Fabtech FTS24001BK Service manual

Installation Instructions
4” Performance Suspension System
1997-2006 JEEP TJ 4WD

4” 1997-2006 JEEP TJ 4WD
FTS24001BK
FTS24001 4" Jeep TJ Box 1 FT50086 Hardware Kit
Qty Part # Description Qty. Description
2 FT50013 Frt Sway Bar Bracket Upper 1 1/2"- 13 x 3" Bolt
1 FT50036 Frt Sway Bar Brk. Lower Dr. 1 1/2"- 13 x 1 1/4" Bolt
1 FT50066 Frt. Sway Bar Brk. Lower Pas 2 1/4"-20 x 1" Bolt
1 FT50068BK 4" Frt Sway Bar Link Drv 2 5/16"- 18 X 1" Bolt
1 FT50069BK 4" Frt Sway Bar Link Pass 6 1/2"- 13 x 3 1/4" Bolt
1 FT50015 Pitman Arm 6 12mm- 1.75 x 80mm
4 FT50027 Urethane Bump Stop 2 1/2"-13x 2 3/4" Bolt
4 FT50018BK Frt & RR Lower Links 4" 2 3/8"-16 Nylok Nut
6 FT50024 T/C Spacer 2 3/8" SAE Flat Washer
1 FT50053BK Rear Axle Trac Bracket 2 5/16"x3/4" Self Tapping Bolt
2 FT50026BK Rear Sway Bar Links 2 1/2"- 13 x 1 1/2" Bolt
1 FT50086 Hardware Kit 6 1/2"-13 Nylok Nut
1 FT50134BK Frt. Trac Bar Bracket 2 1/4"-20 Nylok Nut
1 FT50336 Hdwr Sub-Assembly 4 5/16"-18 Nylok Nut
18 1/2" SAE Flat Washer
FT50336 Hdwr Sub-Assembly Kit 6 12mm Flat Washer
Qty Part # Description 4 1/4" SAE Flat Washer
2 FT50067 Sway Bar link Frame Bracket 6 5/16" SAE Flat Washer
2 FT42 Sway Bar Pin 1 1/8" x 2" Cotter Pin
2 FT90036 Lynch Pin 8 Zerk Fittings
2 FT45 Sway Bar Key Ring 1 1/2"
2 FT50096 Bolt Tab Sway Bar
1 FT46 Rear Trac Bar Bracket Sleeve
2 FT50023 Frt Brake Hose Bracket
6 FT50205 97-02 Pan Bolt Taper Insert
1 FT50063 TC Shift Bracket
2 FT50048 Bushing Kit
1 FT50089 Sleeve Kit (frt sway bar)
1 FT50092 Sleeve Kit (rear sway bar)
1 FT95010 Trac Bar Frame Insert
1 56122251081 9/16"-12 x 2 1/4" Bolt
1 56120003052 9/16"-12 C-Lock Nut
1 56000005081 9/16" SAE Flat Washer
2 50130004152 1/2"-13 C-Lock Nut
2 50000005081 1/2" SAE Flat Washer
1 50131751081 1/2"-13 x 1 3/4" bolt
1 12002007000 Cotter Pin
1 FTREGCARD Registration Card
1 FTAS12 Decal
1 FTAS16 Driver Warning Sticker
2 FT24001i Instruction Sheet

4” 1997-2006 JEEP TJ 4WD
FTS24001
READ BEFORE BEGINNING INSTALLATION
TOOL LIST: (NOT INCLUDED)
FLOOR JACK & JACK STANDS
ASSORTED METRIC AND S.A.E SOCKETS, & WRENCHES
TORQUE WRENCH
DRILL AND ASSORTED DRILL BITS
SOME 2003 & UP MODELS MAY REQUIRES FRONT DRIVE MODIFICATION, CHECK DRIVE
LINE BEFORE DRIVING JEEP.
DO NOT ALTER THE FINISH OF THESE COMPONENTS, EXAMPLE- CHROMING, ZINC PLATING OR
PAINTING. CHANGING THE FINISH CAN CAUSE STRUCTURAL FATIGUE
OF COMPONENTS.
SUSPENSION SYSTEM MUST BE INSTALLED WITH FABTECH SHOCK ASBORBERS
VEHICLES THAT WILL RECEIVE OVERSIZED TIRES SHOULD CHECK BALL JOINTS, TIE RODS ENDS AND
IDLER ARM EVERY 2500-5000 MILES FOR WEAR AND REPLACE AS NEEDED
THIS KIT IS DESIGNED TO BE INSTALL ON A JEEP WITH STOCK AXLES & STOCK TRANSFER CASE &
STOCK SUSPENSION
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 THE KIT. IF ANY PIECES ARE MISSING, CONTACT FABTECH AT 909-597-7800
NOT ALL JEEPS COME WITH FRONT ECCENTRIC CAMS FROM THE FACTORY,SOME JEEPS WILL
REQUIRE MORE CASTER TO HELP WITH ALIGNMENT.

