ROUGH COUNTRY 921406000 2021 F 150 4 Inch 6 Inch 2wd Lift Kit Instructions

ROUGH COUNTRY 921406000 2021 F 150 4 Inch 6 Inch 2wd Lift

Product Information

• Product Name: FORD 2021 F-150 4 – 6 2wd Lift Kit
• Product Code: 921406000
• Manufacturer: Rough Country
• Recommended Installation: Certified technician
• Usage: Suspension system for FORD 2021 F-150 2-wheel drive

Product Usage Instructions

1. Before beginning installation, read the instructions carefully.
2. Check the kit hardware against the parts list to ensure you have all the necessary parts.
3. Review the tools needed list and make sure you have all the required tools.
4. For safety reasons, Rough Country recommends wearing seat belts and shoulder harnesses at all times due to the possibility of rollover.
5. Take into consideration that braking performance and capability may be decreased when using larger/heavier tires and wheels.
6. Do not add, alter, or fabricate any factory or after-market parts to increase vehicle height beyond the intended height of the Rough Country product purchased.
7. Mixing component brands is not recommended.
8. Prior to installation, disconnect the EPAS (Electronic Power Assist Steering) plugs of the vehicle. Failure to do so may result in damage to the EPAS module and require replacement.
9. Install the Warning to Driver decal provided by Rough Country on the inside of the windshield or on the vehicle’s dash to remind the driver of the unique handling characteristics of the vehicle

Torque Specs

280
Class 10.9| 9| 23
45| 75| 120
165| 240

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 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 the instructions before beginning installation. Check the kit hardware against the parts list. Be sure you have all the needed parts and know where they go. Also please review the tools needed list and make sure you have the needed tools.

PRODUCT USE INFORMATION

WARNING: The taller a vehicle is, the easier it will roll. We strongly recommend, because of the rollover possibility that 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 them concerning the design, function, and correct use of our products.

The 6” suspension system was developed using a 35X12.50/20 tire with 20 x 9 wheels with 4 1/2” backspace. The lifts were designed to lift the front to level the vehicle. Due to manufacturing, dimension variances, and inflation, all tire and wheel combinations should be tested prior to installation on all oversized / wider-than-stock tires. We recommend using a 20” minimum wheel with a corresponding tire, 9″ in width with a minimum backspacing of 4.5″ to a maximum of 5″. When using a stock wheel, it must be 20” or larger and the maximum tire width is 11 1/2”.

NOTICE: Vehicles 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 the 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.

Tools Needed

• 3/32 Allen Wrench
• 11/32 Socket
• 5mm Allen Wrench
• 8mm Allen Wrench
• 8mm wrench/socket
• 10mm wrench/socket
• 12mm Wrench
• 13mm wrench/socket
• 15mm wrench/socket
• 16mm wrench/socket
• 18mm wrench/socket
• 19mm wrench/socket
• 21mm wrench/socket
• 22mm wrench/socket
• 24mm wrench/socket
• 30mm wrench/socket
• T45 Torx Bit
• Floor Jack
• Jack stands
• Hammer
• 9/16 wrench/socket
• 1 1/16 Wrench
• Torque Wrench
• Trim Remover Tool

Torque Specs

KIT CONTENTS

4” KIT CONTENTS

40830 (4” Kit w/ N3 Rear Shocks)

• 555BOX3
• 1555BOX4
• 587BOX3
• 40830BOX3
• 40830BOX4

4 0870 (4” Kit w/ V2 Rear Shocks)

• 555BOX3
• 1555BOX4
• 587BOX3
• 40830BOX3
• 40830BOX4

6” KIT CONTENTS

40630 (6” Kit w/ N3 Rear Shocks)

