FABTECH FT24131i Long Travel Box Kit Installation Guide

: June 13, 2024
: FABTECH

Table of Contents

FABTECH FT24131i Long Travel Box Kit
Product Information
Parts List

FABTECH FT24131i Long Travel Box Kit

Product Information

The 2007-18 Jeep Wrangler (JK) Long Travel Box Kit (FT24131i) is a suspension system designed and manufactured by Fabtech Motorsports. It includes various components such as the JK Pitman Arm, front and rear sway bar end links, hardware subassembly, front and rear bump stop spacers, front track bar bracket, weld-on rear track bar bracket, lower shock mounts, and other hardware necessary for installation.
Fabtech Motorsports is located at 4331 Eucalyptus Ave. Chino, CA 91710. Their technical line can be reached at 909-597-7800, and their website is www.fabtechmotorsports.com .

Parts List

FTS24131 – Long Travel Box Kit
FT50294 – JK Pitman Arm
FT50261BK – Front Sway Bar End Link
FT50037BK – Rear Sway Bar End Link
FT50508 – Hardware Subassembly
FT50492 – Front Bump Stop Spacer
FT50724 – Rear Bump Stop Spacer
FT50517 – Hardware Kit
FT50368 – Front Track Bar Bracket Weld On
FT50342 – Rear Track Bar Bracket Weld On
FT50434BK – Lower Shock Mount (Driver)
FT50435BK – Lower Shock Mount (Passenger)

Required Tools (Not Included)

Basic Hand Tools
Floor Jack
Jack Stands
Torque Wrench
Drill with assorted drill bits
Welder
Assorted Metric and S.A.E sockets

Pre-installation Notes

Check all parts against the parts list before starting installation. Contact Fabtech at 909-597-7800 if any parts are missing.
Read all instructions thoroughly before beginning the installation to avoid frame, driveline, and suspension damage.
Check local laws for legality before installing the system.
Perform a front end alignment and record before installing this suspension system. Do not proceed if the vehicle alignment is not within factory specifications. Check for frame and suspension damage beforehand.
The installation should be done by two professional mechanics.
This suspension system must be installed with Fabtech shock absorbers.
Apply the provided thread locking compound on all hardware.
Installation of this system may alter the vehicle’s center of gravity and increase the risk of rollover compared to stock.
Vehicles with oversized tires should regularly inspect and replace worn ball joints, uniballs, tie rod ends, pitman arm, and idler arm every 2500-5000 miles.

Product Usage Instructions

To install the 2007-18 Jeep Wrangler (JK) Long Travel Box Kit, follow these steps:

Ensure you have all the necessary tools mentioned in the “Required Tools” section.
Refer to the optional kit box instructions prior to installation.
Read and understand all pre-installation notes provided in the user manual.
Carefully check all parts against the parts list to ensure everything is included. Contact Fabtech if any parts are missing.
Perform a front end alignment and record the results. Do not proceed if the vehicle alignment is not within factory specifications.
Inspect the vehicle’s frame and suspension for any damage. Do not install the suspension system if there is existing damage.
Follow the step-by-step installation instructions provided in the user manual, starting from the beginning and proceeding in order.
Use the provided thread locking compound on all hardware to ensure secure installation.
Ensure that the suspension system is installed by two professional mechanics for proper installation and safety.
After installation, regularly inspect and replace worn components as mentioned in the user manual.

If you encounter any difficulties or have technical questions during the installation process, contact Fabtech Motorsports at 909-597-7800 or email info@fabtechmotorsports.com for
assistance.