FRONT SUSPENSION INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. With the
Jeep 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 just behind the front bumper with jack stands.
NEVER WORK UNDER AN UNSUPPORTED
VEHICLE! Remove the front tires. Support the front axle
with a floor jack just enough so that axle does not hang
freely.
2. Working from both sides of the Jeep, remove the front
upper track bar nut and save. Pull the trac bar free from
factory mount.
3. Remove the sway bar link ends from the sway bar and
lower axle mounts and discard.
4. On 2003 models equipped with automatic transmissions,
you will need to remove the automatic transmission skid
plate and discard.
5. Remove the front shocks and discard. Save factory lower
shock hardware, discard upper hardware.
6. Remove the front drive shaft and save all hardware. On
some 2003 & up models you will need to
shorten the front driveline 1 ¾”, check drive
shaft for proper clearance before driving. On
1997-2002 models the stock driveline can be reinstalled
without modification.
7. Remove front coil springs and discard, save the lower coil
spring retainer (if equipped) and hardware. Remove factory
upper bump stop and discard.
8. Working from the driver side of the truck, locate the factory
lower link arm, remove and discard link and save factory
hardware.
9. Locate the new Fabtech lower link arm FT50018. Install
one supplied grease fitting into each end of the Fabtech
Link arm. Using factory hardware install the new link arm
into factory frame mount, then attach to axle mount using
the factory alignment cam bolts. Leave loose. NOTE:
MAKE SURE THE GUSSETS ON BOTH ENDS OF
THE LINK ARM ARE FACING DOWN. SEE PHOTO
IN NEXT COLUMN.
10. If installing Fabtech’s optional upper link arm kit, install
front upper at this time. See instructions included in
Fabtech’s upper link arm kit.
Step 11 is to be performed on NON RUBICON
models only.
Rubicon models brake lines will remain in stock
location.
11. Locate the factory brake line tab on the frame and remove
bolt. Locate the new Fabtech brake line bracket FT50023
and attach it to the frame with the stock bolt. Now attach
the stock brake line tab to the new Fabtech bracket with the
supplied 5/16 x 1” bolt, nut, and washer. SEE PHOTO
BELOW.
12. Locate the new Fabtech bump stop FT50027. Install into
factory pocket by pushing bump stop in until fully seated.
SEE PHOTO ON NEXT PAGE.

13. Repeat steps seven through twelve on the passenger side of
the truck.
14. Working from both sides of the truck Torque the lower link
arm bolts on the frame mounts to 130 ft lbs and to the axel
mounts to 85 ft lbs.
15. Locate the new Fabtech lift coil springs FT50004 and
install into the truck. You will want to slide coil over the
upper bump stop first than seat the coil in the lower pocket.
If truck was equipped, reinstall lower coil spring retainer.
16. Locate the new Fabtech front shocks FT7172 (not included
in kit) and install using factory lower hardware and the
supplied upper hardware from shock kit.
17. Locate the new Fabtech upper sway bar end link bracket
FT50013. Attach to the factory sway bar with the included
3/8” nyloc nut and washer. Locate the new Fabtech lower
sway bar end link bracket FT50036 (Note: There is a
driver and passenger lower sway bar end link bracket
take care to locate the correct bracket. When installing
bracket onto truck make sure the key way on the new
bracket is locked into the factory mount and that the
bracket is straight up and down). Attach to the factory
axle mount with the supplied ½” x 1 ½” bolt, nut and
washer. Locate the new Fabtech sway bar end link
FT50070 (Note: There is a driver and passenger sway
bar end link, see drawing) and press one bushing and one
sleeve from the supplied bushing kit into each end of the
end link. With the supplied ½” x 2 3/4” bolt, nut, and
washers connect to the upper sway bar mount. On 1997-
2002 Models locate the new Fabtech quick disconnect
frame bracket FT50067. With the supplied Fabtech quick
disconnect pin FT50025, connect to the quick disconnect
bracket, as shown below. Once connected swing the sway
bar end link with bracket forward until the bracket comes in
contact with the frame. Mark the spot on the frame with a
center punch and drill a guide hole. With the supplied 5/16”
self taper bolt, attach the quick disconnect bracket to the
frame. On 2003 Models locate the new Fabtech quick
disconnect frame bracket FT50067. Place on top of the
frame, under the brake line as shown below. Locate the
supplied FT50096 bolt tab and insert into the frame from
the bottom side. Using the supplied 5/16” nylok nut, and
washer attach the bracket to the frame. SEE PHOTOS
BELOW AND ON NEXT PAGE. Do not connect the
sway bar to the axle at this time.
Drv. Side End Link Pass. Side End Link
Frame Bracket on 1997-2002 Models

