Installation Instructions
Contents
1. maintain proper working order Failure to perform inspections may result in component failure 7 Have headlight readjusted to proper settings 8 Take the vehicle to be aligned to factory specifications by a certified alignment shop 9 Re torque all fasteners after 500 miles Visually inspect components and re torque fasteners during routine vehicle service MAINTENANCE INFORMATION It is the ultimate buyers responsibility to have all bolts nuts checked for tightness after the first 100 miles and then every 100 miles A qualified mechanic must inspect wheel alignment steering system suspension and driveline systems at least every 3000 miles SUSPENSION SYSTEMS ROUGH COUNTRY SUSPENSION SYSTEMS We have most of the additional accessories you need for your Cherokee We have Rock Sliders Diff Guards Slip Yoke Eliminator Drive Shafts Steering Stabilizers Adjustable Controls Arms Etc 59 95 Diff Guar ART N 49 95 Stabilizer GA ON 269 00 Pas SYE Kits 9 95 RC Hat i 159 95 Adj Arms Call For Price Drive Shafts 129 95 Adj Track Bar Thank you for purchasing a Rough Country Suspension System2. 921633XN200 84 01 4 5 XJ CHEROKEE LIFT KIT Thank you for choosing Rough Country for your suspension needs Rough Country recommends a certified technician installs this system In addition to these instructions professional knowledge of disassemble reassembly procedures as well as post installation checks must be known Attempts to install this system without this knowledge and expertise may jeopardize the integrity and or operating safety of the vehicle Please read all the instructions before beginning the installation Check the kit hardware against the parts list Be sure you have all the needed parts and understand where they go Also please review the tools needed and make sure you are confident about undertaking this installation If you have any questions about the installation of this kit call Rough Country at 800 222 7023 PRODUCT USE INFORMATION As a general rule the taller a vehicle is the easier it will roll We strongly recommend because of rollover possibility that the vehicle be equipped with a functional roll bar and cage system Seat belts and shoulder harnesses should be worn at all times Avoid situations where a side rollover may occur Braking performance and capabilities are decreased when significantly larger heaver tires and wheels are used Take this into consideration while driving Also speedometer recalibration is necessary when larger tires are installed Do not add alter or fabricate any factor
3. ake fluid on painted sur faces REAR LIFT INSTALLATION 1 Remove rear factory shocks using a 13mm wrench on top and a 3 4 wrench on bottom and retain hardware 2 Chock the front wheels and jack up the rear of the vehicle and place the vehicle on jack stands Remove the wheels and tires 3 Working from the drivers side remove the factory u bolts and lower the axle with a floor jack Repeat for passenger side 4 Remove the spring from the shackle and from the frame using a 21mm wrench SEE PHOTO 3 Locate and grind off thie excess from the bolt pictured in PHOTO 4 This will allow the shackle to move rearward PHOTO4 REMOVE SPRING FROM SHACKLE amp FRAME GRIND BOLT Install new rear springs at this time with factory hardware using 21mm wrench and skip to Step 10 The larger spring eye will bolt back in the stationary mount This kit includes 2 3 4 amp 3 diameter u bolts for rear axle options on the Jeep Confirm axle diameter and use appro priate u bolt Install the u bolts and torque to factory specs using 3 4 wrench Install the new shocks Part 658708 with factory hardware Torque the upper using a 13mm wrench and lower bolts using 3 4 wrench to factory specs Repeat for other side 9 Install the tires and wheels Jack up the vehicle and remove the jack stands Lower the vehicle to the floor 10 Torque the frame bolts and shackle bolts to factory specs using a 21mm wrench 11 Install the rear brake lin
4. bit 19mm wrench and a 15mm for the upper nut SEE PHOTO 1 Remove the track bar from the axle housing on passenger side using a 15mm wrench SEE PHOTO 2 Retain fac tory bolt and flag nut for re use rior REMOVE THE SWAY BAR HARDWARE REMOVE THE TRACK BAR Locate and remove the coil clip on the driver side lower coil spring seat using a 13mm wrench Lower the axle to allow for removal of the coil spring Do not overextend the brake lines The caliper can be removed from the rotor to allow the axle to lower Do not let the brake caliper hang from the brake line Remove coil spring SEE PHOTO 3 Repeat for opposite side With the differential supported remove the driver side lower control arm from the vehicle using a 21mm wrench SEE PHOTO 4 Retain factory hardware as it will be reused Repeat for opposite side Lower the axle using the floor jack With the axle lowered install coil springs on both sides making sure the lower coil wrap is seated in the lower spring cup Install factory spring retainer and secure with factory hardware using a 13mm wrench REMOVE THE STOCK CONTROL ARMS SUSPENSION SYSTEMS 11 Adjust new lower control arm to 16 5 from center to center and install using factory hardware SEE PHOTO 5 12 Remove the stock upper control arm by removing the factory hardware from the axle bracket and then removing the nut and bolt from the frame bracket doing one side at a time Do not remove the factory bush