PARTS LIST

| FTS24131| LONG TRAVEL BOX KIT
---|---|---
1| FT50294| JK PITMAN ARM
2| FT50261BK| FRONT SWAY BAR END LINK
2| FT50037BK| REAR SWAY BAR END LINK
1| FT50508| HARDWARE SUBASSEMBLY
2| FT50492| FRONT BUMP STOP SPACER
2| FT50724| REAR BUMP STOP SPACER
1| FT50517| HARDWARE KIT
1| FT50368| FRONT TRACK BAR BRACKET WELD ON
1| FT50342| REAR TRACK BAR BRACKET WELD ON
1| FT50434BK| LOWER SHOCK MOUNT (DRIVER)
1| FT50435BK| LOWER SHOCK MOUNT (PASSENGER)
| FT50508| HARDWARE SUBASSEMBLY
---|---|---
1| FT157| SLEEVE 1.000 X .563 X 1.570
2| FT50048| SWAY BAR END LINK BUSHINGS (4 PACK)
2| FT50089| SWAY BAR END LINK SLEEVES (4 PACK)
2| FT50060| FRONT BUMP STOP NUT TAB
1| FT50451| BRAKE LINE PAIR (FRONT)
1| FT50452| BRAKE LINE PAIR (REAR)
1| FT167| SLEEVE .875 X .563 X 1.344
2| FT50443| SLEEVE 1.000 X .500 X 1.550 (SHOCK MOUNT)
1| FT50362| REAR TRACK BAR GUSSET
1| FT50360| SWAY BAR LINK MOUNT (DRIVER)
1| FT50361| SWAY BAR LINK MOUNT (PASSENGER)
2| FT42| SWAY BAR PIN
2| FT45| KEY RING
2| FT50359| SWAY BAR RETAINER
2| FT90036| LYNCH PIN 1/4”
1| FT50298| E-BRAKE BRACKET
1| FT24131i| INSTRUCTIONS
1| FTLUBE| URETHANE LUBE PACKET
1| FTAS12| STICKER FT BLUE 10X4
1| FTAS16| DRIVER WARNING DECAL
1| FTREGCARD| REGISTRATION CARD
| FT50517 – HARDWARE KIT| LOCATION
---|---|---
3| 9/16-12 X 3 HEX BOLT G8 ZC| TRACK BAR
3| C-LOCK NUT 9/16”-12 CLEAR ZINC|
6| 9/16 SAE WASHER G8 ZINC|
2| 1/2-13 X 3-3/4 HEX BOLT G8 ZINC| FRONT BUMP STOP
6| 1/2-13 X 2-3/4 HEX BOLT G8 ZINC| SWAY BAR FRT/REAR
2| 1/2-13 X 1-1/4 HEX BOLT G8 ZINC| SWAY BAR BRACKET
2| 1/2-13 X 4-1/2 HEX BOLT G8 ZINC| LOWER SHOCK MOUNT
10| 1/2-20 C-LOCK NUT ZINC|
20| 1/2 SAE WASHER G8 ZINC|
6| 3/8-16 X 1 HEX BOLT G8 ZINC|
6| 3/8-16 C-LOCK NUT ZINC|
12| 3/8 SAE WASHER G8 ZINC|
4| 5/16-18 X 1 HEX BOLT G8 ZINC| REAR BUMP STOP
4| 5/16-18 C-LOCK NUT ZINC|
8| 5/16 SAE WASHER G8 ZINC|
6| 1/4-20 X 1” HEX BOLT G5 ZINC| BRAKE LINES
4| 1/4-20 X 1-1/4” HEX BOLT| SWAY BAR
10| 1/4-20 C-LOCK NUT ZINC|
24| 1/4 SAE WASHER G5 ZINC|
4| CLAMP 3/8X1/2W .26THK NEOPRENE|
4| BRAKE LINE SPRING|
4| 1/2” TEK SCREW|
1| 7/8” LOCK WASHER| PITMAN ARM
1| THREAD LOCKING COMPOUND|

– TOOL LIST –

Required Tools (Not Included)

Basic Hand Tools
Floor Jack
Jack Stands
Torque Wrench
Drill w/ assorted drill bits
Welder
Assorted Metric and S.A.E sockets

NOTE: REFER TO OPTIONAL KIT BOX INSTRUCTIONS PRIOR TO INSTALLATION.