18. Locate the factory pitman arm, remove and discard, save
hardware. Locate the new Fabtech drop pitman arm
FT50015. Install back onto the truck in the same clock
position as when removed, use the factory hardware and the
supplied cotter pin to attach, torque to 185 ft lbs. SEE
PHOTO BELOW.
19. Using a drill with a ¾” drill bit, drill the factory upper trac
bar mount hole out. Locate insert 95010 and insert into the
factory mounting hole from the topside. Locate FT50134
Trac Bar Drop bracket and place against the frame as
shown below. Insert the supplied 9/16” bolt from the top of
the factory trac bar mount down into the new drop bracket
and follow with another flat washer and C-Lock nut. With
the new drop bracket flush to the factory mount, torque to
95 lbs. Using a drill with a ½” drill bit, drill the second hole
on the drop bracket out through the frame mount. Using the
supplied ½” x 2” bolt nut and washers secure it to the frame
(use care to put a ½” washer on both the bolt side and nut
when installing. Torque both bolts to 75 ft. lbs. SEE
DRAWING IN NEXT COLUMN AND ON LAST PAGE
Check fit front trac bar bracket before drilling the
hole, if bracket does not fit contact Fabtech tech line
887-432-2832
SEE DIAGRAM ON LAST PAGE
20. Reattach factory trac bar to the new drop bracket with the
factory hardware torque to 55 ft. lbs. Insert the new
supplied cotter pin through the factory trac bar.
21. With a transmission jack support the transmission and
transfer case, remove the factory transmission
crossmember, discard factory hardware.
22. Locate the factory transfer case shift linkage on the driver
side of the transmission. Remove the two bolts securing the
linkage to the body. (On some models you may need to
remove the linkage pivot arm for the truck and bend
the tab connecting the linkage pivot arm to the floor
shifter to clearance the new linkage drop bracket bolts.
It is recommend to install the linkage drop first to check
for clearance, if clearance is needed then proceed in
bending tab. See Photo In Next Column). Locate the
new Fabtech linkage drop bracket FT50063. Using the
supplied ¼ x 1” bolts, nuts, and washers attach the factory
linkage to the lower two holes in the new linkage bracket.
Using the factory hardware attach the new Fabtech bracket
to the body. SEE PHOTOS ON NEXT PAGE. NOTE:
WHEN INSTALLATION OF LIFT KIT IS
COMPLETE YOU MAY NEED TO ADJUST
LINKAGE ROD ON THE TRANSFER CASE
LINKAGE FOR PROPER SHIFTING.
Linkage Pictured Bent Above

23. On manual transmission models you will need to remove
the shifter arm from the center console of the truck and
make a small bend in the shift arm as shown below. SEE
PHOTO BELOW AND IN NEXT COLUMN.
Shifter Unbent
Shifter Bent
24. Locate the Fabtech transmission crossmember spacers
FT50024 and (FT50205 Pan Bolt Taper Insert for 97-02
Models only). Using the correct supplied bolts and washers
for your year Jeep, ½” x 3 1/4”(1997-2002) or 12mm-1.5 x
69.5mm (2003) reattach factory crossmember to the truck
with the Fabtech spacer between the frame and the
crossmember. Torque bolts to 85 ft lbs. On 97-02 models,
place the Pan Bolt Taper Inset into the crossmember before
the bolting the crossmember to the frame. SEE PHOTOS
BELOW AND ON NEXT PAGE.

