Warrior SR 180-2 User Manual

Protecting Your Adventure Lifestyle

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

QUALITY • INTEGRITY • INNOVATION • SERVICE

Warrior Products, Inc.

16850 SW Upper Boones Ferry Rd

Ste. A

Durham, OR 97224

Phone [phone]

Fax [phone]

[e-mail]

SR 180-2 SYSTEM

1976 – 1986 CJ5 and CJ7

INSTALLATION INSTRUCTIONS

*** READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION***

To install your WARRIOR SR 180 SYSTEM, be sure your jeep is on a level surface before
removal of front wheels and tires. You will need jack stands or a way to support your axle and your
chassis before you begin installing your new kit. If you have after market springs you must verify your
vehicle wheel base. The original location of your housing is very important, measure your wheel base
before beginning any work. Remember, your new kit was designed to fit with all factory springs.
After market springs may alter this wheelbase and your new kit may have to be adjusted accordingly.
Please read the instructions completely and understand all the provisions before you begin. If you
have any questions about your installation, call our factory direct technical department and ask for
assistance at 1-888-220-6861. AFTERMARKET LEAF SPRINGS may be longer. If they are you
may have to adjust the placement of your rear shackle hanger to insure that the prescribed angle for
the shackle is maintained!

***ALL WELDING MUST BE DONE BY A CERTIFIED WELDER***

1) Make all necessary measurements and make notes before jacking vehicle and removing

wheels.

2) Jack up front of jeep, put on frame supports (jack stands). Behind the rear of the front leaf

springs, firmly place on the frame to suspend entire front of jeep off the ground. Be sure jeep

is level and secure. Shake jeep to be sure it is stable.

3) Remove front wheels for ease of installation.

4) Remove front u-bolts (4). Raise front housing up and out of your way with a floor jack, support

housing with additional jack stands.

5) You should now be able to remove both front leaf springs completely from the jeep. Remove

the stock spring bushings on both ends of both front leaf springs and replace with the

polyurethane bushings supplied in your kit.

6) Remove both front shackle brackets from your front cross member. Retain all four (4) bolts, as

you will need these with your new front cross member. Remove front rivet from each side of

the frame and drill out hole, (1/2” drill bit), to except a new _” bolt included in installation kit.

Do this to both sides.

NOTE: the frame width on CJ7’s vary slightly, most are 27 9/16” which our kit is designed for. If your
frame is slightly wider, call the factory for assistance.

Protecting Your Adventure Lifestyle

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

QUALITY • INTEGRITY • INNOVATION • SERVICE

Warrior Products, Inc.

16850 SW Upper Boones Ferry Rd

Ste. A

Durham, OR 97224

Phone [phone]

Fax [phone]

[e-mail]

Install WARRIOR front cross member using the bolts you removed in step six (6) above with flat
washers, PLUS two(2) additional _” x 1” bolts supplied, also with flat washers and nuts. Tighten all
six (6) bolts, three (3) on each side, after all have been installed. Tighten factory bolts to factory
torque specifications, approximately 62 ft. lbs. and the _” bolts and nuts to 65 ft. lbs. of torque.

8) Remove front leaf spring rear brackets from the frame.

9) Clean frame thoroughly for welding purposes.

10) Measure 44 _” from the center of the front leaf spring mounting hole on your new WARRIOR

front bracket to the frame, make a scribe mark on the frame. Clamp rear WARRIOR bracket

to frame so measurement of 44 _” is centered in middle of hole in rear bracket. Before welding

be sure your new shackle will look like the picture A-4. If your not sure, install the front leaf

spring in the WARRIOR front bracket, install your warrior H-shackle to the rear of the spring,

install new bushings in the WARRIOR frame bracket, hook up the H-shackle to the frame

bracket and compare to picture A-4. Do not tighten bolts. If necessary, adjust the frame

bracket on the frame slightly to make it similar to picture A-4. The shackle should be straight

down to approximately 10 degrees forward, but no more. If you have after market springs this

measurement may vary slightly, so clamp shackle hanger to frame at that distance and

assemble the system. With vehicle back on the ground, adjust placement of shackle hanger to

assure the shackle will be pointed towards the front of the vehicle slightly at an angle of 0 to 10

degrees. Mark that location and then weld the hangers in place.

***IF YOU ARE IN DOUBT, CALL FACTORY BEFORE WELDING***

11) Proceed with welding of the frame bracket in accordance with picture A-5. IMPORTANT: Do

not weld completely around frame bracket but only in accordance with picture A-5. Not abiding

by this welding pattern will void all warranties.

12) If not done in step ten above, install front leaf springs with your WARRIOR H-bracket. The

front bolt is a 4” x 7/16”and the rear bolts are 41/2” x _”. Tighten front leaf spring bolt to 45 ft.

lbs. rear leaf spring bolt to 35 ft. lbs. and shackle frame bracket to 35 ft. lbs.

13) Lower front housing onto leaf springs, be sure leaf spring locating pin is in correct location,

reinstall front u-bolts, replace all that were stripped upon removal, not supplied in kit, torque to

factory specifications.

14) Install front wheels and tires, tighten to factory specifications.

15) Check all bolts for tightness, yes again.

16) For added strength you may wish to tac-weld front leaf spring bracket, do not make

continuous welds, paint all welds after they have had time to cool.

17) Lower Jeep to floor and test drive. Please inspect all bolts for tightness and all welds for

fractures.

18) Enjoy the way your Jeep now drives with your SR-180 SYSTEM.

*** ALL WELDING MUST BE DONE BY A CERTIFIED WELDER***