PRE-INSTALLATION NOTES

For technical assistance call: 909-597-7800 or e-mail: info@fabtechmotorsports.com

READ THIS BEFORE YOU BEGIN INSTALLATION –

Check all parts to the parts list above before beginning installation. If any parts are missing contact Fabtech at 909-597-7800 and a replacement part will be sent to you immediately.
Read all instructions thoroughly from start to finish before beginning the installation. If these instructions are not properly followed severe frame, driveline and / or suspension damage may occur.
Check your local city and state laws prior to the installation of this system for legality. Do not install if not legal in your area.
Prior to the installation of this suspension system perform a front end alignment and record. Do not install this system if the vehicle alignment is not within factory specifications.
Check for frame and suspension damage prior to installation.
The installation of this suspension system should be performed by two professional mechanics.
This suspension must be installed with Fabtech shock absorbers.
Use the provided thread locking compound on all hardware.
WARNING- Installation of this system will alter the center of gravity of the vehicle and may increase roll over as compared
to stock.
Vehicles that receive oversized tires should check ball joints, uniballs, tie rods ends, pitman arm and idler arm every 2500-5000 miles for wear and replace as needed.
Verify differential fluid is at manufactures recommended level prior to kit installation. Installation of the kit will reposition 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.
THE INSTALLATION OF THIS KIT REQUIRES WELDING, AND SHOULD BE PERFORMED BY A CERTIFIED WELDER

FOOTNOTES –

For heavy offroad use, front driveshaft is required. Order FTS94057
For heavy offroad use, rear driveshaft is required. See a quality driveline supplier to order

INSTRUCTIONS

FRONT SUSPENSION
NOTE: REFER TO OPTIONAL KIT BOX INSTRUCTIONS PRIOR TO INSTALLATION.