• 587BOX1
• 587BOX2
• 40630BOX4
• 40630BOX5
• 557BOX3 760751

KIT CONTENTS

4” KIT BOX CONTENTS

555BOX3

• 2-Strut Spacers

1555BOX4

• 1-Front Crossmember
• 1-Rear Crossmember

587BOX3

• 1-Dr Side Knuckle
• 1-Pass Side Knuckle

40830BOX3

• 4-9/16” U-bolts
• 2-Rear Blocks
• 2-Rear Bump Stop Brackets
• 1-Rear Brake Line Bracket

40830BOX4

• 4-Cam Bolts
• 1-1556BAG2
• 2-U-bolts
• 4-3/8”-16 Flange Lock Nuts

1-551BAG1 (Hardware)

• 2-3/8” Flat Washers
• 1-3/8”-16×1” Bolt
• 1-3/8”-16 Lock Nut
• 4-5/16” Flat Washers
• 3-5/16”-18×0.75” Bolts
• 3-5/16”-18 Lock Nuts
• 8-7/16” Flat Washers
• 4-7/16”-14×1.25” Bolts
• 4-7/16”-14 Lock Nuts

1-1553BAG1

• 4-3/4” Flat Washers
• 2-18MM-2.5x150MM Bolts
• 2-18MM-2.5 Lock Nuts
• 2-Swaybar Drop Brackets

1-Rear N3 Shock Pair
1-Rear V2 Shock Pair

6” KIT BOX CONTENTS

587BOX1

• 1-Front Crossmember
• 1-Rear Crossmember

587BOX2

• 1-Dr Side Knuckle
• 1-Pass Side Knuckle

40630BOX4

• 4-9/16” U-bolts
• 2-Rear Blocks
• 2-Rear Bump Stop Brackets
• 1-Rear Brake Line Bracket

40630BOX5

• 4-Cam Bolts
• 1-1556BAG2
  • 2-U-bolts
  • 4-3/8”-16 Flange Lock Nuts
• 1-551BAG1 (Hardware)
  • 2-3/8” Flat Washers
  • 1-3/8”-16×1” Bolt
  • 1-3/8”-16 Lock Nut
  • 4-5/16” Flat Washers
  • 3-5/16”-18×0.75” Bolts
  • 3-5/16”-18 Lock Nuts
  • 8-7/16” Flat Washers
  • 4-7/16”-14×1.25” Bolts
  • 4-7/16”-14 Lock Nuts
• 1-1553BAG1
  • 4-3/4” Flat Washers
  • 2-18MM-2.5x150MM Bolts
  • 2-18MM-2.5 Lock Nuts
  • 2-Frt Brake line Brackets
  • 2-Swaybar Drop Brackets

557BOX3

• 1-10MMSTUDBAG-2
• 6-10MM-1.25 Stud
• 6-10MM-1.25 Flange Nut
• 1-10MM-1.25 Nut
• 1-1/2” Jam Nut
• 2-Rear N3 Shocks
• 2-6” Strut Spacers

557BOX4 (40670 Kit Only)

• 1-10MMSTUDBAG-2
• 6-10MM-1.25 Stud
• 6-10MM-1.25 Flange Nut
• 1-10MM-1.25 Nut
• 1-1/2” Jam Nut
• 2-6” Strut Spacers

1-Rear N3 Shock Pair
1-Rear V2 Shock Pair

FRONT INSTALLATION INSTRUCTIONS

1. Chock the rear wheels and jack up the front of the vehicle.

2. Place jack stands under the frame rails and lower onto jack stands.

3. Remove the wheels/tires using a 21mm socket.

4. Remove the carpet and skid plate (If equipped) with a 13mm socket/wrench. See Photo 1.

5. Remove the 3 EPAS (Electronic Power Assist Steering) Plugs on the steering assembly. Pull the red tab back to un-lock as shown by the middle plug in Photo 2.
   This must be done BEFORE installation is started.

