Fabtech FTS26016BK User manual

Installation Instructions
6” Performance Suspension System
2006-07 Toyota FJ Cruiser 2WD & 4WD
FTS26016BK / FTS26017BK / FTS26018BK
Fabtech Motorsports 4331 Eucalyptus Ave. Chino, CA 91710
Tech Line 909-597-7800 Fax [phone] Web www.fabtechmotorsports.com

2006-07 Toyota FJ Cruiser 2WD & 4WD
FTS26016BK / FTS26017BK / FTS26018BK
PARTS LIST:
FTS26016B
K Box 1 Front FTS26017BK
Box 2 Front
Qu
a Part # Description Qu a Part # Description
1 FTS70097D Driver Spindle 1 FT70082BK Front Crossmember
1 FTS70097P Pass. Spindle 1 FT70083BK Rear Crossmember
2 FT70099 Tie Rod End 2 FT70098 Crssmber Weld in Plate
2 FT70066BK Impact Tube 1 FT70058BK Skid Plate
2 FT70059BK Impact Tube Mount 1 FT70053 Drv. Lower Diff Bracket
2 50133501081 1/2"-13 X 3 1/2" Hex Bolt 1 FT70054 Pass. Lower Diff Bracket
1 FT70063 Spindle Brake Line Brkt Drv. 1 FT70056BK Drv. Frt. Bump Stop
1 FT70064 Spindle Brake Line Brkt Ps. 1 FT70057BK Pass. Frt. Bump Stop
1 FT70100BK Sway Bar Drop Driver
1 FT70101BK Sway Bar Drop Passenger FTS26018BK
Box 3 Rear
2 FT70106 Sway Bar Drop Nut Tab Qu
a Part # Description
2 FT70105 Sway Bar End Link 2 FT70084BK Upper Link Arm D/P
4 FT95023 1/2" Heim 2 FT70085BK Lower Link Arm D/P
2 FT70102 Sway Bar Hat
2 FT70103 Mis-Alignment Low Pro 1 FT70086BK Driver Coil Spacer
4 FT95020 or FT70159 Mis-Alignment 1 FT70086BK Passenger Coil Spacer
2 FT70094 Body Mount Weld In Plate 1 FT70088BK Trac Bar Bracket
2 FT70061 Front Brake Line Bracket 1 FT70096 Trac Bar Brk. Nut Tab
1 FT70069 Front Hardware Kit 1 FT70089 Brake Line Bracket
2 FT133 Sleeve, Impact Strut Brkt 2 FT70090BK Sway Bar End Link
1 FT1044 Bushing Kit 2 FT70093BK Rear Bump Stop Bracket
1 FT90087 Bushing Kit 1 FT50116 Sway Bar Bushing Kit
2 FTS88 Bump Stops 1 FT50089 Sway Bar Sleeve Kit
2 FT260161 Instruction Sheet 1 FT70091 Front & Rear Hardware Kit
2 FT83239 Rear Shock Spacer
FTS26010BK Coil Spacer Box 1 FT70092 Rear Bushing Kit
Qu
a Part # Description 2 103600007 Rear Shock Bushing
2 FT70055BK Coil Spacer

2006 Toyota FJ Cruiser 2WD & 4WD
FTS26012BK / FTS26013BK / FTS26014BK
FT70069 Hardware Kit - FT70091 Hardware Kit -
Qu
a Description Location Qu a Description Location
2 3/4"-10 x 4 1/2" Bolt Front Crossmember 4 7/16-14 x3 1/2" Bolt Impact Tube
2 3/4"-10 C-Lock 4 7/16"-16 C-Lock
4 3/4" SAE Flat Washer 8 7/16" SAE Flat Washer
2 9/16"-12 x 5" Bolt Rear Crossmember 2 1/2"-13 x 3" Hex Bolt Impact Tube Bracket
2 9/16"-12 C-Lock 2 1/2"-13 C-Lock
4 9/16" SAE Flat Washer 4 1/2" SAE Flat Washer
2 5/16"-18 x 1 1/4" Bolt Diff Skid Plate 2 5/16"-18 x 1" Bolt Frt Brake Line Drop
2 5/16"-18 C-Lock 2 5/16"-18 C-Lock
4 5/16" SAE Flat Washer 4 5/16" SAE Flat Washer
1 1/2"-13 1 1/2" Bolt 12 1/4"-20 x 3/4" Bolt ABS & Brake Line Clmps
1 1/2"-13 C-Lock 12 1/4" Split Washer
2 1/2" SAE Flat Washer 12 1/4" SAE Washer
2 1/2"-13 x 4" Bolt Diff Mounts 2 3/8"-16 x 1 1/4" Bolt Front Sway Bar Bracket
2 1/2"-13 C-Lock 2 3/8" SAE Flat Washer
4 1/2" SAE Flat Washer 2 3/8" Split Washer
4 3/8"-16 x 1 1/4" Bolt Bump Stop Brkt 2 3/8"-16 x 2 1/4" Bolt Sway Bar End Link (btm)
4 3/8"-16 C-Lock 2 3/8"-16 x 3" Bolt Sway Bar End Link (top)
8 3/8" SAE Flat Washer 4 3/8"-16 C-Lock Nut
2 10mmx1.25 x 25mm Bolt 6 3/8" SAE Flat Washer
2 10mm Flat Washer 4 1/2"-20 Jam Nut
2 3/8"-16 Nyloc Bump Stop 6 3/8"-16 x 1 1/4" Bolt Coil Spacers
2 3/8" SAE Flat Washer 6 3/8"-16 C-Lock Nut
4 3/8"-16 x 1 1/4" Bolt Sway Bar & Brkt 12 3/8" SAE Flat Washer
4 3/8"-16 C-Lock 4 8mm x 1.25x30 mm Bolt
8 3/8" SAE Flat Washer 4 8mm Split Washer
6 3/8"-16 C-Lock Coil Spacers 4 8mm Flat Washer
6 3/8" SAE Flat Washers 4 5/16"-18 x 1" Bolt Bumpstops
8 1/8" Cotter Pin 4 5/16"-18 C-Lock Nut
2 Thread Locking Cmpnd 8 5/16" SAE Flat Washer
1 9/16"-12 x 3 1/2" Bolt Trac Bar Bracket
1 9/16"-12 C-Lock Nut
2 9/16" SAE Flat Washer
1 1/2"-13 x 1 1/2" Bolt
1 1/2" Split Washer
1 1/2" SAE Flat Washer
3 5/16"-18 x 3/4" Bolt Brake & E-Brk Cbl Brkt
3 5/16"-18 C-Lock Nut
6 5/16" SAE Flat Washer

