ROUGH COUNTRY 4 Inch Lift Kit Installation Guide

ROUGH COUNTRY 4 Inch Lift Kit

Product Information

• Product Name: Rough Country Suspension Kit
• Product Code: 92114500
• Compatibility: 1973-1987 GM Pick-Up Trucks, 1973-1991 Blazer, Suburban, 1/2 Ton 4WD
• Kit Type : 4-6 Lift Kit

Product Usage Instructions

1. Professional Installation: It is recommended to have a certified technician install this suspension system. They should have knowledge of disassembling/reassembly procedures and post-installation checks to ensure the vehicle’s integrity and operating safety.

2. Read Instructions: Before starting the installation, read all
   the instructions provided.

3. Check Kit Contents: Compare the kit hardware with the Kit
   Contents list on the next page. Ensure you have all the required
   parts and understand their placement.

4. Required Tools: Review the tools needed list to ensure you have
   all the necessary tools for completing the installation.

5. Safety Precautions: Due to the increased height of the vehicle after installation, it is advised to always wear seat belts and shoulder harnesses to minimize the risk of rollover. Avoid situations that may lead to side rollovers. Note that braking performance may be affected when using significantly larger/heavier tires and wheels. Speedometer recalibration is necessary when installing larger tires.

6. Do Not Modify: Do not add, alter, or fabricate any factory or aftermarket parts that increase the vehicle’s height beyond the intended height of the Rough Country product. Mixing component brands or lifts with this suspension lift will void all warranties. Any modifications made to the product will not be covered under warranty.

7. Warning Decal: Any vehicle equipped with a Rough Country product must have the Warning to Driver decal installed on the sun visor or dash. This decal serves as a constant reminder of the vehicle’s unique handling characteristics.

8. Installation Guidance: The vehicle’s construction and assembly process may result in some parts being difficult to install. The flexible nature of the vehicle’s frame may cause slight shifting during disassembly. The use of pry bars and tapered punches for alignment is considered normal and does not indicate a faulty product. If uncertain about any aspect of the installation process, contact Rough Country’s tech support department at 800-222-7023.

9. Warranty Void : Modifying the Rough Country parts in any way will void any expressed or implied warranty.

Kit Contents

• Front Leaf Springs with Bushings
• Front U-Bolts
• Brake Line Brackets
• Steering Arm
• Four (4) Shocks
• Rear U-Bolts

Thank you for choosing Rough Country for all of 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 all the instructions before beginning the installation. Check the kit hardware against the Kit Contents list on next page. Be sure you have all the needed parts and understand where they go. Also please review the tools needed list to be certain that you have the tools necessary to complete the installation.

PRODUCT USE INFORMATION

WARNING: As a general rule, the taller a vehicle is the easier it will roll. We strongly recommend, because of rollover possibility, that 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/heavier tires and wheels are used. Take this into consideration while driving. Also, speedometer recalibration is necessary when larger tires are installed.
Do no add, alter, or fabricate any factory or after-market parts that increase vehicle height over the intended height of the Rough Country product purchased. Mixing component brands, and lifts, with this suspension 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.

NOTICE TO DEALER AND VEHICLE OWNER

NOTICE: 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 characteristics. INSTALLING DEALER—It is your responsibility to install the warning decal and to forward these installation instructions on too the vehicle owner for review and to be kept in the vehicle for its service life.

We hope installing your Rough Country lift kit is a positive experience. Please note that variations in construction and assembly in the vehicle manufacturing process will virtually ensure that some parts may seem difficult to install. Additionally, the current trend in manufacturing vehicles results in a frame that is highly flexible and may shift slightly on disassembly prior to installation. The use of pry bars and tapered punches for alignment is considered normal and usually does not indicate a faulty product. However, if you are uncertain about some aspect of the installation process, apartment at 800-222-7023. We do not recomparts in any way as this will void any warranty please feel free to call our tech support to recommend that you modify the Rough Country expressed or implied.

