Rough Country 276P User Manual

92127400

88-98 GM 4”- 6” SUSPENSION KIT

Thank you for choosing Rough Country for 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 parts list. Be sure
you have all the needed parts and understand where they go. Also please review the tools needed list and make sure
you have needed tools.

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/heaver tires and wheels are used. Take
this into consideration while driving. Also, speedometer recalibration is necessary when larger tires are installed.

Do not 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, and/or combining body lift with 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.

This kit is packaged as a leveling kit. If you desire a different look or if your truck has a tool box or something else that is
going to bring the rear end down, please consult with your sales person about higher block and u-bolt options. If your

vehicle is equipped with a rear sway bar (Tahoe and Suburban standard equipment), we recommend that you
purchase longer sway bar links, part # 1038. Steering Stabilizer Part # 87369 is also available from Rough Coun­try for use with this kit.

Important Note:
addition to the standard kit to complete installation, if you have not ordered/received 89501 – Torsion Bar Kit,
then please call your Rough Country distributor before

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.

4 Door Tahoe’s and Yukon’s require part number 89501 torsion bar cross member bracket in

you begin installation.

NOTICE TO DEALER AND VECHICLE OWNER

Tools Needed
10mm Wrench 1 1/16” Wrench

11mm Wrench 7/8” Socket
13mm Socket 3/8” Allen Head
14mm Wrench Grinder
15mm Wrench Saw
15mm Socket Jack Stands
18mm Wrench Reciprocating Saw
18mm Socket
21mm Wrench
21mm Socket
24mm Socket
24mm Wrench
35mm Socket

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

KIT CONTENTS

Lower Skid Plate

Upper Control Arm Drop Upper Control Arm Drop

Kicker Brace

Torsion Bar Drop

Diff Bracket Diff Bracket

Steering Link Front Cross Member

Steering Assembly

Rear Cross Member

Block & U-bolts

Kicker Brace

Torsion Bar Drop

1274BOX1:

Pass Upper Arm Bracket
Driver Upper Arm Bracket
Steering Center Link
Steering Assist Link
Dr Diff Bracket (2)
Torsion Bar Bracket (2)
Front Brake Hose Bracket (2)

1274BOX2

Front Cross member
Rear Cross-member
Pass Kicker Bar
Driver Kicker Bar

1274BOX3

Lower Skid Plate

1274BOX5
Front Skid Plate

Front and Rear Shock Absorbers
Rear U-bolts (4)
Rear Blocks (2)

1274BOX7

Steering Center Link
6112-Add a leaf-6” Kit Only

FRONT INSTALLTION INSTRUCTIONS

1. Chock the rear wheels to prevent movement. Place a jack under the lower control arm and jack the vehicle up.
Place jack stands on the frame rails to support the vehicle. Remove tires and wheels.

2. The next step will require a special tool to unload the torsion bars. This tool is available at some parts houses and
also at Kent Moore Tool Group, Roseville, MI…..PH: [phone] or [phone]. Part # J-22517-C.

Please Note the torsion bar is under extreme load. Substituting a tool for an actual torsion bar tool may re­sult in injury.

3. On either side of the vehicle, position unloading tool on cross member. See Photo 1. Apply light lubricating grease
to tool threads. Be sure to leave adequate clearance to remove the adjuster bolt from the cross member. Tighten
the adjuster bolt on the cross member and tighten tool on adjuster arm to relieve tension on the bolt .Loosen the ad­juster bolt and remove the bolt and threaded block from cross member. Loosen torsi on bar tool until adjuster arm is
loose. Slide the bar forward and the adjuster arm will fall free. In the event the bar seems lodged, use a punch and
hammer routed through the hole in the back of the cross member to drive it forward. Repeat on opposite side.

4. On vehicles with stock exhaust, it may be necessary to jack-up the exhaust to allow clearance for cross member re­moval. Using a 18mm wrench and 18mm socket remove the torsion bar cross member, out side bolts. Using a
15mm socket and wrench remove the center bolts. Retain stock hardware. With the cross member out of the way ,
the bars can be dislodged from the lower control arms and removed. Mark the bars driver / passenger side, front /
rear. The bars must be installed on the same side and in the same direction as they were removed.

5. If your vehicle is equipped with factory skid plates remove them using a 15mm wrench.

See Photo 2.

Photo 1 Photo 2

6. Using a 3/8” allen head socket remove the bolts holding the caliper. Tie the caliper out of the way. See Photo 3.

7. Remove the rotor.

8. Using a 35mm socket remove the axle nut. Save the stock hardware. See Photo 4.

Photo 3

Photo 4

9. Using an 18 mm wrench remove the nut holding the drag link to the knuckle. It may be necessary to hit the knuckle
with a hammer to dislodge the drag link. Be careful to only hit on flat surfaces, so you will not break the knuckle. See
Photo 5.

10. Unplug the ABS wire from the frame. See Photo 6.

11. Remove the rubber fender skirt by taking a flat screwdriver and pry out the plastic rivets.

Photo 5

12. Using a 1 1/16” wrench remove the nut from the ball joint on the upper control arm. Using a hammer hit the knuckle
beside the ball joint to dislodge arm. Save the stock hardware. See Photo 7.

13. Using a 21mm wrench remove the nuts and bolts that hold the upper control arm, save the stock hardware. Remove
the arm. See Photo 8.

Photo 6

Photo 7 Photo 8

14. Remove the upper and lower shock bolts using a 18mm socket and wrench. Remove the shock.

15. Using a 15mm socket remove the 6 bolts holding the axle shaft to the differential. Save the stock hardware. Remov e
the shaft. See Photo 9.

16. Using a 1 1/16” wrench remove the nut holding the lower control arm ball joint to the knuckle. Wrap on the side of
the knuckle to dislodge the ball joint from the lower control arm. Save the stock hardware. See Photo 10.

Photo 9

Photo 10