YJ Pro-Comp CSC removal Rock Krawler 8" install - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 03-07-2006, 09:29 AM   #1 (permalink)
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YJ Pro-Comp CSC removal Rock Krawler 8" install

I am new to welding and fabricating so I deserve any flaming I get. The Procomp kit 5.5" coil spring kit was fine for street but didn't articulate well and basically drove like a tank. I decided to go with Rock Krawler due to design, heavy duty components and price. the 8" lift will allow 36-37" tires as well.
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Old 03-07-2006, 09:33 AM   #2 (permalink)
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I had to fix the cross member bolts first as 2 were spinning with the factory threaded inserts in the frame and one bolt broke off. I cut a hole in the side of the frame to access the inside. I welded a nut onto a 1.5" x 4" piece of 1/4 " steel with a hole drilled in the center of it. that way I could tighten it from below without it spinning in the frame. then I thought it would be even better if it was welded in place so I drilled a hole on each side of the bolt hole to weld it from below. Then I welded a patch using 1/4" steel with 1" overlap over the access hole.
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Old 03-07-2006, 09:35 AM   #3 (permalink)
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the Rock krawler kit lower control arm mount goes between the cross member and frame and gets welded in place. I had to cut off the factory mounts front and rear.
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Old 03-07-2006, 09:37 AM   #4 (permalink)
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this image shows the relationship of the factory mounts with the new lower control arm mounts.
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Old 03-07-2006, 09:42 AM   #5 (permalink)
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The lower control arm mounts have holes to line up with the factory mount holes for the cross member. however the large welds interfered with the flush mounting of the mount. I had to grind down the welds a little and rounded the inside of the mount to angle it a bit.
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Old 03-07-2006, 09:46 AM   #6 (permalink)
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The upper control mounts in the rear bolts to the frame directly above the lower control mount with a reinforcement plate on both sides of the frame. the exhaust had to be cut off as it will interfere with the rear triangulated upper control arms.
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Old 03-07-2006, 09:48 AM   #7 (permalink)
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On the drivers side the rear upper control arm mount interferes with the fuel lines and the emergency brake mounts. So they had to be removed.
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Old 03-07-2006, 09:51 AM   #8 (permalink)
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The rear axle components were put in place and welded to the axle. The truss needed some grinding to match the axle diameter but the shock mount was a perfect fit underneath. The tabs for the upper end of the shock were welded to the underside of the frame. then the control arms were adjusted and put into place.
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Old 03-07-2006, 09:51 AM   #9 (permalink)
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Rear coilover lower mount
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Old 03-07-2006, 09:52 AM   #10 (permalink)
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rear upper shock mounting tabs
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Old 03-07-2006, 09:53 AM   #11 (permalink)
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the front uses a track bar and a triangulated drivers side control arm
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Old 03-07-2006, 09:54 AM   #12 (permalink)
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It was a serious pain but the front upper shock mount was cut away in place of the RK mount. 1/4 inch steel and welded all the way around.
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Old 03-07-2006, 09:56 AM   #13 (permalink)
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In the front the lower coilover attachment is built into the axle hardware.
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Old 03-07-2006, 09:57 AM   #14 (permalink)
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The rear tires were put on and I had to wait for my new front axle. Got tired of breaking the D30 front so I had a hybrid 9"/D60 built.
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Old 03-07-2006, 09:58 AM   #15 (permalink)
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Side shot
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Old 03-07-2006, 09:59 AM   #16 (permalink)
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Front axle arrived built 2" wider than stock.
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Old 03-07-2006, 10:00 AM   #17 (permalink)
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Drivers side axle mount needed some serious cutting to fit. Had to be careful to allow room for the heim joints and used a cardboard template.
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Old 03-07-2006, 10:01 AM   #18 (permalink)
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With everything installed the front end sagged a bit.
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Old 03-07-2006, 10:03 AM   #19 (permalink)
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Found that the shock body was threaded and all that was needed was to thread the upper end of the coil stop down farther on the shock.
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Old 03-07-2006, 10:05 AM   #20 (permalink)
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Things leveled up nicely after that.
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Old 03-07-2006, 10:06 AM   #21 (permalink)
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I am still waiting on a new drag link with the larger ends and the pitman is being reamed out to accept that. went to a stock pitman arm and there is no bump steer due to the high steer setup. The muffler was installed with the turn facing down and cut off flush with the cross member. I'm not sure if I'll find a way to run it the rest of the way back. i may need to do some fender trimming once I go for a test ride.
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Old 03-07-2006, 01:08 PM   #22 (permalink)
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Looks good man!!! How do you like that kit? Im looking into going coil over in the near future and just wanted to get your ideas on the kit. Is it well put together? Im going to flatfender the front and rear so that should give me the additional clearance that I need to run and stuff 37's. Looks like it is coming together for you.

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Old 03-07-2006, 02:30 PM   #23 (permalink)
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This is my first experience with a project of this level. the kit is extremely heavy duty and mechanicallly seems to function well. Right after I bought this kit they came out with their new upgraded version. I didn't seem much difference except that the lower control arm mounts are now implemented into a new cross member, kind of like the warn kit. I'll have to let you know how well it functions and articulates once I get the drag liink from the fabricator. Noone has posted the ramp numbers. The rear shocks are 8" travel and the front are like 10" but it seems to articulate in the garage fairly well. they also changed to a different shock manufacturer, this kit has the Fox racing shocks. i like the adjustablitliy of the coil overs to level out the load. The lower control arms are like 1/2 inch steel and very heavy duty. They didn't give any recommendations for the exhaust on how to finish it. really no room to get past the rear upper triangulated control arms. It took more fabricating than I was expecting but even as a newbie I got through okay. A lot of the fab work was due to the new front axle swap to a 9"/D60 hybrid. even at 2" wider than stock there wasn't much driver side axle tube left for the mount. one side of the driver side mount was round and the other side was circular.
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Old 03-07-2006, 02:35 PM   #24 (permalink)
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I love the Stazworks beadlocks even though it took forever to get them. They were promised before christmas (6 weeks) and it actually took 3 months.
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Old 03-07-2006, 02:36 PM   #25 (permalink)
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Another shot with the IROKs. I went with 17x9 rims with 37" tires just in case I decided to go taller later on.
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