6. Remove the tie-rod end using a 21mm wrench. Strike the knuckle with a hammer to loosen the tie rod end. Photo 3.

7. Remove ABS line snap clips using a trim remover tool to get more slack in the line. See Photo 4.

8. Remove the upper ball joint nut using an 18mm socket/wrench. Strike the knuckle to loosen. See Photo 5.

9. Using a 21mm socket, remove the brake caliper as shown in Photo 6. Hang the caliper out of the way. Do not let the caliper hang by the brake hose as this will damage the hose.

10. Remove the rotor. See Photo 7.

11. Remove the ABS wire from the bearing assembly using a 5mm Allen wrench. See Photo 8.

12. Remove the sway bar link using a 21mm wrench and T45 Torx bit. See Photo 9.

13. Remove the lower ball joint using a 21mm socket/wrench and remove the knuckle. See Photo 10.

14. Remove the lower strut nuts using an 18mm socket/wrench. See Photo 11.

15. Remove the upper strut nuts using an 18mm wrench. See Photo 12.

16. Remove the strut from the vehicle. See Photo 13.

17. Remove the swaybar from the frame using a 15mm socket/wrench.

18. Remove lower control arms using a 27mm socket/wrench on the nut and a 21mm socket/wrench on the bolt. See Photo 15.

19. Install the rear cross-member with the supplied 18mm x 150 mm bolt. The bolt will be installed through the sway bar bracket and rear cross-member, securing it to the stock location. Do not tighten at this time. Install the RC decal on the sway bar brackets with supplied #8-32 bolts, and nuts using a 3/32” Allen wrench and 11/32” socket. Torque nuts to 35ft-lbs. using a 15mm socket. See Photo 16.
    NOTE: Depending on the vehicle, pocket trimming may be required to ensure proper fitment. See Photo 17.

20. Install the front cross-member using the factory hardware. See Photo 18. Do not tighten at this time.

21. Install the lower control arms using the supplied 18mm x 160mm cam bolts, washers, and nuts using a 1 1/16” socket/wrench. See Photo 19. Do not tighten at this time.

22. Tighten all upper cross-member bolts. Torque to 190 ft-lbs using a 21mm, 1 1/16” socket and 1 1/16” wrench.

23. Using a 10mm wrench remove the brake line bracket from the driver and pass side frame. See Photo 20.

24. On the passenger side remove the brake line from the two factory clips. See Photo 21.

25. Install the new brake line bracket on the driver and passenger side with the stock hardware. See Photo 22.

26. Install the factory passenger side brake line in the new bracket using the supplied 5/16’ x 3/4” bolt, washer, and nuts. Take care to not kink the brake line. See Photo 23.

27. On the driver’s side, pull slightly on the brake line to allow the line to be installed on the new bracket. Secure the brake line to the new bracket with the supplied 5/16” x 3/4” bolt, washers, and nut. Take care to not kink the brake line.

28. Using a 13mm socket/wrench, torque the supplied brake line bolts to 15 ft lbs. Torque stock hardware to 18ft-lbs.

29. Install the supplied 10mm studs in the strut spacers with a 17mm wrench, using the 1/2” jam nut. See Photo 24.

30. Using the stock hardware, install the strut spacers on the struts. Torque to 45ft-lbs. using a 15mm. See Photo 25.

31. Install the strut with strut spacers installed in the stock upper mount. Secure with supplied 10mm nuts, washers, and lock washers. See Photo 26. Do not tighten at this time.

32. Install the lower strut in the lower control arm using the factory hardware. Torque using an 18mm socket.

33. Torque upper strut mount hardware using a 17mm wrench.

34. Reconnect the sway bar links to the knuckles using a 21mm wrench and T45 Torx bit. Install nut to hold the sway bar in place but do not tighten at this time. See Photo 27.

35. Swing up the sway bar and install the sway bar drop brackets using the supplied 7/16” x 1” bolts, washers, and nuts. Torque to 45ft-lbs. using a 5/8 wrench and socket. Torque the sway bar links to 18 ft-lbs. using an 18mm socket. See Photo 28

36. Install the RC knuckles to the lower control arm first using a 24mm socket/wrench. See Photo 29.
    NOTE : Do not use an impact drill on the upper and lower ball joints, tighten with hand tools.

