Install the WARRIOR, INC. track rod extension bracket in the factory location as shown in Figure #2. Slide the bracket

all the way up to the flange in the stock bracket. Install the stock bolt in the upper hole and tighten. Using the bracket as

Figure 2