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. Support the front axle. Do not allow to hang freely. Refer to coil spring instructions for disassembly of end links, coil springs and other components.
Working from the driver side of the truck, unbolt the front brake line bracket from the frame and save the hardware. Remove the ABS sensor wire from the C-Clips on the front knuckle. Remove and discard the sway bar end link, save the hardware. On Rubicon models only: Unplug the front diff locker harness from the axle.
Remove the front shock, Remove the factory coil spring and discard, you will need to allow the front axle to hang freely to remove the coil spring. Do not remove the factory upper coil isolator. Repeat on passenger side.
Use a pitman arm puller and remove the stock pitman arm. Discard the arm and save the nut and washer. Locate the FT50294 pitman arm and 7/8” lock washer, install in the same position as the stock one was with the factory hardware. NOTE: Use thread locker. Torque to 195 LBS SEE FIGURE 1
With the Trac Bar removed from the Jeep, remove any and all paint, dirt, or debris from the axle housing where the new bracket is to be installed. The inside front corner of the coil spring mount will need to be cut / trimmed. From the front of the mount, cut 1 ¼” back and ¾” in and down to the axle (This is just a starting point. Each vehicle will need to be trimmed to fit due to variances from Jeep to Jeep). SEE FIGURES 2-3
Locate FT50368 Trac Bar Bracket, supplied 9/16” bolt, washers, & nut, and FT167 Track Bar Sleeve. Place a
9/16” flat washer on the outside of the bolt and put it through the new bracket and put another 9/16” flat washer on the bolt. Position the new bracket with the bolt and washers onto the top of the axle and track bar mount. Weld the gusset as shown in the photos. SEE FIGURES 4- 6
Once the bracket has completely cooled, paint all bare metal areas. SEE FIGURE 7
Place the new FT50492 (Front bumpstop) onto the factory bumpstop pad. Using a center punch mark for drilling. SEE FIGURE 8
Drill out the bumpstop pad to 1/2” SEE FIGURE 9
Repeat steps 8-9 on passenger side.
Install the new coils and bumpstops together using the supplied 1/2-13 X 3-3/4” bolts and FT50060 (Nut Tab). SEE FIGURES 10-12 Torque to 127 ft-lbs
Locate FT50434BK (Driver Lower Shock Mount), FT50443 Sleeve, 1/2-13 X 4-1/2” bolt, 3/8-16 X 1” bolts and necessary washers/nuts. Install the bracket like shown
in FIGURES 13-16. Install the 1/2” bolt through both the new bracket and factory shock bracket using the spacer sleeve in the old shock location. Then install (2) 3/8” bolts and hardware on the bottom of the same bracket. NOTE: The existing hole on the side of the coil perch needs to be drilled out to 3/8”, then install the 3rd 3/8” bolt and hardware.
REPEAT STEP 12 ON THE PASSENGER SIDE. NOTE: The forward hole on the passenger side lower shock mount needs to be marked and drilled out to 3/8”. SEE FIGURE 17. Torque 3/8” hardware to 52 ft-lbs.
Locate and install the front shocks supplied in your kit using the hardware included with the shock and the 1/2” bolt/ hardware that was used in the previous step. Torque 1/2” hardware to 127 ft-lbs. SEE FIGURE 18
Locate FT50360 drv. & FT50361 pass. Sway Bar Link Mounts, FT50261 Front Sway Bar Endlinks, FT50048
& FT50089 bushing and sleeve kits. Press one bushing and one sleeve from the supplied bushing kit into each end of the end link. Attach the link mount brackets to the factory sway bar mount on the axle with the supplied ½”x 1- 1/4” bolts and hardware. Torque to **127 ft. lbs. With the supplied ½” x 2 ¾” bolts & hardware, connect the new end link to the sway bar (factory hole in sway bar may need to be enlarged with a die grinder out to ½”). Mount the bolt with the head of the bolt facing outward towards the tire. Then, using the FT42 Sway Bar Pin, FT45 Key Ring, & FT90036 Lynch pin, connect to the new lower sway bar mount. Torque the upper hardware to 25 ft-lbs SEE FIGURES 19-21
Locate FT50359 Sway Bar Retainer and the supplied ¼”x 1¼” hardware. Disconnect the sway bar from the lower axle mounts. Rotate the sway bar end links up toward the coil bucket and attach the retainers to the end links. Position the retainer bracket to the coil bucket and mark the bucket for the retainers. Mark the two holes from the retainer to the bucket. Lower the retainers and drill the two new holes to 1/4”. Attach the retainer to the coil bucket, then attach the end link to the new retainer with the sway bar pin & lynch pin. After test fitting, re-attach link to axle. SEE FIGURES 22-23
Install the track bar and torque hardware to 179 ft-lbs. Re-attach the draglink to the pitman arm and torque to 77 ft-lbs.

REAR SUSPENSION

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. Do not allow to hang freely. Remove the factory shocks and rear sway bar end links and discard. Disconnect the brake lines from the frame and save hardware. Remove the plastic clips that hold the ABS lines to the frame and at the rear upper link arm pockets. Do not damage the clips, they will be reused. Remove the (2) nuts attaching the factory E-brake cable from the body and save.
Remove and discard the factory coil springs and save the rubber isolators for re-installation.
With the rear axle supported. Remove the rear Track Bar from the Jeep. Remove any paint, dirt, or debris from the axle housing where the new gussets are to be installed.
Locate FT50362 Gusset, position it onto the axle and the factory track bar mount as shown in photo. Weld the gusset on the two sides. SEE FIGURE 24
Locate FT50342 Rear Track Bar Bracket, position it onto the top of the axle and track bar mount. Use the supplied 9/16” bolt to align the new bracket to the original mount. Use a punch and mark the factory mount through the two holes in the new bracket. Remove the bracket and drill out the (2) holes to 3/8”. SEE FIGURES 25-27
Re-install the track bar bracket using the supplied 3/8” hardware, 9/16-12 X 3” bolt, FT157 sleeve and hardware. SEE FIGURE 28
Weld the new bracket like shown in FIGURE 29-30.
Locate FT50724 Rear Bumpstop Spacer. Position the spacer onto the factory bumpstop pad on the axle and attach with the supplied 5/16” x 1” bolts and hardware. SEE FIGURE 31
Locate FT50298 E-Brake Bracket and supplied ¼” hardware. Position the bracket to the factory mounting position and attach with the factory hardware. Attach the factory bracket to the new Fabtech bracket with the ¼” hardware. Torque to 10 lbs. SEE FIGURE 32
Locate & install new Fabtech rear coil spring with the factory isolators on the top into the upper mount first, then onto the factory coil perch on the axle. (make sure upper isolator is fully seated into the upper pocket / mount). SEE FIGURE 33
Position the track bar into the new track bar bracket and attach with the 9/16-12 X 3” hardware. Torque the 9/16” to **184 ft. lbs
Install the supplied Fabtech shock using the factory upper hardware to mount the bar bin and the supplied ½” x 2 ½” bolt, large USS washers, and hardware. (insert one large USS washer per side inside the shock mount with the shock) Torque the upper hardware to 58 ft. lbs and the lower to 65 ft-lbs. SEE FIGURE 34
Locate FT50037BK (rear sway bar end links), bushings and sleeve. Install the bushings and sleeves into the new end links. Using the supplied 1/2-13 X 2-3/4” hardware, install the end links to the sway bar and axle. Torque to 25 ft-lbs. SEE FIGURE 35-36

