ROUGH COUNTRY 921677000B 2.5 Inch Lift Suspension Kit Instructions
- June 13, 2024
- Rough Country
Table of Contents
921677000B 2.5 Inch Lift Suspension Kit
JEEP JL 2.5” SUSPENSION KIT
Thank you for choosing Rough Country for your suspension needs.
Rough Country recommends a certified technician install 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 instructions before beginning installation. Check the kit hardware against the parts list. Be sure you have all needed parts and know where they go. Also please review tools needed list and make sure you have needed tools.
PRODUCT USE INFORMATION
As a general rule, the taller a vehicle is, the easier it will roll. Seat belts and shoulder harnesses should be worn at all times. Avoid situations where a side rollover may occur.
Generally, braking performance and capability are decreased when larger/heavier tires and wheels are used. Take this into consideration while driving. Do not add, alter, or fabricate any factory or after-market parts to increase vehicle height over the intended height of the Rough Country product purchased. Mixing component brands is not recommended.
Rough Country makes no claims regarding lifting devices and excludes any and all implied claims. We will not be re sponsible for any product that is altered.
This suspension system was developed using a 35×12.50×20 tire on a 20×10 wheel with -18 offset. Different wheel and tire combinations my be used but different tire manufactures designs may result in a tire width that could result in contact with the lower control arm and/or front sway bar link in a sharp turn. Please consult with your tire and wheel expert be fore purchasing. Also note that if wider tires are desired, offset wheels will be required. If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products by calling 1-800-222-7023.
NOTICE TO DEALER AND VEHICLE OWNER
Any vehicle equipped with any Rough Country product should have a “Warning to Driver” decal installed on the inside of the windshield or on the vehicle’s dash. The decal should act as a constant reminder for whoever is operating the vehi cle of its unique handling characteristics.
Tools Needed:
6mm Allen
10mm Socket & Wrench
15mm Socket & Wrench
18mm Socket & Wrench
21mm Socket & Wrench
22mm Deep Well Socket
Pliers
9/16” Socket & Wrench
3/4” Socket & Wrench
Jack
Jack Stands
Prior to installing this kit, with the vehicle on the ground, measure the heights of your vehicle. This measurement can be recorded from the center of the wheel straight up to the top of the inner fender lip. Record the measurements.
LF:__ ,RF:___,
LR:__, RR:___
KIT CONTENTS
Kit Box 67700
Qty
|
Description
2
|
Front Coil Spacer
2
|
Front Shock Bracket
2
|
Front Sway Links
2
|
Front Bump Stop Spacers
2
|
Rear Sway Links
2
|
Rear Coil Spacer
2
|
Rear Shock Bracket
2
|
Rear Bump Stop Spacers
1
|
1676BAG Hardware Bag
1
|
67730BAG2 Hardware Bag
1
|
1677BAG4 Instruction Bag
1
|
1609BAG6 Rear Bump Stop Bag
1
|
1609BAG7 Front Bump Stop Bag
Torque Specs:
Size Grade 5 Grade 8
5/16” 15 ft/lbs 20 ft/lbs
3/8” 30 ft/lbs 35 ft/lbs
7/16” 45 ft/lbs 60 ft/lbs
1/2” 65 ft/lbs 90 ft/lbs
9/16” 95 ft/lbs 130 ft/lbs
5/8” 135 ft/lbs 175 ft/lbs
3/4” 185 ft/lbs 280 ft/lbs
Class 8.8 Class 10.9
6MM 5 ft/lbs 9 ft/lbs
8MM 18ft/lbs 23 ft/lbs
10MM 32ft/lbs 45ft/lbs
12MM 55ft/lbs 75ft/lbs
14MM 85ft/lbs 120ft/lbs
16MM 130ft/lbs 165ft/lbs
18MM 170ft/lbs 240ft/lbs
1676BAG
Qty
|
Description
4
|
Shock Bracket Crush Sleeve
2
|
3/8” x 1” Bolt
2
|
3/8” Flat Washer
2
|
3/8” Flange Locknut
4
|
12mm x 65mm Bolt
4
|
12mm Flange Locknut
2
|
JK Spacer Washer
2
|
1/2” x 2.5” Bolt
2
|
1/2” 1.25” Bolt
6
|
1/2” Flat Washer
2
|
1/2” Nylock Nut
67730BAG2
Qty
|
Description
6
|
1/2” Flat Washer
4
|
12mm x 65mm Bolt
4
|
12mm Flange Lock Nut
1609BAG6
Qty
|
Description
4
|
3/8” Flat Washer
4
|
3/8” x .75” Bolt
4
|
3/8” Flange Lock Nut
1609BAG7
Qty
|
Description
2
|
3/8” Flat Washer
2
|
3/8” x 3” Bolt
2
|
3/8” Flange Lock Nut
FRONT INSTALLATION INSTRUCTIONS
1. Place vehicle in park and chock the rear wheels. Raise the front of the vehicle with a jack and secure a jack stand beneath each frame rail behind the front control arms. Ease the frame down onto the stands. Place the jack under the front axle for support when removing the coil springs.
