Fabtech FTS26016BK Manuel utilisateur

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 909-597-7185 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

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

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 -

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

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