Fabtech FTS24048BK User manual

Installation Instructions
8” Rear Crawler System
FTS24048BK
1987-1995 JEEP YJ 4WD
Fabtech Motorsports 4331 Eucalyptus Ave. Chino, CA 91710
Tech Line 909-597-7800 Fax [phone] Web www.fabtechmotorsports.com

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8” Rear Crawler System
FTS24048BK
1987-1995 JEEP YJ 4WD
Parts List:
FTS24067BK Sub-Box 1
Qty Part # Description
2 FT50222BK Rear Leaf Shackle
1 FT50264 Bushing & Sleeve Kit
2 FT50243BK Rear Axle Saddle
2 FT50244BK Rear U-Bolt Plate
4 FT730U U-Bolt
1 FT12H 1/2" U-Bolt Hardware
2 FTT20 Pass. Rear Shock Tabs
2 FT50272 Drv. Rear Shock Tabs
1 FT50251 Hardware Kit
1 FT50035 Rear Brake Hose
1 FTT79 Brake Line Clip
1 FT50268 E-Brake Cable Guide
FTS24068BK Sub-Box 2
Qty Part # Description
1 FT50254BK Traction Bar
1 FT50255 Traction Bar Axle Mount weld on
1 FT50258BK Crossmember
1 FT50256BK Crossmember Frame Bracket Drv
1 FT50257BK Crossmember Frame Bracket Pass
1 FT50259BK Shackle Traction Bar
2 FTS43 Mis-Alignment
1 FTS98003 Heim 3/4"
2 FTS98002 Solid Heim 3/4"
2 FT24048i Instruction Sheet
2 FTS44016 Rear Leaf Pack (not included)

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8” Rear Crawler System
FTS24048BK
1987-1995 JEEP YJ 4WD
FT50251 Rear Hardware Kit
Qty. Description Location
2 1/2"-13 X 2 3/4" Hex Cap Bolt Rear Shock Bolts
2 1/2"-13 C-locks
4 1/2" SAE Washer
2 1/2"-13 X 4 1/2" Hex Cap Bolt Rear Shackle @ Leaf Spring
2 1/2"-13 C-locks
4 1/2" SAE Flat Washer
2 9/16"-12 X 4 1/2" Hex Cap Bolt Rear Shackle @ Frame
2 9/16"-12 C-locks
4 9/16" SAE Washers
8 1/2"-20 C-Locks U Bolts Front And Rear
8 1/2" SAE Washer
4 7/16"-14 X 4 1/2" Hex Cap Bolt Rear Traction Bar Frame Brk.
4 7/16"-14 C-Locks
8 7/16" SAE Flat Washer
2 1/2"-13 X 4 1/4" Hex Cap Bolt Rear Traction Bar Cross bar
2 1/2"-13 C-Locks
4 1/2" SAE Flat Washer
1 1/2"-13 X 4 1/2" Hex Cap Bolt Rear Traction Bar @ Pivot
1 1/2"-13 C-Locks
2 1/2" SAE Flat Washer
1 1/2"-13 X 3" Hex Cap Bolt Rear Traction Bar @ upper Heim
1 1/2"-13 C-Locks
2 1/2" SAE Flat Washer
3 3/4"-16 Jam Nuts Rear Traction Bar
2 3/4"-10 X 2 1/2" Hex Cap Bolt
2 3/4"-10 C-Lock
4 3/4" SAE Flat Washer

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8” Rear Crawler System
FTS24048BK
1987-1995 JEEP YJ 4WD
** THIS SYSTEM IS DESIGNED TO BE USED ONLY WITH THE STOCK FACTORY YJ AXLES **
READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING
INSTALLATION! IF THESE INSTRUCTIONS ARE NOT PROPERLY FOLLOWED, SEVERE FRAME,
DRIVELINE AND / OR SUSPENSION DAMAGE MAY RESULT.
CHECK ALL PARTS INCLUDED IN THIS KIT TO THE PARTS LIST BEFORE BEGINNING
INSTALLATION OF THE KIT. THE LIST HAS ALL THE APPLICATIONS FOR ALL THE
VARIATIONS OF THE SYSTEMS. VERIFY THAT YOU HAVE THE CORRECT COMPONETS FOR
YOUR PARTICLUAR APPLICATION AND SYSTEM SELECTED. IF ANY PIECES ARE MISSING,
CONTACT FABTECH AT 909-597-7800
THIS KIT IS DESIGNED TO BE INSTALLED ON A JEEP WITH STOCK AXLES & STOCK
TRANSFER CASE & STOCK SUSPENSION
NOTE- PRIOR TO THE INSTALLATION OF THIS SUSPENSION SYSTEM A FRONT END
ALIGNMENT MUST BE PERFORMED AND RECORDED. DO NOT INSTALL THIS SYSTEM IF THE
VEHICLE ALIGNMENT IS NOT WITHIN FACTORY SPECIFICATIONS. CHECK FOR FRAME AND
SUSPENSION DAMAGE PRIOR TO INSTALLATION. THIS SUSPENSION SYSTEM DOES
REQUIRE WELDING FOR INSTALLATION.
THE INSTALLATION OF THIS SUSPENSION SYSTEM SHOULD BE PERFORMED BY TWO
PROFESSIONAL MECHANICS.
DO NOT ALTER THE FINISH OF THESE COMPONENTS, EXAMPLE- CHROMING, ZINC PLATING
OR PAINTING. CHANGING THE FINISH CAN CAUSE STRUCTURAL FATIGUE OF
COMPONENTS.
THIS SUSPENSION SYSTEM MUST BE INSTALLED WITH FABTECH SHOCK ASBORBERS
WILL NOT FIT ON 4CYL.