2 12mm x 1.75x70mm Bolt Sway Bar End Link
2 12mm x 1.75 C-Lock Nut
6 1/2" USS Flat Washer
2 3/8"-24 C-lock Nut
7 Adel Clamp (FTCLAMP) ABS Lines
2006 Toyota FJ Cruiser 2WD & 4WD
FTS26016BK / FTS26017BK / FTS26018BK
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.
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.
CHECK ALL PARTS INCLUDED IN THIS KIT TO THE PARTS LIST ABOVE BEFORE BEGINNING INSTALLATION OF
THIS KIT. IF ANY PARTS ARE MISSING, CONTACT FABTECH AT 909-597-7800
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 WILL NOT WORK ON TRUCKS EQUIPPED WITH ELECTRONIC CONTROLLED SHOCK
ABSORBERS
IF INSTALLING THE OPTIONAL DIRT LOGIC COILOVER, RECORD THE RIDE HEIGHT OF THE VEHICLE SO THAT
THE PROPER RIDE HEIGHT CAN BE DONE WHEN COMPLETED
YOU MUST RUN A 17X8 RIM OR LARGER WITH A 4 5/8” BACK SPACING WITH THIS KIT FOR PROPER WHEEL
CLEARENCE. 16” RIM WILL NOT FIT THE TRUCK ONCE THE KIT IS INSTALLED.
WELDING REQUIRED
VERIFY DIFFERENTIAL FLUID IS AT MANUFACTURES RECOMMENDED LEVEL PRIOR TO KIT INSTALLATION.
INSTALLATION OF THE KIT WILL RE-POSITION THE DIFFERENTIAL AND THE FILL PLUG HOLE MAY BE IN A DIFFERENT
POSITION. (FOR EXAMPLE, IF THE MANUFACTURE RECOMMENDS 3 QUARTS OF FLUID, MAKE SURE THE DIFF HAS 3 QUARTS
OF FLUID). CHECK YOUR SPECIFIC MANUAL FOR CORRECT AMOUNT OF FLUID.
TOOL LIST: (NOT INCLUDED)
•FLOOR JACK & JACK STANDS
•ASSORTED METRIC AND S.A.E SOCKETS, & WRENCHES
•LARGE C CLAMP OR C CLAMP VISE GRIPS
•DIE GRINDER WITH CUTOFF WHEEL OR SAWZALL

•TORQUE WRENCH
•MIG WELDER
•COIL SPRING COMPRESSOR
FRONT SUSPENSION INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. With the
vehicle on level ground, set the emergency brake and block
the rear tires. Jack up the front end of the truck and support
the frame rails with jack stands. NEVER WORK UNDER
AN UNSUPPORTED VEHICLE! Remove the front tires.
2. Working from both sides of the truck, locate and remove the
factory skid plate and brackets. Discard skid plate and
hardware, these will not be reinstalled on the truck. SEE
PHOTO BELOW.
3. Remove factory mud flaps off front of the vehicle and discard.
4. Remove the nut from the tie rod ends. Disconnect the tie rod
ends from the steering knuckle by striking the knuckle with a
large hammer to dislodge the tie rod end. Use care as to not
hit the threads on the tie rod end with the hammer as you
will damage them. Save all hardware. SEE PHOTO BELOW
5. Remove the sway bar end links from the factory steering
knuckles and leave connected to the bar. Then remove the bar
from the truck. Save the bar and end links with all hardware.
SEE PHOTOS BELOW.