25. Reinstall the front driveline, using factory hardware.
26. Install the front tires and wheels. Torque the lug nuts to
wheel manufacturers specifications.
REAR SUSPENSION INSTRUCTIONS:
27. Jack up the rear end of the vehicle and support the frame
rails just in front of the rear bumper with jack stands.
NEVER WORK UNDER AN UNSUPPORTED
VEHICLE! Remove the rear tires. Support the rear axle
with a floor jack just enough so that axle does not hang
freely.
28. Working on both sides of the truck and supporting the rear
differential with a jack remove and discard the rear shocks,
save shock hardware. Use care not to over extend the brake
hose.
29. Remove and discard the factory rear sway bar end links.
Save hardware.
30. Locate the lower track bar mount on the axle. Disconnect
the track bar from the axle and save hardware. Pull track
bar free from the factory mount. Remove the factory
plastic trim guard from the trac bar axle mount and discard.
31. Remove the coil springs and discard.
32. Remove the factory rubber bump stop and discard.
33. Working from the driver side of the truck, locate the factory
lower link arm, remove and discard link, save the factory
hardware.
34. Locate the new Fabtech lower link arm FT50018. Install
one of the supplied grease fitting into each end of the new
Fabtech link arm. Using factory hardware install new
Fabtech link arm into the factory frame mount, than attach
to axel mount using factory hardware. Leave loose. NOTE:
MAKE SURE THE GUSSETS ON BOTH ENDS OF
THE LINK ARM ARE FACING DOWN. SEE PHOTO
BELOW.
35. If installing Fabtech’s optional upper link kit, install rear
upper at this time. See instructions included in Fabtech’s
upper link arm kit.
36. Locate the new Fabtech bump stop FT50027. Install into
factory pocket by pushing bump stop in until fully seated.
37. Repeat steps thirty through thirty-five on passenger side of
truck.
38. Working from both sides of the truck torque the lower link
arms to 130 ft. lbs.
39. Locate the new Fabtech lift coils FT50005. Install new lift
coils into truck.
40. Locate the new Fabtech shocks FTS6001 (not included in
kit). Install on truck using factory hardware.
41. Locate the supplied FT50026 rear sway bar end links. Press
in one bushing and one sleeve into each end of the end link.
Install the end links onto truck using stock hardware.
Torque to 45 ft lbs.
42. Locate the new Fabtech rear track bar bracket FT50053BK.
Place the bracket on factory axel mount. With the supplied
½” x 3 ” bolt, nut, washers, and Fabtech sleeve FT46 attach
the lower hole of the bracket to the factory hole in the axle
bracket. (NOTE: THE SUPPLIED SLEEVE WILL BE
PLACED INSIDE THE FACTORY TRAC BAR POCKET
TO TAKE THE PLACE OF WERE THE TRAC BAR
WAS ORIGINALLY MOUNTED). Locate the hole in the
Fabtech bracket on the outer side. Drill a ½” hole through
the factory axle mount. Attach with the supplied ½” x 1¼”
bolt, nut, and washers. Reattach the track bar to the new
bracket with the factory hardware. Torque all trac bar bolts
to 74 ft. lbs. SEE PHOTO BELOW.

43. Install rear tires and wheels and torque lug nuts to wheel
manufacturer’s specifications. Turn front tires left to right
and check for appropriate tire clearance.
44. With the truck on level ground, connect front Sway Bar
End Links to axle mounts. SEE PHOTO BELOW.
45. Using a grease gun, grease all grease fittings in the new
Fabtech Link Arms.
46. Recheck all nuts and bolts for proper torque tightness
before driving. Drive the truck for 50 miles and have it
aligned to factory specifications.
47. Check front-end alignment and set to factory specifications.
Re-adjust headlights.

9/16” bolt install
from the top of
the factory trac
bar bracket
FT95010
Frame Sleeve
Factory drag link
Factory Trac
Bar Bracket
FT50134
Drop Trac Bar Bracket