Rough Country 280N2 User Manual

00-06 CHEVY/GM TAHOE, YUKON,

921280N2

SUBURBAN, YUKON XL & AV ALANCE

6” NTD 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

We strongly recommend, because of rollover possibility, 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.
Take this into consideration while driving.
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.

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
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
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

TORQUE SPECS:

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

Rr Sway
Bar Link

Track Rod Brkt

Rr Shock

Brkt (2)

Pas NTD

Bracket

Pass Side

Knuckle

Front

Shock

NTD Sleeve (2)

Sway Bar

Link

Bump-

stops (2)

Front Cross Member

Pass Diff Brkt

CV Spacer

Brake Line Brkt

Rear Cross Member

Skid Plate

Dr NTD
Bracket

Sway Bar

Link

Front

Shock

Dr. Diff Brkt

Driver Side

Knuckle

CV Spacer

Kit Contents:
1280X Box 1
Rear Cross Member
Front Shock (2)
Frt. Shock Bag (1280Bag4)
Stem Bushings Female(2)

Stem Bushings Male (2)
Stem Washer (4)
3/8” Nut (2)

CV Shaft Spacers (2)
Rear Track Rod Bracket
Front Sway Bar Links (2)
Rear Sway Bar Links (2)
Fr Dr & Pass NTD brackets
NTD Sleeves (2)
1280X Box 2 OR 1279
Rear Pass Shock Brkt
Rear Driver Shock Brkt
Rear Bump Stop Brackets (2)
Rear Brake Line Bracket
Rear Coils
1280Bag1 (see fastener breakdown)
1280Bag2-Inst sheet Bag
1280Bag4 (see fastener breakdown)
1280Bag5 (see fastener breakdown)
1272 Box2
Frt Skid Plate
Frt Cross Member
Dr Diff Bracket
Pass Diff Bracket
1285
Driver Side Knuckle
Pass Side Knuckle

Fastener Breakdown:

For Pass Side Dif Drop Brkt.
1/2” x 1 1/2” Bolt (2)
1/2” Washer (4)
1/2” Nut (2)
For Driver Side Dif Drop Brkt.
Poly Bushings (2)

2.41” x 9/16”ID Sleeve (1)
For Axle CV Spacers
10mm x 65mm Allen Bolt (12)
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 Rear Shock Relocation Brkts.
1/2” x 1 1/4” Bolt (2)
1/2” Nut (2)
1/2” Washers (4)
9/16” x 3 1/2” Bolt (2)
9/16” Washer (4)
9/16” Nut (2)
For Front Cross Member
9/16” x 4 1/2” Bolt (2)
9/16” Washer (4)
9/16” Nut (2)
For Rear Cross Member
9/16” x 5 1/2” Bolt (2)
9/16” Washer (4)
9/16” Nut (2)
For Front Sway Links:
4-12mm x 35mm Bolts
4-12mm x 65mm Bolts
8-12mm Flange Lock nuts

For Fr Bump Stops

1/2” x 1 1/2” Bolt (2)
1/2” Lock Nuts( 2)
1/2” Flat Washers (4)

For Rear Track Bar Brkt.

1.75” x9/16” ID Sleeve(1)
9/16” x 3 1/2” Bolt (1)
9/16” Washer (2)
9/16” Nut (1)
7/16” x 1” Bolt (2)
7/16” Washer (4)
7/16” Nut (2)
For Non-Torsion Bar Bracket
1/2” x 1 1/2” Bolt (2)
1/2” Washer (2)
1/2” Nut (2)
Sleeve (2)
3/4” X 5” Bolt (2)
3/4” Nylock Nut (2)
3/4” Washer (4)
For Rear Sway Bars
1/2” x 2 1/2” Bolt (2)
1/2” Nut (2)
1/2” Washers (4)
For Rear Bump Stop Brkts.
3/8” x 1” Self Taping Bolt (4)
For Rear Brake Line Brkt
5/16” x 1 1/4 Bolt (1)
5/16” Washer (2)
5/16” Nut (1)

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

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.

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.

8. Using a 18mm wrench for the upper ball joint and a 24 mm deep well socket for the lower, remove the ball joint nuts.
Using a hammer hit the knuckle as shown until the ball joint is free. See Photo 7 & 8. Remove the knuckle .

Photo 7

Photo 8

Remove the skid plate Remove the knuckle from the lower ball joint

9. Remove the three factory bolts that hold the wheel bearing to the stock knuckle. Remove the wheel bearing and
dust cover using a 15mm socket. Locate the new knuckles supplied with the kit and using Loc-Tite; install the bear­ing with the factory hardware on the new knuckle. Tighten to 133 ft.lbs. See Photo 9.

10. Using a 13mm deep well socket remove the sway bar link from the lower control arm and sway bar. See Photo 10.

Photo 9

Photo 10

Install the bearing in the new knuckle Remove the sway bar link from the lower arm

11. Using a 15 mm wrench remove the upper shock nut. Using a 21 mm socket and 21 mm wrench remove the lower
shock bolt. Remove the shock. Retain the hardware for reuse.

12. Using a 15mm socket remove the 6 inner CV bolts. See Photo 11. Set CV half shaft aside for reuse.

13. Using a 18mm wrench and a 24 mm socket remove the lower control arm hardware and remove the lower control
arm. Retain the hardware for reuse. Repeat steps 5 through 13 on passenger side.

14. Support the differential with a floor jack and remove the two nuts on the passenger side that secures the differential
to the frame using a 21mm wrench. Remove the upper differential bolt that secures the driver side differential to the
frame using a 21mm wrench.

15. Mark the front driveshaft and yoke for reference and remove the front driveshaft from the differential using a 11mm
wrench. Secure driveshaft out of harms way. See Photo 12.

Photo 11

Remove the shaft from the differential

Remove the drive shaft from the differential

Photo 12