6. Remove the brake caliper from the steering knuckle and hang
out of the way. Do not allow the brake caliper to hang from
brake line. Remove the brake line brackets from the knuckle.
Trucks equipped with ABS brakes, unbolt the ABS line and
disconnect from steering knuckle and the upper control arm.
Remove the bracket from the ABS line and discard. SEE
PHOTO ON NEXT PAGE
7. Remove the brake rotor, save all hardware.
8. Support the lower A-Arm with a floor jack. Loosen the upper
ball joint nut. Disconnect the upper ball joint from the upper
control arm by striking the knuckle with a large hammer next
to the ball joint to dislodge the ball joint. Use care not to hit
the ball joint when removing. Remove and save factory
castle nut.
9. Remove the castle nut and two bolts on each side connecting
the lower ball joint assembly to the knuckle. Save the Castle
nut, as you will reuse it. Remove spindle assembly from truck.
Remove remaining portion by striking with a large hammer
next to the ball joint to dislodge. Use care not to hit the ball
joint when removing. SEE PHOTO BELOW.
10. Remove the three upper nuts from the top of the strut
assembly then the lower bolt from the strut at the lower
control arm. Remove the shock assembly as one complete unit
and save with the hardware if installing the Basic Kit (coil
spacer), discard if installing Dirt Logic coilovers. SEE
PHOTOS IN NEXT COLUMN.

11. Remove and save the factory lower control arms with the
hardware.
Skip steps Twelve and Thirteen for 2wd model trucks
12. Disconnect the front drive shaft ONLY from the differential,
do not disconnect from the transfer case. Save hardware. Do
not allow drive shaft to hang freely.
13. Support the front differential with a transmission or floor jack.
Disconnect all electrical, vacuum lines, and breather lines
from the differential. Remove the rear differential nut and
save as you will reuse it during assembly. Remove the two
front differential bracket bolts from the frame. Discard the
bolts, as you will not reuse them. DO NOT SEPARATE
THE C.V. AXLES FROM THE DIFFERENTIAL.
Remove the differential from the truck and set aside. USE
CARE WHEN REMOVING DIFFERENTIAL AS TO
NOT DAMAGE THE C.V. Axles and 4WD VACUUM
ACTUATOR ASSEMBLY. SEE PHOTO ON NEXT
PAGE.
14. Locate the factory rear crossmember. Mark the crossmember
3 ½” from outside edge of the cam pocket adjustment hole
inward. On the top of the crossmember, locate the bottom
hole and measure down ¼”, draw a line strait across the top of
the crossmember and connect to the first line that is on the
back of the crossmember. On the bottom of the crossmember,
draw another line forward from the first line just beside the
weld for the control arm pocket. Take care to cut the
crossmember straight up and down and to not cut into the
control arm pocket itself or cut out the weld. You will use a
Sawzall or Die Grinder with a cutoff wheel to make these
cuts. Remove the rear crossmember section. Cut and discard.
SEE DIAGRAMS AND PHOTOS BELOW AND IN NEXT
COLUMN AND ON LAST PAGE
3 ½” from outside of cam
pocket to cut area

16. Locate FT70073 Weld in plate. You will need to weld in these
plates to cover the holes made by cutting out the original cross
member. Clean area to bare metal and weld in new plates. Let
plate cool and paint with a corrosive resistant paint or under
coating. SEE PHOTOS BELOW.
17. Working from the driver’s side, mark the front frame section /
body mount 5 ¾” from the face of the frame and the back at
8” from the frame SEE PHOTOS BELOW AND ON NEXT
PAGE

18. Use a sawzall and cut the marked area from the mount. Next,
sand and clean the cut area on the mount. Locate FT70094
Weld-in Plate. Check fit the plate against the mount for proper
fitment (it may be necessary to sand the mount for proper
fitment of the plate). Weld the plate in and paint after it has
cooled. SEE PHOTOS BELOW AND IN NEXT COLUMN
Skip step nineteen for 2wd model trucks.
19. Locate the front differential and remove the factory front
mounts. Discard the mounts and save the hardware. Locate
FT70053 Driver Diff mount, FT70054 Pass Diff mount, and
FT70071 Bushing and Sleeve Kit. Install the four bushings
and the two larger I.D. sleeves into the new mounts. Using the

factory hardware and some of the supplied thread-locking
compound, mount the new diff mounts to the front
differential. Torque the hardware to 75 ft. lbs. SEE PHOTO
ON NEXT PAGE.
20. Locate the Fabtech front crossmember FT70051, with the
supplied ¾” x 4 1/2” bolts, nuts, and washers, attach the
crossmember to the factory control arm pockets, leave loose at
this time. SEE PHOTO BELOW.
Skip step twenty-one on 2wd model trucks
21. Install the differential up onto the front crossmember with the
supplied ½” x 4” bolts and hardware. Support the differential
with a transmission jack. Leave loose at this time. SEE
PHOTOS IN NEXT COLUMN.
22. Locate the Fabtech rear crossmember FT70052, with the
supplied 9/16”x5 bolts, nuts, and washers install the
crossmember to the factory control arm pockets. Leave loose
at this time. Re-install the factory rear differential nut at this
time. SEE PHOTO BELOW.
There is no rear
differential on
2wd trucks