KIT CONTENTS

TOOLS NEEDED

• 1/2 socket/ wrench 5/8 socket/ wrench 9/16 socket /wrench 11/16 socket/ wrench 3/4 socket/wrench 13/16 socket/ wrench 15/16 socket/ wrench Loc-Tite Reciprocating Saw Floor Jack
• Jack Stands
• Pliers
• Torque Wrench

TORQUE SPECS

Size Grade 5 Grade 8

• 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
• Class 8.8 Class 10.9
• 10MM 32ft/lbs 45ft/lbs
• 12MM 55ft/lbs 75ft/lbs
• 18MM 170ft/lbs 240ft/lbs

INSTALLATION INSTRUCTIONS

1. Chock the rear wheels.
2. Jack up the front of the vehicle.
3. Place jack stands on the frame behind the lower control arms.
4. Lower the vehicle onto the jack stands and remove the tires and wheels.
5. Place the floor jack under the front axle.
6. Using a 3/4” socket and wrench remove the lower shock bolt. Retain factory hardware. See Photo 1.
7. Using a 3/4” wrench, remove the upper shock bolt. Retain factory hardware. See Photo 2.
8. For 4-6 kits, Remove the 3 nuts securing the steering arm to the knuckle using a 7/8 socket. See Photo 3.
9. Remove the cotter pin. Then, using a 15/16 wrench to loosen the nut securing the steering arm to the drag link, it may be necessary to hit the steering arm with a hammer to break the taper loose. Save hardware for reuse. See Photo 4. You may need to replace the cotter pin.
10. Support the front axle with a floor jack.
11. Using a 7/8 socket, remove the front spring bolts and retain them for reuse. See Photo 5.
12. Using a 13/16 socket, remove the rear spring bolts and retain them for reuse. See photo 6.
13. Lower the axle. Note: use caution when lowering the axle not to over-extend the brake lines.
14. Using a 15/16” socket, remove the u bolts and stock spring. See Photo 7. 1-ton models will have u bolts and studs.
15. After the spring is free from the axle, remove the spring.
16. Install supplied bushings and sleeves on both ends of the leaf spring.
17. Using factory hardware install the front spring bolt and tighten using a 7/8” socket. See Photo 8.
18. Install the factory bolt in the rear spring eye and tighten using a 13/16” socket. See Photo 9.
19. Install supplied bolts, washers, and nuts. Tighten using a 15/16” socket. See Photo 10.
20. Clean the mounting surface thoroughly and install the new Rough Country steering arm using the new nuts supplied in the kit. Torque nuts to 90ft/lbs.
21. Inspect the drag link assembly. If the drag link is worn or the ball joint grease boot is torn, replace the assembly. Install the drag link onto the steering arm but do not tighten. It may need to be adjusted to allow the wheels to travel from stop to stop without binding the steering mechanism.
22. Install new Rough Country N2.0 front shocks. 4” lift kits will use 660768. 6” lift kits use 660792. Upper mount will use spacer bushing and sleeve. 1/2” sleeve will need to be pressed into the lower bushing. Shock body goes down.
23. Using factory hardware, tighten the upper shock bolt using a 3/4” wrench. See Photo 11.
24. Using factory hardware, tighten the lower shock bolt using a 3/4” wrench and socket. See Photo 12.