5. e on the axle and the frame with the supplied c clip TRANSFER CASE DROP INSTALLATION INSTRUCTIONS 1 Position the floor jack under the transfer case cross mem ber and lightly apply pressure 2 Loosen and remove the bolt and the nut on stud on the driver side transfer case cross member 3 Loosen and remove the bolt and nut on the drivers side cross member 4 Carefully lower the transfer case down to the point it clears the stud 5 Using 2 nuts to form a jam nut on the stud remove the stud from the cross member on both sides 6 Carefully lower the transfer case cross member to allow clearance for installation of transfer case spacer and sleeve 4 a 7 Place the spacer between the frame and cross member INSTALL TRANSFER CASE SPACERS install the new 10mm x 60m bolts through cross member e y spacer and into uni body Raise the transfer case and tighten bolts to 35 ft lbs See PHOTO 1 POST INSTALLATION INSTRUCTIONS 1 Check all fasteners for proper torque 2 Check to ensure there is adequate clearance between all rotating mobile fixed and heated members 3 Check steering gear for interference and proper working order 4 Before driving the vehicle check to make sure brakes are operating properly and do not need to be blead 5 Perform steering sweep 6 Check to ensure brake hoses have sufficient slack and will not contact rotating mobile or fixed members Adjust lines brackets to eliminate interference and
6. il the track rod hole lines up Install the track rod with the stock bolt flag nut and using a 15mm wrench Torque to factory specs COUNTRY SUSPENSION SYSTEMS FRONT SWAY BAR DISCONNECT INSTRUCTIONS 1 Install the upper sway bar mount on the top of front sway bar where the stock link was secured using the supplied 3 8 x 1 25 bolt lock washer and thick washer Tighten using a 9 16 wrench making sure the mount is straight See Photo 1 2 Using a hammer remove the lower stock sway bar link mounting bolt from the axle mount 3 Install supplied pin on the axle See Photo 2 Hold using a screwdriver amp tighten 1 2 lock nut using a 3 4 wrench y ty PHOTO 2 INSTALL THE PIN ON THE AXLE 4 Assemble the sway bar link with the link body the jam nut and rod end Adjust the sway bar to a length of 11 1 4 from top to bottom Tighten the jam nut against the rod end using a 5 8 amp 3 4 wrench 5 Install the sway bar link on the upper sway bar mount with the supplied 1 2 flange lock nut See Photo 3 Tighten using a 5 8 amp 3 4 wrench 6 With the sway bar link installed on the supplied frame bracket swing the bracket and sway bar link up and position the bracket on the frame as shown in Photo 4 PHOTO 4 POSITION THE MOUNT ON THE UNI BODY INSTALL THE LINK ON THE MOUNT 7 While holding the bracket in place remove the sway bar link from the bracket Mark and drill the holes using a 1 4 d
7. ing in the axle mount it is reused Lubricate bushings with a lithium grease or equivalent and install the new bushings and sleeves in the Rough Country control arm Adjust the upper Rough Country adjustable control arm to a measurement of 15 2 from center to center and install on the vehicle using factory hardware do not tighten at this time SEE PHOTO 6 a PHOTO 5 PHOTO 6 INSTALL NEW LOWER ADJ ARM i INSTALL NEW UPPER ADJ ARM 12 PHOTO 7 shows the caster adjustment bolts on the lower control arms These bolts can be adjusted in or out if needed for additional caster alignment Final alignment should be performed by a professional 13 Install the Rough Country adjustable track rod in the factory location axle mount using factory hardware Do not at tach the frame end of the new track rod at this time Installation is done after the vehicle is on the ground and axle is centered SEE PHOTO 8 14 Install the new shock absorbers Part 658693 and tighten the factory bottom bolts using a 13mm wrench and the upper with a 9 16 wrench Reinstall the wiper reservoir if removed PHOTO 8 PHOTO 7 NOTE THE ADDITIONAL CASTER ADJ BRKT INSTALL THE NEW ADJ TRACK BAR 15 Install the front wheels and tires Jack up the vehicle Remove jack stands and lower the vehicle to the ground 16 Check to make sure the body is centered over the axle Unlocking the steering wheel and turning the wheel to move the body do this unt
