Rough Country 268.20 User Manual
92201S00
07 & UP 4WD TAHOE, YUKON, SUBURBAN 3.5” LIFT KIT
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 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 against the parts list on the rear cover of
these instructions. Be sure you have all needed parts and know where they go. Also please review tools needed list and
make sure you have needed tools.
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.
tion, and correct use of our products.
This kit does NOT fit vehicles equipped with electric power steering. This kit does NOT fit vehicles equipped with
Auto Ride or Rear Auto Leveling suspension.
This suspension system was developed using a 285/75/17 tire with factory wheels. Note if wider tires are used, offset
wheels will be required and trimming may be required.
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.
INSTALLLING 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.
PRODUCT USE INFORMATION
If questions exist we will be happy to answer any questions concerning the design, func-
NOTICE TO DEALER AND VEHICLE OWNER
Tools Needed:
18MM Wrench
15MM Wrench
21MM Wrench
11MM Wrench
10MM Wrench
10MM Allen Wrench
Floor Jack
Jack stands
Thread Locker
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
8MM 18ft/lbs 23 ft/lbs
10MM 32ft/lbs 45ft/lbs
12MM 50ft/lbs 75ft/lbs
14MM 85ft/lbs 120ft/lbs
16MM 130ft/lbs 165ft/lbs
18MM 170ft/lbs 240ft/lbs
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.
7. Remove the upper ball joint nut using a 18mm wrench. See Photo 4. Strike the knuckle as shown to dislodge the ball
joint. Separate the upper control arm from the knuckle.
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 mount 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. See Photo 6. .
Photo 5
Photo 6
10. Mark location of alignment cams on upper control arms to allow installation of new arm to same position. Using a
21mm wrench and 21mm socket, remove the upper control arms from the vehicle. See Photo 7. Retain the hardware
11. Using a 11mm wrench, remove the drive shaft bolts. See Photo 8. Retain hardware for reuse.
Photo 7 Photo 8
12. Place a floor jack under the differential assembly to provide
support for following steps.
13. Using a 15mm wrench, remove the 6 axle shaft bolts and se-
cure axle shafts out of the way. See Photo 9 Repeat on opposite side. Retain the factory hardware for reuse. Unplug the
electrical connector on differential as shown in Photo 10 and
unplug the diff vent hose. Photo 11
14. Using a 18mm socket remove the 4 differential bolts (2 each
side) securing the differential to the frame. See Photo 9.
15. Slowly lower differential assembly to the ground.
16. Using a hand grinder. Grind away marked portion of the cool-
ing fin as shown in Photo 12 and Photo 13. Grind until flush
with casing.
Photo 10
Electrical Plug
Photo 9
Photo 11
Photo 12
Diff Vent Hose
Photo 13
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