ROUGH COUNTRY 921409000 F-150 Lightning 3 Inch Suspension Kit Instruction Manual

ROUGH COUNTRY 921409000 F-150 Lightning 3 Inch Suspension Kit

Product Information

• Product Name: FORD 2022 F-150 Lightning 3 Suspension Kit
• Product Code: 921409000
• Manufacturer: Rough Country

Product Usage Instructions

1. Before beginning installation, read the instructions carefully.
2. Check the kit hardware against the parts list provided on the next page to ensure you have all the necessary parts.
3. Review the tools needed list and make sure you have all the required tools.
4. This suspension system is designed for use with a 34 or 295/70R18-295/60R20 tire on 9 wheels with a +12 offset. Factory wheels and tires can be used. If using a larger tire on the factory wheel, wheel spacers are required. Note that if wider tires are used, offset wheels will be required and trimming may be necessary.
5. Prior to beginning installation, disconnect the EPAS (Electronic Power Assist Steering) plugs. Failure to do so may result in damage to the EPAS module, requiring its replacement.
6. It is recommended to perform a test drive before installation. While driving, check for any uncommon sounds or vibrations. Any issues identified during the test drive may become more pronounced once the lift kit is installed. Discuss these issues with the customer before proceeding with the installation.
7. Kit Contents:
   • 40900BAG1 x1
   • 569BAG1 x1
   • Dr. Upper Control Arm x1
   • Pass. Upper Control Arm x1
   • 10mm Studbag-2 x1
   • Strut Spacer Side (A) x2
   • Preload Spacer x2
   • RCK6696P2BAG x2
8. Tools Needed:
   • 8mm Wrench
   • 15mm Wrench
   • 15mm Socket
   • 16mm Wrench
   • 18mm Wrench
   • 21mm Wrench
   • 29mm Socket
   • 1 1/16 Wrench
   • 3/8 Wrench
   • 7/16 Socket
   • 9/16 Wrench
   • 9/16 Socket
   • Hammer
   • Floor Jack
   • Jack Stands
9. Torque Specs:

Size| Grade 5 (ft/lbs)| Grade 8 (ft/lbs)| Class 8.8 (ft/lbs)| Class 10.9 (ft/lbs)
---|---|---|---|---
5/16| 15| 20| –| –
3/8| 30| 35| 5| 9
7/16| 45| 60| 18| 23
1/2| 65| 90| 32| 45
9/16| 95| 130| 55| 75
5/8| 135| 175| 85| 120
3/4| 185| 280| 130| 165

1. Installation Instructions:
2. Jack up the front of the vehicle and support it with jack stands so that the front wheels are off the ground.
3. Remove the front tires/wheels using a 21mm deep well socket.
4. If the truck is equipped with a full front skid, use a 15mm socket to remove it.
5. Disconnect the EPAS (Electronic Power Assist Steering) plugs located on the steering assembly as shown in the installation instructions.

FORD 2022 F-150 Lightning 3” Suspension Kit
Thank you for choosing Rough Country for all your suspension needs.
Rough Country recommends a certified technician install this system. In addition to these instructions, professional knowledge of disassembly/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 on the next page. Be sure you have all needed parts and know where they go. Also, please review tools needed list and make sure you have the 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 responsible for any product that is altered. If questions exist we will be happy to answer any questions concerning the de-sign, function, and correct use of our products.

This suspension system was developed using a 34” or 295/70R18-295/60R20, tire on 9” wheels with a +12 offset. Factory wheels and tires can be used. If using a larger tire on the factory wheel, wheel spacers are required. Note if wider tires are used, offset wheels will be required and trimming will be required.
This vehicle will require the EPAS (Electronic Power Assist Steering) plugs to be disconnected prior to beginning installation of this kit. See installation instructions. Failure to disconnect these plugs may result in damage to the EPAS module resulting in an error message being displayed, which will require replacement of the EPAS module.

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 vehicle of its unique handling characteristics.

INSTALLING DEALER – it is your responsibility to install the warning decal and forward these installation instructions on to the vehicle owner for review. These instructions should be kept in the vehicle for its service life.

Note to installer : Before installation begins we recommend that a test drive be performed. While driving check for uncommon sounds and/or vibrations . What you feel and hear during the test drive will only magnify once lift kit is installed. Advise you to discuss possible issues identified from drive with customer before proceeding to install this kit.