REAR INSTALLATION INSTRUCTIONS

1. Chock the front tires.
2. Position a floor jack under the rear differential and jack up the vehicle.
3. Place jack stands under the frame rails just forward of the front leaf spring hangers and lower the frame on the jack stands.
4. Reposition the floor jack under the center of the differential and apply slight pressure for support, but do not raise the frame off the jack stands.
5. Remove the rear shock with a 15/16” wrench on the upper and 13/16” and 7/8” wrenches on the lower mount. Re-tain lower hardware for reuse. See Photos 1 & 2.
6. Using a 15/16” socket, remove the factory bolts and lower axle. See Photo 3. Note: use caution when lowering
7. Kit with rear blocks, place supplied lift block between the leaf spring and axle pad. The thicker end of the block goes to the rear of the truck. See Photo 3. If your kit has new rear leaf springs, skip to the next step.
8. Using a 13/16” socket, remove the front spring bolt and retain it for reuse. See Photo 4.
9. Using a 13/16” and 7/8” socket and wrench, remove the rear spring bolt and retain it for reuse. See Photo 5.
10. Install supplied rear springs using stock hardware. Tighten using 13/16” and 7/8” sockets/wrenches. See Photo 6.
11. Using a cutoff wheel, cut the factory e-brake cable mount and bend. See Photo 7.
12. Remove the e-brake cable and bend the mount back to its original position. See Photo 8. Apply paint to cut surfaces to prevent rust.
13. Attach 1/4” coupler and hose to differential breather hose. See Photo 9.
14. Attach the rear brake line relocation bracket to the differential. Using the supplied 5/16” x 1” bolt washer and nut, attach the factory brake line bracket to the relocation bracket. Tighten using a 1/2” wrench and socket. See Photo 10.
15. Install the supplied shock pin kit into the frame. See Photo 11.
16. Install the rear shock (660788) on the pin and tighten using a 15/16” wrench. See Photo 12. The body of the shock goes down.
17. Insert sleeve into lower shock eye. Attach using factory hardware and tighten using 12/16” and 7/8” wrenches.
18. Install wheels and tires and lower the vehicle to the ground.

POST INSTALLATION INSTRUCTIONS

1. Check all fasteners for proper torque. Check to ensure adequate clearance between all rotating, mobile, fixed, and heated members. Verify clearance between exhaust and brake lines, fuel lines, fuel tank, floor boards, and wiring harness. Check the steering gear for clearance. Test and inspect the brake system.
2. On some vehicles, the front lower skirting will need to be trimmed if using certain wheel /tire combinations and with heavy offset wheels. Trim only as needed.
3. Activate the four-wheel drive system and check the front hubs for engagement.
4. Have a qualified alignment center align the vehicle immediately. Realign to factory specifications. Have headlights adjusted to proper settings.
5. Perform head light check and adjustment to proper settings.
6. Check and retighten the wheels at 50 miles and again at 500 miles.
7. Recheck the lifted height and adjust the torsion bar as necessary.
8. All kit components must be retightened at 500 miles and then every three thousand miles after installation. Periodically check all hardware for tightness.
9. Install the “Warning to Driver” decal on the sun visor.

Alignment Specs

FRONT CONSTANT VELOCITY U-JOINT STOPS MODIFICATION INSTRUCTIONS

The stops on the front cv u-joint and the stops on the front drive shaft must be modified to obtain maximum suspension travel on all 4” and 6” lift systems (see diagram below). These stops are designed to prevent the drive shaft from contacting the road surface in the event of a u-joint failure at the front-end housing.

1. Remove the front drive shaft assembly from the vehicle. Use a grinder or other suitable tool and remove the amount of material needed to gain ample u-joint clearance at the drive shaft stop. (Remove as little material as possible). About 1/8” of material.
2. With the grinding completed, reinstall the drive shaft and check the stop clearance by turning the drive shaft.

TRANSFER CASE LOWERING INSTRUCTIONS
For ½ & ¾T 1980 and later model years on 4” and 6” lifts, the transfer case is lowered by using stock mounting hardware on the transfer case cross-member.

1. Place the floor jack under the transfer case cross-member, and raise the jack until it applies pressure to the cross-member. Remove stock mounting hardware.
2. Lower floor jack until there is enough space between the cross-member and the frame to install stock spacer and mounting hardware per the picture. Tighten all hardware.

Thank you for choosing Rough Country for all of your suspension needs.
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  >>