I finally received the production version of the King front and rear suspension components for the FJ Cruiser (ordered way back in August 2006). King has been prototyping these shocks on FJ4M&E's and sunman's FJC. Here's a photo of my King suspension kit:
Installation instructions were not provided so I documented the installation steps to install the King suspension on my FJC and post them here. Note that rear springs are not provided but the rear King shocks can accommodate up to 2-inch higher rear springs. Both front and rear shocks are 2.5 inches in diameter and the front ride height is adjustable (a tool is provided as part of the kit). List price for the front is $1,350 and the rear is $750. Disclaimer: I'm not in any way affiliated with King Suspension Technology.
Rear suspension
1. place hydraulic jack under axle and lift vehicle until rear tire is off the ground and place jackstand under frame in front of rear tire; place chocks on front tires
2. remove rear wheel/tire (21mm socket)
3. remove OEM shock and keep lower bolt
4. remove the two bolts holding the rubber axle stop
5. install the rear shock reservoir mount between the frame and the rubber axle stop and reinstall the two bolts
6. insert King shock into top shock mount and install top rubber mount and nylok nut; do not tighten nut yet. Stack-up order is rubber shock mount, FJ shock mount, rubber shock mount, anodized aluminum top cap, flat washer, and nylok nut.
7. slowly lower rear axle using hydraulic jack to line up lower shock mount; be careful not to overstretch the brake line
8. install lower shock mount bolt and torque to 72 ft-lb and use loctite grade 242 on bolt
9. tighten top shock mount nut approximately 30 ft-lb (until rubber mount is compressed approximately half of original thickness); the space between body and frame is very tight so a gearwrench™ box wrench would be handy
10. place shock reservoir into bracket and install the two hose clamps
11. install wheel/tire and torque to lug nuts to 85 ft-lb
12. repeat for other side
13. check to make sure rear suspension is not rubbing or binding
Front suspension
1. place hydraulic jack under frame and lift vehicle until the front tires are off the ground; place jackstands under frame behind front tires; place chocks on rear tires
2. remove both front wheels/tires
3. remove skid plate
4. remove sway bar by removing the bolts holding the sway bar to the front spindles and the bolts holding the sway bar mounts to the frame
5. remove the three top shock mount nuts; do NOT loosen the center nut as it holds the spring seat to the shock
6. remove the lower shock mount bolt; note the orientation of the bolt and nut
7. remove OEM front shock assembly; note: the upper A arm may need to be push down in order to remove the front shock assembly
8. repeat for the other side
9. install the provided sway bar spacers/reservoir mounts on the frame for both sides and torque socket head bolts to 50 ft-lb with loctite 242 on the bolts
10. insert the front coilover into the upper mount with the reservoir fitting facing outward and install the three bolts provided with the coilover assembly; do NOT tighten the bolts yet
11. push down on the front suspension and install the factory lower shock mount bolt and nut; torque to 100 ft-lb; note that the King coilovers are longer than the OEM front shock assemblies so a pry bar can be used between the upper A arm and the top pivot bolt to push down the lower A arm
12. tighten the three bolts at the top mount to approximately 40 ft-lb; again, use loctite 242 since there is not room for a torque wrench
13. place shock reservoir into bracket and install the two hose clamps
14. repeat for other side
15. reinstall the sway bar to the front spindles and torque to 52 ft-lb
16. install the sway bar mounts to the spacers/reservoir brackets using the provided bolts and washers and torque to 50 ft-lb; the sway bar spacers move the sway bar mounts forward by approximately 1 inch
17. verify that there is clearance between front coilover assemblies and sway bar and upper and lower A arms
18. install the skid plate
19. install the front wheels/tires and torque lug nuts to 85 ft-lb
20. lower vehicle and verify that front suspension is not rubbing or binding
21. recheck all four wheels lug nuts torque after 500 miles
Special installation notes:
Since I have the Fabfours bumper, I had to modify the bumper brackets that are sandwiched between the frame and the sway bar mounts to clear the sway bar spacer/shock reservoir brackets. I also have the Budbuilt skid plates and the relocated front sway bar rubs very lightly against the front skid plate. The shock reservoir brackets have to be bent slightly to clear the body.
Initial observations:
the King suspension components display outstanding design and build quality; for example, the reservoir brackets are plated and not painted. The front spring seats are a split collar design so when they clamped onto the threaded shock bodies (not a set screw that could mar the threaded body). Custom valving is also available. When I talked to Mike Eads at King shocks at the Pomona Offroad show back in October, Mike asked if I had an aftermarket bumper and winch and how much they weigh so the front coilovers can be valved accordingly to handle the extra weight.
I have put approximately 200 miles (including some offroading) on the suspension and the ride/handling has improved tremendously. The ride is now firm and controlled but not harsh. Gone also is the tendency to nose dive during braking. With higher front spring rates and firmer valving front and rear, the body also sway a lot less when turning. I have not had a chance to go out to Anza Borrego to test in the washes yet but this set up should run all day without ever having to worry about fading due to heat build-up (the front reservoirs are 2.5 inches in diameter and the rear ones are 2 inches). Overall, the front of my FJC is now ~2 inches higher and the rear is ~1/4 inch higher with a full tank. The FJC is tracking straight but I will get the front aligned next week. OK, it's time to go play.
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