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8” Rear Crawler System
FTS24048BK
1987-1995 JEEP YJ 4WD
REAR DRIVE SHAFT INFORMATION
MODELS EQUIPPED WITH A NP231 TRANSFER CASE- INSTALLATION OF A FIXED YOKE CV
STYLE REAR DRIVESHAFT AND FIXED YOKE KIT WILL BE REQUIRED WITH THIS SYSTEM TO
REDUCE DRIVELINE VIBRATION.
THE JEEP YJ’S FROM 1987-1995 CAME WITH TWO OPTIONS FOR REAR DRIVESHAFTS. TO
DETERMINE WHICH DRIVESHAFT YOUR VEHICLE IS EQUPPPED WITH, MEASURE THE WIDTH
ON THE U-JOINT AT THE REAR AXLE. THE TWO OPTIONS ARE 3 ¼” OR 3 5/8”. THE 1987 – 1993
MODELS PREDOMINATELY CAME WITH THE 3 ¼” AND THE 1994-1995 MODELS CAME WITH
THE 3 5/8” U-JOINT. DUE TO MANY DIFFERENT ASSEMBLY PLANTS, YOU MUST MEASURE
THE DRIVESHAFT ON YOUR JEEP TO DETERMINE WHICH SHAFT YOU HAVE.
FTS94004 FIXED YOKE KIT
FTS94045 CV DRIVESHAFT w/ 3 ¼” / 1310 U-JOINT
FTS94046 CV DRIVESHAFT w/ 3 5/8” / 1330 U-JOINT
THE SHOCK TABS PROVIDED WITH THIS KIT ARE A WELD-ON INSTALLATION. ONLY AN
EXPIRENCED CERTIFIED WELDER SHOULD COMPLETE THIS INSTALLATION.
TOOL LIST: (NOT INCLUDED)
FLOOR JACK & JACK STANDS
ASSORTED METRIC AND S.A.E SOCKETS, & WRENCHES
TORQUE WRENCH
DRILL WITH ASSORTED DRILL BITS
DIE GRINDER w/ CUT OFF WHEEL & SANDING DISC
MIG WELDER

REAR SUSPENSION INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. Jack up the
rear end of the vehicle and support the frame rails just in
front of the rear bumper with jack stands.
2. Using a transmission jack or floor jack carefully support the
transmission. Remove the four transmission mount nuts
from the center of the crossmember and save. Remove
factory transmission crossmember from the frame mounts.
Save the factory hardware and the crossmember. (If
installing new optional Fabtech Pan section, discard the
factory transmission crossmember and hardware)
3. Remove the rear drive shaft and discard with the hardware.
A fixed yoke conversion and C.V. rear drive shaft will need
to be installed. Remove the front driveshaft and save with
the hardware. Remove the transfer case at this point, save
all hardware from transfer case. Locate the FTS94004 (not
supplied with this system) T-case conversion kit and follow
the instructions in that kit to complete the conversion. SEE
NOTES AT THE BEGINNING OF INSTRUCTIONS
ABOUT DRIVELINE
4. Re-Install T-Case and factory crossmember using the
factory hardware (or new Fabtech Pan and hardware).
Locate and install factory front drive shaft with factory
hardware (check for wear in the U-Joints and replace as
necessary).
5. Working on both sides of the truck and supporting the rear
differential with a jack, remove and discard the rear shocks,
save upper shock hardware. Use a line clamp or small vise
grip to crimp the factory line to keep the fluid from
draining and disconnect the rear brake hose from the rear
axle. SEE PHOTO BELOW
6. Locate, remove, and discard the trac bar and hardware
7. Locate the factory E-Brake cable adjuster. Measure the
amount of threads above the adjustment nut and write it
down and only loosen the adjuster enough to remove the
cables from the cable retainer. Next remove the cables from
the E-brake cable bracket on the frame and body and save
with the hardware. SEE PHOTO S IN NEXT COLUMN.
8. Supporting the rear differential with two floor jacks or two
heavy duty ratchet straps, remove and discard the factory
leaf springs, shackles, u-bolts with the spring plates, front
bumpstops, and hardware (Do not remove center the
bumpstops). Lower the axle and remove from under the
Jeep. SEE PHOTOS BELOW AND ON NEXT PAGE.
Use a
line
clamp to
prevent
hose
from
leakin
g