8. o be kept in the vehicle for its service life Please verify before installation rear axle tube diameter is 2 3 4 or 3 Both sets are included with this kit to accommodate rear axle options of the vehicle TOOLS NEEDED Spring Compressor Allen Wrenches Silicone Spray Torx Key Socket Drill Motor Tape Measure Drill Assortment 1 8 to 1 2 File Torque Wrench Large C Clamps and or Bench Vise Hammer Hydraulic Floor Jacks 12 Drive Ratchet and Sockets Heavy Duty Jack Stands Combination Wrenches Wheel Chocks Wooden Blocks Grease or Anti Seize Compound If question exist we will be happy to answer any questions concerning the design function and correct use of our prod ucts Please call us at 800 222 7023 The required installation time for this kit is 6 8 hours KIT CONTENT Kit Includes 9269 Front Coil Springs 8047 Rear Springs 7572 Adj Track Rod Tie Rod End Jam Nut Cotter Pin 1633XN2 Kit Box Including Front Upr Adj Control Arms 2 Front Lwr Adj Control Arms 2 Front Disconnect Assemblies 2 Front Disconnect Bracket 2 Front Brake Lines 2 Front Shock 658693 Rear Shock 658708 Rear Components Rear Brake Line Rear U bolts 4 Transfer Case Drop Spacers 4 Rear Leaf Springs 2 U bolts 4 ae Ctrl Arms C ET a em Transfer Case Spacers Sway Bar Disconnects 2 Ny Twr A Frt Adj Track Bar For Transfer Case Spacers 10mm x 60mm Bolts 4 Fo
9. r Front amp Rear Brake Lines Fr Line Crush Washers 4 Brake Line Brackets 3 Brake Line Clip 3 For Sway Bar Bracket 3 8 x 1 1 4 Bolt 2 3 8 Flange Lock nut 2 3 8 Flat Washers 2 For Sway Bar Disconnects 5 16 x 1 Tap Bolts 4 3 8 x 1 1 4 Bolts 2 Thick Washers 2 Disconnect Pins 2 Hitch pins 2 Rod Ends 2 1 2 Nuts 2 1 2 Flat Washer 2 1 2 Flange Lock Nut 2 1 2 Jam Nut 2 2 Upper Adj S Control Arms 2 Ty Frt Coil Springs 2 Front Brake Lines 2 o o NAON PRE INSTALLATION INSTRUCTIONS Layout product and confirm that you have all needed products and know where they install Verify before installation rear axle tube diameter is 2 34 or 3 Both sets are included with this kit to accommodate rear axle options of the vehicle INSTALLATION INSTRUCTIONS Secure and properly block the tires on the vehicle on a level concrete surface Jack up the vehicle and place the front of the vehicle on jack stands Remove the front wheels and tires Support the axle with a floor jack Remove the stock shock absorbers using a 15mm wrench The stock bolts and nuts on the bottom of the shock will be reused Note Access to the upper shock studs will be obtained through the engine compartment It also may be necessary to temporarily remove the washer fluid reservoir to access the driver side upper shock mount nut Remove the sway bar links on both sides using a T 55 torx
10. rill bit Install the supplied 5 16 x 1 self tapping bolt in the drilled holes and tighten using a 1 2 socket See Photo 5 Do not over tighten the self tapping bolts 9 Install on the lower axle mounting pin Install the disconnect pin See Photo 6 Note When disconnected the hitch pin will be used on the upper mount to secure the sway bar link to the mount PHOTO 5 f PHOTO 6 TIGHTEN HARDWARE W INSTALL LINK ON THE AXLE AND SECURE FRONT BRAKE LINE INSTALLATION INSTRUCTIONS Inspect the brake system and repair replace components as necessary 2 Remove the stock hoses from the frame rail and from the brake calipers Be sure that the stock crush washers are removed New washers are supplied Thoroughly clean and inspect all mating surfaces Install the new Rough Country hoses in the stock location using the stock hardware on the axle Using the supplied brake line mounting bracket and brake clip install in the stock location on the frame rail See Photo 1 amp 2 PHOTO 1 mew INSTALL BRAKE LINE BRACKET ON FRAME INSTALL BRAKE LINE IN BRACKET 6 With the suspension supporting the vehicle weight and the tires wheels installed cycle the steering lock to lock and check for adequate hose length and clearance 7 Now raise the vehicle and check length clearance with the suspension hanging at full extension travel 8 Bleed the air from the system as instructed by the factory service manual Avoid getting br
11. y or after market parts which increase vehicle height over the intended height of the Rough Country product purchased Mixing component brands lifts voids all warranties Rough Country makes no claims regarding lifting devices and excludes any and all implied claims We will not be responsible for any product that is altered This kit features Rough Country s adjustable joint design Adjustable end tool is included in kit Assemble the joints per the separate instruction sheet Part 92RCJ120 provided The 6 5 suspension system was developed for 33x11 50x15 tire on 15 x 8 after market wheel with 3 75 of back spac ing This tire size may require the installation of aftermarket flares and due to variation in vehicles when manufactured and the numerous options available the amount of actual lift gained by this lift kit will vary On models outfitted with ex tra bolt on equipment and accessories Rough Country offers new coil spring isolator pads made from polyurethane to boost ride height 3 4 NOTICE TO DEALER AND VECHICLE OWNER Any vehicle equipped with any Rough country product must have the Warning to Driver decal installed on the sun visor or dash The decal is to act as a constant reminder for whoever is operating the vehicle of its unique handling character istics INSTALLING DEALER 1t is your responsibility to install the warning decal and to forward these installation in structions on too the vehicle owner for review and t
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