Rough Country 234N2 User Manual

92123400

99-06 2WD CHEVY/GM 1500 6” LIFT

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 that seat belts and shoulder har­nesses should be worn at all times. Braking performance and capabilities are decreased when significantly larger/
heavier tires and wheels are used. 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. 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. This kit was developed using a 35.12.0-16 on stock wheel.

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.

Kit Contents:

1285:

1-Dr Side Knuckle
1-Pass Side Knuckle

1234BOX1:

Front Cross-member
Rear Cross-member
Fr Coil Spacers (2)
Fr Sway Bar Brkt (4)
Fr Sway Bar Link (2)
Sway Bar Link Bag
Coil Spacer Template

1234BOX2:

658723 Fr Shock (2)
658727 Rr Shock (2)
Fr Shock Bag (2)
Rear Fabbed Block(2)
Rear U-bolts
9/16” Nut U-bolt Bag

Bag Contents:

1234Bag2:
For Cross-Members

5/8” X 4 1/2” Bolt (2)
5/8” x 5 1/2” Bolt (2)
5/8” Lock Nut (4)

1234Bag3:
For Front Spacers:

3/8” Lock Nut (8)
1/2” Lock Nut (2)
1/2” Flat Washer (2)

LinkBag1:
For Fr Sway Bar Links

12MM X 65MM Bolts (4)
12mm X 35MM Bolts (4)
12MM Flange Nuts (8)

INSTALLATION INSTRUCTIONS

1. Set the emergency brake and chock rear tires to prevent rolling.

2. Jack up the front of the vehicle with a floor jack. Place jack stands on the frame rail directly behind the lower control
arm mounts. Lower the vehicle onto the jack stands.

3. Remove the tires\wheels.

4. Remove the bolt on the top of the knuckle that secures the brake line to the knuckle using a 10mm wrench. See
Photo 1.

5. Remove the ABS wire from the mounts on the control arm and from the clip on the upper coil seat. See Photo 2.

PHOTO 1 PHOTO 2

REMOVE BRAKE LINE FROM KNUCKLE REMOVE ABS WIRE FROM FRAME

6. Remove the brake caliper using a 18mm socket and secure out of the way. See Photo 3. Remove the brake rotor
and set aside.

7. Remove the tie rod end from the knuckle using a 18mm socket and secure out of the way. See Photo 4.

PHOTO 3

PHOTO 4

REMOVE THE BRAKE CALIPER REMOVE THE TIE ROD FROM THE KNUCKLE

8. Loosen and remove the tie rod by striking the knuckle as shown to dislodge the tie rod. See Photo 5.

9. Place the floor jack directly underneath the lower control arm and loosen the upper ball-joint nut holding the upper
control arm onto the knuckle using a 18mm wrench. See Photo 6.

PHOTO 5 PHOTO 6

STRIKE TO DISLODGE TAPER REMOVE THE UPPER BALL JOINT NUT

10. Remove the ball joint by either by using a ball joint separator tool or by striking on the upper portion of the knuckle
until the upper ball joint is free. See Photo 7.

11. Loosen the lower ball joint nut using a 18mm wrench. See Photo 8. Do not remove the lower ball joint nut at this
time.

PHOTO 7 PHOTO 8

STRIKE TO DISLODGE TAPER LOOSEN THE LOWER BALL JOINT NUT

12. Remove the sway bar using a 15mm wrench. See Photo 9.

13. Strike to dislodge the lower ball joint as shown in Photo 10 and remove the lower nut and remove the knuckle from
the vehicle.

PHOTO 9

REMOVE THE SWAY BAR LINK

STRIKE TO DISLODGE TAPER

PHOTO 10

14. Remove the coil spring

15. Loosen the lower arm hardware using a 18mm socket & 24mm wrench and remove the lower arm. See Photo 11.
Retain the hardware for reuse.

16. Remove the lower bump stop from the frame using a 15mm socket / wrench. See Photo 12. Retain the hardware for
reuse.

PHOTO 11 PHOTO 12

LOOSEN THE LOWER ARM REMOVE THE FACTORY BUMP-STOP