2. Remove the front tires/wheels, using a 22mm deep well socket.
3. Mark and remove front driveshaft from axle using a 15mm socket. Hang the driveshaft up don’t let it fall or rest on the driveshaft boot or it could damage the boot.
4. Using a 21mm socket and wrench, remove the bolt securing the front track bar to the frame. See Photo 1. Retain hardware for reuse.
5. Using an 18mm socket and wrench remove the bottom sway bar link bolts. Retain hardware for reuse. See Photo 2. 6. Remove the lower shock bolt using a 18mm socket and wrench. You may have to raise the axle with the jack and
PHOTO 1
PHOTO 2
Remove the track bar bolt. Remove the lower sway link bolt.
pull down on the shock to remove the bolt. See Photo 3. Retain stock hardware.
7. Using a 15mm wrench, remove the brake line bracket from the lower control arm. See Photos 4 & 5. Retain hard ware for reuse.
PHOTO 3
PHOTO 4
Remove the lower shock bolt. Remove the brake line bracket.
8. Using pliers, remove the wiring harness from the upper control arm. See Photo 6.
9. Loosen the upper control arms using a 18mm wrench.
PHOTO 5 Remove the brake line bracket
PHOTO 6 Pull the wiring harness from the control arm.
9. Using pliers, remove the axle vent tube from the differential housing. See Photo 7.
10. Unplug the 4×4 actuator for slack. See Photo 8.
11. Lower the jack, careful not to let the axle reach full droop, and remove the coil spring and spring isolator. See Photo 9.
12. Using a 10mm wrench, remove the brake line bracket from the coil mount. Retain hardware for reuse. See Photo 10.
13. Install the supplied spring spacer with coil spring isolator under the spacer. See Photo 11.
14. Install the factory coil spring. See Photo 12.
15. Install the bump stop spacer into the lower coil mount. See Photo 13.
16. Place the supplied 3/8” x 3” bolt, washers, and nut (1609BAG7) through the spacer and coil mount. See Photo 14. PHOTO 13 PHOTO 14
17. Tighten using 9/16” wrenches. See Photo 15.
18. Install the brake line bracket on the coil mount using the factory hardware and a 10mm wrench.
19. Install the supplied shock extension bracket using the supplied 3/8” x 1” bolt, 3/8 washer, and 3/8” flange locknut (1676BAG), through the bottom hole of the bracket. Do Not Tighten. See Photo 16.
20. Place the supplied crush sleeve (1676BAG) into the factory shock bracket. Install the factory shock hardware into the brackets and through the sleeve. See Photo 17.
21. Tighten the lower bolt using a 9/16” socket and wrench. Torque to 30ft/lbs. See Photo 18. PHOTO 17 PHOTO 18
22. Using a jack to compress the suspension, install the shock in the extension bracket using the supplied 12mm x 65mm bolt, 1/2” washers, and 12mm nut (1676BAG). See Photo 19.
23. Tighten the factory bolt using an 18mm socket and wrench. Torque to 55ft/lbs. See Photo 20.
24. Tighten the lower shock bolt using an 18mm socket and wrench. Torque to 55ft/lbs. See Photo 21.
25. Install the brake line bracket on the lower control arm using the factory hardware. Tighten using a 15mm wrench.
Torque to 18ft/lbs. See Photo 22.
26. Remove the sway link from the sway bar using a 6mm Allen and an 18mm wrench. See Photo 23. 27. Install the new supplied bent sway link using the supplied 12mm x 65mm bolt, 1/2” washers, and lock nut (67730BAG2). Torque to 55ft/lbs. See Photo 24.
28. Clip the wiring harness into the upper control arm.
29. Attach the axle vent tube to the differential using a pair of pliers.
30. Plug-in the 4×4 actuator. See Photo 25.
31. Attach the sway bar links, to the axle, using the factory hardware and
an 18mm socket and wrench. Torque to 55t/lbs.
32. Reinstall the front tires/wheels, using a 22mm deep well socket.
33. Lower the vehicle to the floor.
34. Attach the track bar using the factory hardware and a 21mm socket and
wrench. Torque to 120ft/lbs. Turning the steering wheel will help align the
track bar and the mounting hole.