Kit Contents: 40900

• 40900BAG1 x1
• 569BAG1 x1
• Dr. Upper Control Arm x1
• Pass. Upper Control Arm x1
• 10mm Studbag-2 x1
• Strut Spacer Side (A) x2
• Preload Spacer x2
• RCK6696P2BAG x2

40900BAG1: For upper control arm

• Upper Arm Brackets x2
• 6mm x 14mm Bolts x4
• 6mm Lock Nut x2

10mm STUDBAG-2: For upper strut spacers.

• 1/2-20 Jam Nut x1
• 10mm-1.25 Hex Nut x1
• 10mm-1.25 Strut Spacer Stud x6
• 10mm-1.25 Serrated Flange Nut x6

RCK6696P2BAG

• Ball Joint Hardware Bag

Tools Needed

• 8mm Wrench
• 15mm Wrench
• 15mm Socket
• 16 mm Wrench
• 18mm Wrench
• 21mm Wrench
• 29mm Socket
• 1 1/16” Wrench
• 3/8” Wrench
• 7/16” socket
• 9/16” Wrench
• 9/16” Socket
• Hammer
• Floor Jack
• Jack Stands

Torque Specs:

• Size Grade 5 Grade 8 Size Class 8.8 Class 10.9
• 5/16” 15 ft/lbs 20ft/lbs 6MM 5ft/lbs 9ft/lbs
• 3/8” 30 ft/lbs 35ft/lbs 8MM 18ft/lbs 23ft/lbs
• 7/16” 45 ft/lbs 60ft/lbs 10MM 32ft/lbs 45ft/lbs
• 1/2” 65 ft/lbs 90ft/lbs 12MM 55ft/lbs 75ft/lbs
• 9/16” 95 ft/lbs 130ft/lbs 14MM 85ft/lbs 120ft/lbs
• 5/8” 135ft/lbs 175ft/lbs 16MM 130ft/lbs 165ft/lbs
• 3/4” 185ft/lbs 280ft/lbs 18MM 170ft/lbs 240ft/lbs

INSTALLATION INSTRUCTONS

• Jack up the front of the vehicle and support the vehicle with jack stands, so that the front wheels are off the ground. Next, remove the front tires/wheels, using a 21mm deep well socket.
• Using a 15mm socket remove the front skid, if the truck is equipped with a full front skid.
• Disconnect the EPAS (Electronic Power Assist Steering) Plugs as shown located on the steering assembly by the front differential. See Photo 1 & 2. This must be done BEFORE installation is started.

• Using a 21mm wrench remove the nut from the tie rod on the knuckle. Using a tie rod/ball joint puller, remove the tie rod from the knuckle. Push linkage forward to make room for installation. Retain factory hardware. See Photo 3.
• Using a 8mm socket remove the ABS bracket from the knuckle and also remove the brake line bracket with a 10mm socket. See Photo 4.

• Next remove the caliper bolts with a 18mm socket as shown in Photo 5 and the dust shield bolts with a 8mm socket. Remove the ABS wire from the knuckle with a 5mm Allen wrench.
• Use a pair of pliers to pull off the axle dust cap and remove the axle nut with a 15mm socket. See Photo 6.

• Using a 21mm wrench and a 1 1/16” socket loosen the lower control arm bolts. Do not remove the bolts just loosen them so you can later swing the lower control arm down.
• Remove the sway bar nut from the knuckle using a 18mm socket. Retain factory hardware. See Photo 7.
• Place jack stand under the lower control arm for support. Loosen the upper ball joint nut using a 18mm wrench. Un-seat the upper ball joint taper from the knuckle using a hammer, striking the knuckle. Then remove the upper ball joint nut and remove the upper ball joint from the knuckle. See Photo 8.
• Do not allow the knuckle to pull out far enough that it pulls the shaft out of the differential.

• Remove the lower strut nuts using a 18mm socket for 21 models. See Photo 9. Retain hardware for reuse.
• Using a 18mm wrench, remove the nuts on the upper strut tower that holds the assembly in place. See Photo 10.
• Lower the jack to let the lower control arm and knuckle swing down so the strut can be removed.

We recommend using OE instructions for disassembly and assembly of IWE actuator, the following instructions are for reference only.

• Using a 8mm wrench, remove the (3) bolts securing the actuator to the knuckle. See Photo 11.

• Push CV axle inward allowing the knuckle to pivot outward to allow for more clearance to remove the strut.
  NOTE: If installing N3 Loaded Struts, V2 Monotube Shocks, or Vertex Coilovers, refer to the instructions pro-vided with those kits and skip to step 26.

• Make an alignment mark on the strut through the top hat, coil spring and the strut. See Photo 12.

• Compress the strut in the strut compressor. Then use a 15mm socket to remove the nut from the top of the strut, remove the strut. See Photo 13.
• Remove the top hat from the rubber isolator leaving the rubber isolator on the coil spring. See Photo 14.

