Rough Country 1272BOX4 User Manual

92127200

99-06 CHEVY/GM 1500 6” LIFT KIT

Thank you for choosing Rough Country for all of 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 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

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 which increase vehicle height over the intended height of
the Rough Country product purchased. Mixing component brands, 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.

Due to differences in manufacturing, dimension and inflated measurements, tire and wheel combinations should be test
fit prior to installation. For this application we recommend a wheel not to exceed 9” in width with 4.5 “ of backspacing..
Additionally a quality tire of radial design is recommended, not exceeding 35” tall and 12.5” wide. If this vehicle was
equipped from the factory with 17” wheels and if purchasing new wheels, the wheel size must not be below 17” but can
be larger than 17” due to the vehicle being equipped with larger calipers /rotor.

NOTICE TO DEALER AND VEHICLE 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 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 of 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, please feel free to call our tech support department at 800-222-7023. We
do not recommend that you modify the Rough Country parts in any way as this will void any warranty ex­pressed or implied.

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

Sway Bar

Link (2)

KIT CONTENTS

Rear U-bolts (4) Rear Blocks (2)

Torsion Bar Bracket (2)

Dr Bump Stop Bracket Pass Bump Stop Bracket

Rear Shocks (2)

Rear Cross Member

Front Shocks (2)

Front Cross Member

Pass Side

Knuckle

Kit Contents:
1272 Box1
Rear Cross Member
Dr Torsion Drop Bracket
Pass Torsion Drop Bracket
Dr Bump Stop Bracket
Pass Bump Stop Bracket
1272 Box2
Frt Skid Plate
Frt Cross Member
Dr Diff Bracket
Pass Diff Bracket
1272 Box3
Front Shock Part #658441 (2)
Rr Shock Part # 658556 (2)
CV Shaft Spacers (2)
Lift Blocks (2)
9/16” X 2 1/2” X 12 1/2” U-bolts (4)
Front Sway Bar Links (2)
1285
Driver Side Knuckle
Pass Side Knuckle

Dr. Diff Brkt

Skid Plate

Pass Diff Brkt

Fastener Breakdown:

For Driver Side Dif Drop Brkt.
Poly Bushings (2)

2.41” x 9/16”ID Sleeve (1)
For Bump Stop Bracket
1/2” x 1 1/2” Bolt (2)
1/2” Washer (2)
1/2” Nut (2)
For Rear Cross Member
5/8” x 5 1/2” Bolt (2)
5/8” Washer (4)
5/8” Nut (2)
For Pass Side Dif Drop Brkt
1/2” x 1 1/2” Bolt (2)
1/2” Washer (4)
1/2” Nut (2)
For Front Cross Member
5/8” x 4 1/2” Bolt (2)
5/8” Washer (4)
5/8” Nut (2)
For Skid Plate
3/8” x 1” Self Taping Bolt (2)
1/2” x 4 1/2” bolt (1)
1/2” Washer (2)
1/2” Nut (1)
For Axle CV Spacers
10mm x 65mm Allen Bolt (12)

Driver Side

Knuckle

CV Spacer (2)

For Torsion Bar Drop Brackets
1/2” x 1 1/2” Bolts (8)
1/2” Lock Nuts (8)
Bushings (4)
Sleeves (2)
For Front Shock Absorbers
Stem Bushings Female(2)
Stem Bushings Male (2)
Stem Washer (4)
3/8” Nut (2)
For Rear U-Bolts
9/16” Washer (8)
9/16” Nut (8)
7/16” Washer (8)
7/16” Nut (8)
For Rear Shock Absorbers
Hourglass Bushing (4)
Shock Sleeve (4)

TOOLS NEEDED:

Floor Jack
Jack Stands
10mm socket /wrench
11mm socket /wrench
13mm Deep Socket
13mm wrench
15mm socket / wrench
17mm socket / wrench
18mm socket /wrench
19mm socket /wrench
21mm socket /wrench
24mm socket /wrench
35mm socket

CAD DRAWING SHOWING KIT COMPONENTS AND INSTALLED LOCATIONS

9/16 socket /wrench
7/8” deep well socket
Torsion bar Tool
Drill
17/32 Drill Bit
Loc-Tite
Reciprocating Saw

Size Grade 5 Grade 8

TORQUE SPECS:

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

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

DRAWING SHOWN WITH OPTIONAL KICKER BRACES

DRAWING SHOWN WITH OPTIONAL KICKER BRACES

FRONT INSTALLATION

1. Place the truck on a clean level surface and set the parking brake. Chock the rear wheels. Using a floor jack raise
the front of the truck and support the frame rails with jack stands. Never work under an unsupported vehicle. Using a
7/8” deep well socket remove the front wheels.

2. Locate the torsion bar adjuster bolt on the bottom of the rear cross member, measure the threads showing on the
torsion bar adjuster bolt. Mark the position of the torsion bars on the control arm and torsion bar key. Mark both the
drivers side and passenger side. See Photo 1.

3. Using a torsion bar tool, relieve the pressure from the torsion bar adjuster bolt and remove the bolt and threaded
block. See Photo 2.Warning: Be extremely careful when loading and unloading the torsion bars; there is a tremen-
dous amount of stored energy in the bars. Keep you hands and body clear of the adjuster arm assembly and the
puller tool in case anything slips or breaks.

Photo 1

Mark torsion bar and torsion bar keys

Remove torsion bar keys

Photo 2

4. Using a 15 mm socket remove the factory lower skid plate. See Photo 3.

5. Starting on the drivers side use a 10mm socket to remove the brake line from the upper control arm and knuckle.
Unplug the ABS wire from the frame rail. See Photo 4.

Photo 3

Photo 4

Remove the skid plate

Remove the brake line from the upper arm

6. Using a 18mm socket unbolt the brake caliper and rotor. Secure the brake caliper out of harms way. See Photo 5.

7. Using a 35 mm socket remove the CV nut from the knuckle. See Photo 6. Remove the tie rod from the stock
knuckle using a 18mm wrench. Strike the side of the knuckle where the tie rod mounts to dislodge the tapered tie rod
end. Retain the stock hardware for reuse.

Photo 5 Photo 6

Remove the brake caliper bracket

Remove the spindle nut