35. Retighten the lower control arms using a 21mm & 24mm wrench.
36. Retighten the upper control arms using a 18mm wrench.
REAR INSTALLATION INSTRUCTIONS
1. Jack up the rear of the vehicle and support the vehicle with jack stands, so that the rear wheels are off the ground. Chock front wheels. Position a jack so it supports, but does not raise the rear axle.
2. Remove the rear tires/wheels, using a 22mm deep well socket.
3. Using a 21mm socket remove the track bar bolt at the axle. Retain the stock hardware for reuse. See Photo 1.
4. Using an 18mm socket and wrench, remove the lower shock mounting hardware. Save for reuse. See Photo 2.
5. Using an 18mm socket and wrench, remove the lower sway bar link hardware. See Photo 3.
6. Lower the axle and remove the coil spring and coil spring isolator. See Photo 4.
7. Install the supplied bump stop spacer on the axle using the supplied 3/8” x .75” bolts, washers, and flange lock nuts. PHOTO 3 PHOTO 4
(You will use 2 bolts, 2 washers, and 2 nuts per side) See Photo 5.
8. Using a 9/16” wrench and socket, torque the hardware to 30ft/lbs. See Photo 6.
9. Using a 6mm Allen and an 18mm wrench remove the sway link from the sway bar. See Photo 7. 10. Attach the supplied straight sway link using the supplied 12mm x 65mm bolt, 12mm washers (bolt head side only), and 12mm flange nut (1677BAG1). See Photo 8.
11. Using 18mm wrenches, tighten the upper sway link bolt. Torque to 75ft/lbs. See Photo 9.
12. Install the supplied coil spring spacer washer (67730BAG3) on top of the coil spring pocket. See Photos 10 & 11.
13. Install the supplied rear coil spacer, using the supplied 1/2” x 2.5” bolt (67730BAG3). Tighten using a 3/4” socket. Torque to 35ft/lbs. Do Not Over Torque. See Photo 12.
14. Install the coil spring isolator and coil spring. See Photo 13.
15. Install the supplied rear shock extension bracket using the factory shock bolt and supplied crush sleeve (1676BAG). Do Not Tighten. See Photo 14.
16. Install the supplied 1/2” x 1.25” bolt, washer and 1/2” nylock nut in the bottom shock mounting hole. The washer will go under the nut. Do Not Tighten. See Photo 15.
17. Install the shock in the shock extension bracket using the supplied 12mm x 65mm bolt, 1/2” washers, and 12mm nut (1676BAG). See Photo 15.
18. Tighten the factory shock bolt using an 18mm socket and wrench. Torque to 55ft/lbs. See Photo 16. PHOTO 15 PHOTO 16
Install the lower mounting bolt & shock. Tighten the factory hardware. 19. Tighten the lower shock bolt using an 18mm socket and wrench. Torque to 55ft/lbs. .
20. Tighten the lower shock bracket bolt using a 3/4” socket and wrench. Torque to 65ft/lbs. See Photo 18. 21. Install the sway bar links, in the lower mount using the factory bolts and an 18mm socket and wrench. Torque to 55ft/lbs.
22. Reinstall the rear tires/wheels, using a 22mm deep well socket
23. Lower the vehicle to the ground.
24. Reinstall the track bar in the factory location using the factory hardware and tighten using a 21mm
POST INSTALLATION
1. Confirm that the draglink was adjusted to the center steering wheel BEFORE the vehicle is driven. Failure to do so will cause a computer error, odd handling, and poor performance.
2. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and heated members. Check steering for interference and proper working order. Test brake system. 3. Perform steering sweep. The distance between the tire sidewall and the brake hose must be checked closely. Cycle the steering from full turn to full turn to check for clearance. Failure to perform inspections may result in component failure.
4. Re-torque all fasteners after 500 miles and recheck after 1000 miles. Alignment must be checked by a qualified me chanic. Visually inspect components and re-torque fasteners during routine vehicle service. 5. Readjust headlights to proper settings.
6. Have a qualified alignment center realign the front end, to the factory specifications immediately.
MAINTENANCE INFORMATION
It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 500 miles and then every 1000 miles. Wheel alignment, steering system, suspension and driveline systems must be inspected by a qualified professional mechanic at least every 3000 miles.
Thank you for purchasing a Rough Country Suspension System.
By purchasing any item sold by Rough Country, LLC, the buyer expressly warrants that he/she is in compliance with all applicable , State, and Local laws and regulations regarding the purchase, ownership, and use of the item. It shall be the buyers responsibility to comply with all Federal, State and Local laws governing the sales of any items listed, illustrated or sold. The buyer expressly agrees to indemnify and hold harmless Rough Country, LLC for all claims resulting directly or indirectly from the purchase, ownership, or use of the items.
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