Rough Country 208 User Manual

92120800

07-UP AVALANCHE 1500 5” KIT

Thank you for choosing Rough Country for your suspension needs. We appreciate your business!!

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. Be sure you have all needed parts and know
where they go.

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. We will be happy to answer any questions concerning the design, function, and correct
use of our products.

This kit will not fit vehicles equipped with factory auto leveling or auto ride systems.

This kit is packaged as a leveling kit—raising the front 5” and the rear 3”. If you desire a different look or if the vehicle has a
tool box or added weight in the rear, please consult with your sales representative about an add-a-leaf option.

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 18” or larger wheel not to exceed 9” in width. When using a 18”
wheel backspacing should be maximum of 5.5” and a minimum 5.0” . With a 20” or larger wheel backspacing should be a
maximum of 6.0” and a min of 5.5”. Additionally a quality tire of radial design is recommended, not exceeding 33” tall and

12.5” wide. Please note that use of a 33” x 12.5” tire may require modification to the front valance. Important note: For-

alignment purposes, it may be necessary to trim/shorten the tie rod end to allow the front end alignment to be set
properly. Please alert your alignment specialist of this possibility.

Optional kicker Bars Part #1262 are available for this kit. Please contact you local Rough Country Dealer for infor­mation.

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.

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 800­222-7023. We do not recommend that you modify the Rough
Country parts in any way as this will void any warranty expressed or implied.

PRODUCT USE INFORMATION

NOTICE TO DEALER AND VEHICLE OWNER

KIT COMPONENTS

This kit is packaged in 4 boxes. Please confirm that you have all the needed parts and know where they go prior to begin­ning installation.

1264Box1
Front Cross Member

Rear Cross Member

1264Box3
Dr Knuckle

Pass Knuckle

1208Box1

Front Strut Spacers
Driver Diff Bracket
Pass Diff Bracket
Skid Plate
Sway Bar Drop Bracket
CV Spacers
Front Brake Line Brackets
3/8 Stud Bag
1264Bag1
1264Bag2

1208Box2

Rear 3” Spring Spacers
Rear Spacer Washers
Driver Rear Shock Bracket
Pass Rear Shock Bracket
Sway Bar Links
Track Bar Bracket
201SBag
1208Bag2

Front Cross Member
5/8” X 4 1/2” Bolt (2)
5/8” Nuts (2)
5/8” Flat Washers (4)
Rear Cross Member
5/8” x 5 1/2”Bolt (2)
5/8” Lock Nuts (2)
5/8” Flat Washers (4)
Front CV Axle Spacers
10mm x 65mm SHCS Bolt (12)
Driver Side Diff. Drop Bracket
12mm x 35mm Bolt (2)
12mm Flange Nut (2)
12mm Washer (2)

Pas Side Differential Brkt

12mm x 45mm Bolt (2)
12mm Flange Nut (2)
12mm Washer (2)

Lower Strut to Ctrl Arm Mt

10mm x 55mm Bolt (4)
10mm Lock Nuts (4)
10mm Washers (8)
Sway Bar Bracket
10mm x 35mm Bolt (4)
10mm Lock Nuts (4)
10mm Lock Washer (4)
10mm Washers (8)
Frt & Rr Brake Line Brackets
5/16” x 3/4” Bolt (4)

5/16” Nylon Lock Nut (4)
5/16” Washer (8)

3/8” x 1” Bolt (4)

3/8” Lock Washer (4)
3/8” Flat Washer (4)
Rear Spring Spacer
3/8” x 3 3/4” Bolt (2)
3/8” Flangelock
Spring Spacer Washers
Rear Shock Brackets
5/8” x 1.5” Bolt (2)
5/8” Lock Nut (2)
5/8” Washers(4)
14mm x 75mm Bolts (2)
14mm Nylocks (2)
14mm Washers (4)
Rear Sway Bar Links
12mm x 65mm Bolts (2)
12mm Flangelocks (2)
12mm Washers (2)
Sleeves (4)
Brake Line
8mm x 60mm Bolt
Spacer Sleeve
Track Bar Bracket
Sleeve .562 x .750 x 1.75
9/16” x 3 1/2” Bolt
9/16” Lock Nut
9/16” Washer (2)
7/16” x 1” Bolt (2)
7/16” Nylock (2)
7/16” Washers (4)

Skid Plate Installation

CAD DRAWING SHOWING KIT COMPONENTS AND INSTALLED LOCATIONS

DIAGRAM SHOWN WITH OPTIONAL KICKER BARS PART #1262

INSTALLED

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

Tools Needed:

Floor Jack /Jack Stands

8mm Allen Socket

10mm socket / wrench

11mm socket / wrench

13 mm socket/ wrench

15mm socket / wrench

17mm socket/ wrench

18mm socket / wrench

21mm socket / wrench

22mm socket / wrench

24mm socket / wrench

19mm socket / wrench

35mm socket

7/16” socket / wrench

9/16 socket / wrench

Reciprocating Saw

Drill

11/16” Drill Bit

Hand Grinder

Loctite

FRONT INSTALLATION

1. Park the vehicle on a level surface and chock the rear wheels.

2. Jack up the front of the vehicle. Place jack stands under the frame rails and lower onto jack stands letting the front sus­pension hang.

3. Remove the tires and wheels. Remove the upper and lower factory skid plates using a 15mm wrench. Retain factory
hardware and front skid plate for reuse.

4. Using a 21mm wrench, remove the tie-rod nut as shown in Photo 1. Strike the side of the mount to dislodge the tie rod
end. Remove from the knuckle.

5. Remove the sensor wire from the plastic clip. Remove the bracket from the control arm using a 10mm wrench. See

Photo 2.

Photo 1

Strike here to dislodge tie rod end

6. Remove and unplug the ABS sensor wire from the frame as shown in Photo 3 and remove the two bolts holding brake

caliper to the factory knuckle using a 18mm wrench. Remove the caliper assembly from the knuckle and hang securely
out of the way. Do not hang the caliper by the brake hose.

7. Remove the axle nut from the knuckle as shown in Photo 4 using a 35mm socket. Retain the hardware for reuse.

Photo 3

Photo 2

Photo 4

8. Using a 18mm wrench, remove the upper strut nuts as shown in Photo 5. Retain factory hardware for reuse.

9. Using a 15mm wrench, remove the 2 bolts securing the lower strut as shown in Photo 6, to the lower control arm and

remove the strut from the vehicle. Remove and discard the factory lower retainer clips. New hardware will be used.

Photo 5

Photo 6