37. Install the tie rod end using a 21mm socket wrench and install the rotor. See Photo 30.

38. Install the ABS wire on the bearing assembly, torque to 8 ft-lbs. using a 5mm Allen. See Photo 31. Install the factory dust shield on the supplied knuckle, using factory hardware. torque to 14ft-lbs. use an 8mm socket.

39. Install the caliper to the knuckle with the stock hardware, Torque to 140ft-lbs. using a 21mm socket. See Photo 32.

40. Make sure the ABS wire is out of harm’s way. Using a zip tie, secure the ABS wire to the knuckle neck.

41. Install the tires and wheels using a 21mm socket. Remove the jack stands and lower the truck to the ground.

42. Tighten the lower control arm bolts using a 1-1/16” wrench and socket. Torque to 240 ft/lbs.42. Make sure the ABS wire are out of harms way. Using a zip tie, secure the and ABS wire to the knuckle neck.

43. Install the tires and wheels using a 21mm socket. Remove the jack stands and lower the truck to the ground.

44. Tighten the lower control arm bolts using a 1-1/16” wrench and socket. Torque to 240 ft/lbs.

REAR INSTALLATION INSTRUCTIONS

1. Chock the front tires and jack the rear the rear end up. Put the jack stand under the frame rail and lower the truck onto the jack stand.
2. Remove tires and wheels using a 21mm socket.
3. Remove rear shocks from the upper and lower mount using an 18mm and a 15mm wrench. See Photo 1 & 2. Retain the stock hardware.
4. Using a 10mm wrench, remove the brake line assembly on the inner driver-side frame rail. See Photo 3.
5. Install the brake line assembly to the new bracket using the supplied 3/8” x 1” bolt, washers, and nut. Torque to 30ft-lbs. using a 9/16” socket and wrench. See Photo 4.
6. Install the brake line extension bracket on the frame using the stock hardware and torque to 18 ft-lbs. using a 10mm socket. See Photo 4.
7. Using a jack to support the rear end remove U-bolts using a 21mm socket and remove the factory blocks. See Photo 5.
8. Install the supplied blocks on the block pin holes on the axle and raise the axle into place. See Photo 6. NOTE: Taller end of the block to the rear of the truck!
9. Install the axle u-bolts, and torque to 90ft-lbs. using a 22mm socket.
10. Install the supplied rear bump stop bracket, with the supplied 3/8” x 3.5” round u-bolt, and 3/8” nylock nuts, making sure the bracket lines up with the factory bump stop. Torque to 30ft-lbs. with a 9/16” socket. See Photo 7.
11. For V2 rear shocks and Vertex rear shocks follow the shock installation instructions included in the shock package and skip to step 15.
12. Install the new shock absorbers in the upper and lower mounts using the stock hardware. Torque to 55ft-lbs. using an 18 and 15-mm wrench. N3 shocks will mount with the body down.
13. Install the rear tire and wheels.
14. Raise up the rear of the vehicle and remove the jack stands. Lower the vehicle to the ground.

POST-INSTALLATION INSTRUCTIONS

1. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed, and heated members. Check the steering gear for interference and proper working order. Test brake system
2. Perform a steering sweep. Check to ensure brake hoses have sufficient slack and will not contact rotating, mobile, or fixed members, and adjust lines/brackets to eliminate interference, and maintain proper working order. Failure to perform inspections may result in component failure
3. Readjust headlights to factory settings
4. Have the vehicle aligned by a certified alignment professional.
5. Re-torque all nuts, bolts, and especially u-bolts after the first 100 miles, again after another 100 miles, and then check periodically thereafter
6. All components must be retightened after 500 miles, and every three thousand miles after installation.

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 buyer’s 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.

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>