BRAKE LINE INSTALLATION

Remove the factory brake line at the frame and at the brake caliper. SEE FIGURE 37-38
Install the supplied brake line bracket in the factory location using the factory bolt. SEE FIGURE 39
Insert the new brake line fitting through the bracket and install onto the factory brake hard-line. Next, install the supplied u-clip to secure the line to the bracket. SEE FIGURE 40
Using the factory brake line bolt install the new supplied crush washers and install to the brake caliper. SEE FIGURES 41-42
Locate the supplied cushioned clamps, 1/4” X 1” bolts, washers, nuts, TEK screws and springs. Install the clamp around the brake using the 1/4” hardware. NOTE: Install the eyelet of the spring between the clamp and washer. SEE FIGURE 43
Mount the opposite end of the spring to the frame using the supplied TEK screw and washer. SEE FIGURE 44
Repeat steps 31-36 on other (3) brake lines.
Bleed brakes per manufacturers specifications.
Install tires and wheels and torque lug nuts to wheel manufacturer’s specifications. Turn front tires left to right and check for appropriate tire clearance. Note – Some oversized tires may require trimming of the front bumper & valance.
Check front end alignment and set to factory specifications. Readjust headlights.
Recheck all bolts for proper torque.
Recheck brake hoses, ABS wires and suspension parts for proper tire clearance while turning tires fully left to right.
Check the fluid in the front and rear differential and fill if needed with factory specification differential oil.
Note – some differentials may expel fluid after filling and driving. This can be normal in resetting the fluid level with the new position of the differential/s.
Install Driver Warning Decal. Complete product registration card and mail to Fabtech in order to receive future safety and technical bulletins on this suspension.

Vehicles that will receive oversized tires should check ball joints, uniballs and all steering components every 2500-5000 miles for wear and replace as required.
RE-TORQUE ALL NUTS, BOLTS AND LUGS AFTER 50 MILES AND PERIODICALLY THEREAFTER.
For technical assistance call: 909-597-7800

