1997 Jeep Wrangler TJ - Fabtech Suspension Install

Project Teal-J II, Intro
Project Teal-J II, Part 1
Project Teal-J II, Part 2
Project Teal-J II, Part 3
Project Teal-J II, Part 4
Project Teal-J II, Part 5
Project Teal-J II, Part 6
Project Teal-J II, Part 7
Project Teal-J II, Part 8
Project Teal-J II, Part 9
Project Teal-J II, Part 10
Project Teal-J II, Part 11
Project Teal-J II, Part 12
Project Teal-J II, Part 13
Project Teal-J II, Part 14

In our previous installment of the buildup of our '97 Jeep Project Teal-J, we improved its capability on nasty trails by swapping in an Atlas II transfer case from Advance Adapters. This month, we decided to help keep the Teal-J's tires on the ground by installing a flexible suspension.

When our TJ was first built, there weren't many suspension systems available for it, but now lots of companies have TJ kits. One that was introduced recently that caught our eye was the Fabtech 6-inch long-arm suspension kit. Fabtech has its roots in desert racing and has always built strong stuff, so we were interested to see the company's take on a Jeep suspension. Plus, we knew that it was time to try out a long-arm kit on a TJ.

So once a kit was available, we drove to Fabtech and followed along as a much more flexible suspension was grafted onto our Teal-J. What follows are the highlights of the installation.

Back in 1997, our Project Teal-J was equipped with a Teraflex system that consisted of new lower arms with pivots and coils. This system did what it was designed to do, and it held up well to the abuse the Teal-J has seen, but we wanted to try one of the newer long-arm kits. So the first step was to get the old suspension out of the way.
Back in 1997, our Project Teal-J was equipped with a Teraflex system that consisted of new
With the front suspension gone, the crossmember/skidplate assembly can be removed.
Once that was accomplished, the torch was busted out and the lower control-arm mounts on the frame were removed. They have to come out to allow clearance for the much longer Fabtech lower control arms.
Once that was accomplished, the torch was busted out and the lower control-arm mounts on t

With the skidplate removed and the lower control-arm mounts cut out of the way, the new Fabtech subframe assembly can be put into place. It provides the mounting location for the new control arms.
With the skidplate removed and the lower control-arm mounts cut out of the way, the new Fa
The new subframe bolts to the framerail using the three existing factory holes, but for further strength, three more holes are drilled so the subframe can be securely mounted.
The new subframe bolts to the framerail using the three existing factory holes, but for fu
The crossmember/skidplate assembly is then bolted to the bottom of the subframe. This lowers the back of the transmission and transfer case to help get the driveshaft angle right and ensure that there is no vibration. It does reduce ground clearance, but Fabtech is working on an improved crossmember/skidplate that does not rob any clearance. It uses different engine mounts to angle the driveline to ensure the proper driveshaft angle.
The crossmember/skidplate assembly is then bolted to the bottom of the subframe. This lowe

To get the driveshaft angles right, your TJ's transfer case will have to be equipped with a slip-yoke eliminator kit. Without one, there is no way to get a vibration-free driveshaft into place. In the previous installment of our Teal-J project, we installed an Atlas II transfer case from Advance Adapters. It is roughly half an inch shorter than an NP231 with a slip-yoke eliminator kit, so a proper-length driveshaft will not be a problem.
To get the driveshaft angles right, your TJ's transfer case will have to be equipped with
Next, the new Fabtech upper and lower arms can be put into place. They are much longer and stronger than the stockers, and allow for plenty of flex.
Next, the new Fabtech upper and lower arms can be put into place. They are much longer and
Instead of a rod end, the Fabtech arms feature a joint that is similar to a Currie Johnny Joint. It allows for plenty of rotation, like a rod end, but is encased in urethane to eliminate vibration. The two urethane halves also interlock with each other and are greaseable with a standard zerk fitting.
Instead of a rod end, the Fabtech arms feature a joint that is similar to a Currie Johnny

With the mounting holes enlarged, the new track bar can be put into place. It features a rod end for maximum articulation on one end and a urethane joint on the other end to keep vibration from getting transmitted to the frame.
With the mounting holes enlarged, the new track bar can be put into place. It features a r
The Fabtech kit utilizes the stock steering. To get the angles correct, a dropped pitman arm comes with the new suspension system.
The Fabtech kit utilizes the stock steering. To get the angles correct, a dropped pitman a
Next, the coil springs can be squeezed into place. Make sure to install the extended bumpstops before the coils go in.
Next, the coil springs can be squeezed into place. Make sure to install the extended bumps

All that is left to finish up the front is to install the shocks and the extended brake lines.
All that is left to finish up the front is to install the shocks and the extended brake li
With the front done, it is time to handle the rear suspension. It is fairly similar to the front, so the install is about the same.
With the front done, it is time to handle the rear suspension. It is fairly similar to the
The Fabtech suspension system also includes much longer upper and lower rear arms to provide maximum flex. With the new subframe already in place, it is just a matter of bolting the long arms into position.
The Fabtech suspension system also includes much longer upper and lower rear arms to provi

It is fairly common on TJs that get used for their rear lower track bar mount to crack--and of course, ours had. The folks at Fabtech welded up the cracks before continuing with the install on the rear.
It is fairly common on TJs that get used for their rear lower track bar mount to crack--an
Since the new arms rotate the axle upward slightly for proper driveshaft angle, the factory lower shock mounts no longer work. Fabtech includes these beefy new shock mounts that weld into place.
Since the new arms rotate the axle upward slightly for proper driveshaft angle, the factor
To get the angle right on the rear track bar, a new bolt-on mount is used in the rear to raise the lower end of the track bar. A new hole must be drilled, and once that is done, it can be put into position.
To get the angle right on the rear track bar, a new bolt-on mount is used in the rear to r

A new upper mount is also used to lower the upper end of the rear track bar. With both new mounts in place, the track bar can be installed.
A new upper mount is also used to lower the upper end of the rear track bar. With both new
Next the bumpstop extensions can be installed and the coils squeezed into place.
After the coils are in, the shocks can go on and the rear suspension is finished.

Finally, the new Fabtech subframe can be welded onto the frame. It is not fully welded to the frame, but rather along three small tabs to provide some extra strength. Once done, the vehicle can be put on the ground and the track bars checked for proper alignment.

Longer is Better
So is it really worth extra time, cutting and welding to install a long-arm kit onto your TJ? Well, it depends upon what you intend to do with your rig. Since we wanted the most articulation we could get, it was definitely worth it for us. Longer control arms allow for more travel and articulation simply through their length. While the explanation involves some physics, there is a very easy way to visualize it by using your body. Stick your arm straight out in front of you. Now, using your elbow as a pivot point, move your hand up and down. Notice how far your hand can travel. Next, lock your elbow and use your shoulder as the pivot point. It is very easy to notice how much farther your hand can go up and down. If there was an axle attached to your hand it would be easy to see how much farther it could travel. Something else you should notice is how much less of an angle change there is with your hand when using your shoulder as a pivot point. This is another major benefit of longer control arms. In fact, as the Fabtech suspension system cycles through its travel, there is no pinion-angle change, making for proper suspension cycling and happy driveshafts.