9. Remove the shackle bushings with the sleeves from the
frame and discard. Locate the supplied bushings and ½”
I.D. sleeves. Apply a small amount of grease to the
bushings and sleeve. Press the bushings into the frame first,
then the sleeve SEE PHOTO.
10. Locate FT50222 Rear Leaf Shackle and the supplied ½” x
4½” bolt and hardware. Place the shackle over the bushings
(the part of the shackle without the center gusset goes up)
and install with the bend of the boomerang facing towards
the rear of the Jeep. Leave loose at this time. SEE PHOTO
BELOW
Rear of Jee
p
11. Locate supplied leaf spring bushings and 9/16” sleeves and
install them into the rear leaf springs.
12. Install the assembled rear leaf pack with the supplied 9/16”
x 4½” hardware. Install the spring with the large military
style wrap in the front mount first, then into the new
boomerang shackle. Leave loose at this time. SEE PHOTO
BELOW.
non-military style wrap
in r
ear
13. Locate FT50243 Rear Axle Saddles, FT50244 Rear U-bolt
Plates, and supplied U-bolts. Place the Saddles on top of
the axle inside the factory leaf spring perch (the longer
side of the Saddle goes towards the rear of the Jeep).
Raise the axle enough for the saddle to make contact with
leaf springs. Place the u-bolt plates on top of the springs
and install the u-bolts and supplied hardware. Torque to 75
ft. lbs. SEE PHOTO ON NEXT PAGE.

14. Locate FT50255 Traction Bar Axle Mount “weld on” and
supplied 2¾” hardware. Position the bracket on the driver’s
side axle and into the factory trac bar mount (clean the axle
tube of any paint or grease). Insert the ½” hardware and
tighten only enough to hold the bracket to the axle for
welding at this time (make sure bracket is flush on axle
tube). Weld the bracket to axle housing. Paint the bracket
and axle housing after they have cooled. SEE PHOTOS
BELOW AND IN NEXT COLUMN.
ONLY AN EXPIRENCED CERTIFIED WELDER
SHOULD COMPLETE THIS INSTALLATION
Paint the
axle and
bracket
after
they
have
cooled
Long side of the Saddle
on rear of axle
15. Locate the factory lower shock mounts on the axle. Using a
die grinder with a cut-off wheel, cut and remove both of the
factory mounts from the axle. Once they are removed, use a
die grinder with a sanding disc to remove the remainder of
the bracket. SEE PHOTOS BELOW.
Insert ½” bolt
into factory
rear trac bar
mount and
bracket to
locate the
bracket on the
axle
Passenger side shown

16. Working from the driver’s side, locate FT50272 Driver
Side shock tabs, FTT20 Passenger side shock tabs, supplied
½”x 2 ¾” hardware, factory upper shock hardware, and
FTS7129 rear shocks (not included in this kit). Insert one of
the provided shock sleeves into the bushings on the body
end of each shock. Mount the shocks (with the body down)
to the upper shock mount with the factory hardware. Fully
extend the shocks. Mount the tabs to the shocks with the ½”
hardware and leave loose. Fabtech shocks must be
used with this system. They are the suspension
/ driveline limiting stop.SEE PHOTO BELOW.
Driver Side Shown
17. Use a floor jack to raise the axle so that the axle hub-to-
fender height is 28 3/8” on both sides of the Jeep. On the
driver’s side, place the tabs up to the axle and position them
so the tab fits on the trac bar bracket and axle with the
shocks fully extended. The outer tab mounts 2” inward
from the Fabtech axle saddle. Place tack welds on the
corners of each tab to the axle. On the passenger side, place
the tabs up to the axle and position them so they are at the
same position as the driver’s side tabs with the shocks fully
extended. The outer tab mounts 2” inward from the Fabtech
axle saddle. Place tack welds on the corners of each tab to
the axle. Double check all of the measurements and remove
the shocks. Weld both sides on each of the gussets to the
axle tube. Once cooled, paint the axle and tabs and re-
install shock. Torque the upper hardware to 44 ft. lbs and
the lower to 75 ft. lbs. SEE PHOTOS IN NEXT
COLUMN.
THESE TABS ARE A WELD-ON INSTALLATION.
ONLY AN EXPIRENCED CERTIFIED WELDER
SHOULD COMPLETE THIS INSTALLATION.
Driver Side Shown
Driver Side Shown
Passenger Side Shown
2” distance
2” Distance

Passenger Side Shown
18. Locate the factory brake hose from the frame to the rear
axle. Remove and discard hose. Locate the Fabtech rear
brake hose FT50035 and FTT79 brake hose clip. Slide the
new brake hose through the factory bracket and attach the
brake hose to the hard line on the frame. Using the supplied
brake hose clip FTT79, attach the brake hose to the bracket.
Then attach it to the hard line on the axle using the factory
hardware. SEE PHOTOS BELOW ON IN NEXT
COLUMN.
Hose needs run down from factory hard line and parallel the frame
19. Locate the factory bottom hole on the e-brake cable retainer
for the driver’s side. Measure down 2” and drill a 9/16”
hole and insert the driver’s side cable. SEE PHOTO
BELOW.
20. Route the passenger side cable over the top of the leaf
spring and then over the top of the muffler hangers and
insert into the retainer.
bend hard
line to fit
properly
around the
weld on trac
bar bracket
Drill 2” below factory
hole for the driver’s
side cable