Product Warranty and Warnings

Fabtech provides a Limited Lifetime Warranty to the original retail purchaser who owns the vehicle, on which the product was originally installed, for defects in workmanship and materials.
The Limited Lifetime Warranty excludes the following Fabtech items; bushings, bump stops, ball joints, tie rod ends, limiting straps, cross shafts, heim joints and driveshafts. These parts are subject to wear and are not considered defective when worn. They are warranted for 60 days from the date of purchase for defects in workmanship.
Dirt Logic and Performance Coilover take apart shocks are considered a serviceable shock with a one year warranty on leakage only. Service seal kits are available separately for future maintenance. All other shocks are covered under our Limited Lifetime Warranty.
Fabtech does not warrant any product for finish, alterations, modifications and/or installation contrary to Fabtech’s instructions. Alterations to the finish of the parts including but not limited to painting, powder coating, plating and/or welding will void all warranties. Some finish damage may occur to parts during shipping, which is considered normal and is not covered under warranty.
Fabtech products are not designed nor intended to be installed on vehicles used in race applications or for racing purposes or for similar activities. (A “RACE” is defined as any contest between two or more vehicles, or any contest of one or more vehicle against the clock, whether or not such contest is for a prize). This warranty does not include coverage for police or taxi vehicles, race vehicles, or vehicles used for government or commercial purposes. Also excluded from this warranty are sales outside of the United States of America.
Installation of most suspension products will raise the center of gravity of the vehicle and will cause the vehicle to handle differently than stock. It may increase the vehicle’s susceptibility to a rollover, on road and off road, at all speeds. Extreme care should be taken to operate the vehicle safely at all times to prevent rollover or loss of control resulting in serious injury or death. Fabtech front end Desert Guards may impair the deployment or operation of vehicles equipped with supplemental restraining systems/air bag systems and should not be installed if the vehicle is equipped as so.
Fabtech makes every effort to ensure suspension product compatibility with all vehicles listed on the website, but due to unknown auto manufacturer’s production changes and/or inconstancies by the auto manufacturer, Fabtech cannot be responsible for 100% compatibility, including the fitment of tire and wheel sizes listed. The Tire and Wheel sizes listed in Fabtech’s website are only a guideline for street driving with noted fender trimming. Fabtech is not responsible for damages
to the vehicle’s body or tires. Fabtech is not responsible for premature wear of factory components due to the installation of oversized tires and wheels.
Fabtech’s obligation under this warranty is limited to the repair or replacement, at Fabtech option, of the defective product only. All costs of removal, installation or re-installation, freight charges, incidental or consequential damages are expressly excluded from this warranty. Fabtech is not responsible for damages and/or warranty of other vehicle parts related or non related to the installed Fabtech product. This warranty is expressly in lieu of all other warranties expressed or implied. This warranty shall not apply to any product that has been subject to accident, negligence, alteration, abuse or misuse as determined by Fabtech.
Fabtech suspension components must be installed as a complete system including shocks as shown on our website. All warranties will become void if Fabtech parts are combined and/or substituted with other aftermarket suspension products. Combination and/or substitution of other aftermarket suspension parts may cause premature wear and/or product failure resulting in an accident causing injury or death. Fabtech does not warrant products not manufactured by Fabtech.
Depending on the condition of the factory suspension components retained after the installation of a Fabtech suspension not all vehicles may have the same ride stance front to rear as described in the website. The blue color of suspension components shown in all Fabtech photographs are for display purposes only. Majority of all Fabtech components will be black specifically where noted with part numbers ending in BK.
Installation of Fabtech product may void the vehicles factory warranty; it is the consumer’s responsibility to check with their local vehicle’s dealer for warranty disposition before the installation of the product. Some state laws may prohibit modification of suspension to a vehicle in whole or in part. It is the responsibility of the installer and consumer to consult local laws prior to the installation of any Fabtech suspension product to comply with such written laws.
It is the responsibility of the distributor and/or the retailer to review all warranties and warnings of Fabtech products with the consumer prior to purchase.
Fabtech reserves the right to super cede, discontinue, change the design, finish, part number and/or application of parts when deemed necessary without written notice. Fabtech is not responsible for misprints or typographical errors within the website or price sheet. For the most recent Product Warranty and Warnings visit our website www.fabtechmotorsports.com

2007-18 JEEP WRANGLER (JK) LONG TRAVEL BOX KIT
FT24131i
Fabtech Motorsports | 4331 Eucalyptus Ave. Chino, CA 91710
Tech Line: 909-597-7800 | Fax: 909-597-7185 | Web: www.fabtechmotorsports.com