• Place the preload spacer onto the isolator and install the top hat. See Photo 15.
• Line up the marks made on each part and install onto the coils spring. See Photo 16.

• Install the strut lining the marks up and tighten using a 15mm socket. See Photo 17.
• Insert the stud through the back side of the spacer. Use the supplied washers and nut to pull the stud into place. See Photo 18.

• For 2021 Looking at the strut spacer make sure you have two (A) spacers as shown below in the CAD drawing. When installing the spacers both sides will have the RC logo to the outside.

• Install the new strut spacer on the strut use supplied 10mm nuts and 17mm socket from 569bag1. Torque to 30 ft/lbs. See Photo 19.
• If equipped with the automatic adjusting headlamp sensor. Remove the ball stud nut from the upper control arm us-ing an 8mm wrench. Retain hardware. See Photo 20.

• Remove the upper control arm using a 21mm and 22mm wrench. Retain hardware for reuse. See Photo 21.
• Install the supplied headlamp adjusting bracket (57730BAG2) to the Dr and Pass forged aluminum control arms using the supplied 6mm x 14mm button head bolts (57730BAG2). Tighten using a 4mm Allen. See Photo 22.

• Install the new forged upper control arm using the factory hardware. Do not tighten at this time. See Photo 23.
• Install the strut into upper mount using the 10mm nut, lock washer and flat washer from 569bag1. See Photo 24.

• Spin and align the lower mount of the strut with the lower control arm mount. Install the factory studs back into the barpin on the lower mount of the strut. It may be necessary to hit the top of the studs with a hammer to seat the splines before tightening the factory nuts with a 18mm. See Photo 25.
• Make sure the actuator splines line up to the splines on the CV shaft. See Photo 26.

• Install CV shaft into the knuckle assembly. See Photo 27.
• Using a floor jack, raise the lower control arm and connect the upper ball joint on the upper control arm to the knuck-le. See Photo 28. Ball joint must be greased before use and checked every 3000 miles.

• Reinstall the steering linkage nut using a 21mm wrench. See Photos 29.
• Install the sway link into the knuckle using the OE nut. Tighten using a 18mm socket. See Photo 30.

• Install the (3) bolts securing the actuator to the knuckle and tighten using an 8mm wrench. See Photo 31.
• Measure the depth of the CV shaft threads protruding through the hub bearing. If minimum 15.5mm or .61” is not achieved, rotate the hub several times to eliminate binding of the splines and ensure proper seating of the CV. See Photo 32.
• Install axle nut and tighten to 30 ft/lbs.
  Do Not Use an impact, caution must be taken or damage to shaft may occur.

• Next slide on the brake rotor and install the brake caliper with the factory hardware and a 18mm socket.
• Install the ABS line to the knuckle.
• Verify free rotation of the hub with NO CV shaft rotation. No clicking or grinding noise should be present
• Activate actuator via the 4wd selector in the cabin of the vehicle. Rotate the hub to engage the actuator. You may hear/feel the actuator engage.
• Verify that the hub and CV rotate together. Disengage the 4wd.
• Repeat steps 4-44 on opposite side of vehicle.
• Using a 18mm wrench, reinstall sway bar using factory hardware. Torque to factory specs.
• Install the wheels / tires, using a 21mm deep well socket.
• Reconnect the EPAS plugs.
• Jack up the vehicle and remove the jack stands. Lower the vehicle to the floor and torque all bolts to factory specifi-cations.
• Tighten the upper control arms using a 21mm and 22mm socket.
• Vehicle will have to have a front-end alignment.
• If the rear block kit & shocks were ordered with the kit please proceed to the next section.

REAR INSTALLATION INSTRUCTIONS

• Chock the front wheels.
• Jack up the rear of the vehicle and place jack stands underneath the frame rail.
• Remove the tires and wheels.
• Remove the upper strut hardware using a 18mm wrench. See Photo 1.
• Push the lower control arm down with the strut enough to install the spacer on top of the strut. See Photo 2. NOTE: The strut is removed from the vehicle for picture purposes, but the install is easier without removing the strut.

• Secure the strut with the spacer using the stock hardware. See Photo 3.
• Put on wheels and lower.

Warning
For 2015-21 Do not cut or remove factory crash bar if equipped.

POST INSTALLATION INSTRUCTIONS

• Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and heated components. Check steering for interference and proper working order. Test brake system.
• 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.
• Re-torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during routine vehicle service.
• Readjust headlights to proper settings.

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 pro-fessional 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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