Rough Country 297N2 User Manual
92127400
02-10 GM 2500HD / 01-06 1500HD
92129700
Thank you for choosing Rough Country for your suspension needs.
& 07 1500HD CLASSIC 6” SUSPENSION KIT
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—raising the front 6” and the back 5”. 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 other block and u-bolt
options.
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. Please note that use
of a 35” x 12.5” tire may require modification to the front valance. 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.
An optional kicker Bars Part #1297Box6 is available for this kit. Please contact you local Rough Country Dealer
for more information.
NOTICE TO DEALER AND VECHICLE 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.
Rear Application Valved
Shock (2)
KIT COMPONENTS
Rear Axle U Bolt (4)
Lift Block (2)
Torsion Bar Drop Brkt (2)
Passenger Side Knuckle
Axle Spacers (2)
Pass Diff Mount Brkt
Rear Cross Member
Diff Skid
Plate
Dr Diff Mount Brkt
Front Cross Member
Rad Hose Bracket—Used on 2500HD only
CV Spacer—2
Front Application Valved
Shock (2)
Sway Bar Link—2
Driver Side Knuckle
This kit is packaged in 5 boxes. Please confirm that you have all the needed parts and know where they go
prior to beginning installation.
HARDWARE BAGS
KIT CONTENTS:
1297BOX1- Driver side knuckle
1297BOX2- Pass side knuckle
1297BOX3
1-Rear Cross Member
1-Driver side Diff Bracket
1-Pass side Diff Bracket
2 -Sway Bar Link
2 -CV Spacers
4– Sway Bar Brackets
1297BOX4 for2500 or 1259 1500HD
1-Front Cross Member
1-Dr side torsion bar drop bracket
1-Pass side torsion bar drop brkt
1-Rad hose bracket-2500HD
1–Differential Skid Plate
1297BOX5
2-Fr Part # 651997 Shock
2-Rr Part # 658556 Shock
2– 4” Lift Blocks
4- U Bolts 5/8” x 2 5/8” x 14” Square
9/16” Lock Nut (8)
9/16” Washer (8)
1297BAG1
For Rear Cross Member
16mm x 130mm Bolt (2)
16 mm Lock Nut (2)
16mm Washer (4)
For Front Cross Member
16mm x 120mm Bolt (2)
16 mm Lock Nut (2)
16mm Washer (4)
1/2” X 4 1/2” Bolt
1/2” Washer
1/2” Nut
For Driver Side Diff. Drop Bracket
Bushing (2)
Sleeve
10mm x 55mm Bolt (5)
10mm Washer (5)
For Pas Side Differential Brkt
1/2” x 1 1/2’”Bolt (2)
1/2” Washer (4)
1/2” Nut (2)
For Skid Plate Installation
3/8” Self Tap Bolt (2)
For Radiator Hose Bracket
1/2” Self Tap Bolt
For Torsion Bar C-Member Bracket
Bushings (4)
Sleeves (2)
1/2” x 1 1/4” Bolt (8)
1/2” Flat Washer (16)
1/2” Nut (8)
For Front CV Axle Spacers
10mm x 65mm Allen Bolt (12)
For Front Shock Absorber
Stem Bushings (4)
Bushing Retainer (4)
Stem Nut (2)
Shock Sleeve (14mm X1.25)-2
Large ID Eye-ring Bushing (2)
For Rear Shock Absorber
Eye-ring Bushings (4)
Sleeve (4)
LINK BAG 1
12mm x 65mm Bolts (4)
12mm Flange Nut (8)
1297BAG2
1297BAG 3:
12mm x 35mm Bolt (4)
KIT ILLUSTRATION
Tools Needed:
Assorted Metric wrenches
Assorted Standard wrenches
Reciprocating saw
Floor Jack
Jack stands
Torsion bar tool
Hand grinder w/ cutoff &
grinding disk
Thread Locker
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
1 Make sure you have all of the proper tools and understanding of these directions before you proceed.
2 Measure the front and rear of the truck from center hub to top of fender. Keep measurement for later step. Driver
Front Measurement________, Pass Front_______, Driver Rear Measurement________, Pass Rear________
3 Place the truck on a clean level surface and set the parking brake. Chock the rear wheels and using a floor jack
raise the front of the truck and support the frame rails with approved jack stands. NEVER WORK UNDER AN UN-
SUPPORTED VEHICLE. Using a 21mm deep well socket remove the front wheels.
4. 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. Warning: Be extremely careful when loading and unloading the torsion bars; there
is a tremendous amount of stored energy in the bars. Keep your hands and body clear of the adjuster arm assembly
and the puller tool in case anything slips or breaks.
5. Using GM approved torsion bar tool relieve the pressure from the torsion bar adjuster bolt. Remove the bolt and
threaded block from cross-member. Repeat for opposite side. See Photo 1.
INSTALLATION INSTRUCTIONS
PHOTO 1
PHOTO 2
6. Using a 15 mm socket remove the factory upper and lower skid plates.
7. Starting on the drivers side use a 10mm wrench to remove the brake line from the upper control arm. Unplug the
ABS wire from the frame.
8. Using a 21 mm socket remove the caliper bracket, pads, rotor and set aside.
9. Remove the bearing cap using a flat head screw driver remove the CV nut from the knuckle using a 35 mm socket.
10. Using a 18 mm deep well socket loosen but do not remove the tie rod nut. Hit the knuckle as shown in Photo 2 until
the tie rod pops out. Remove nut.
11. Using a 24 mm deep well socket loosen but do not remove the lower ball joint nut. Using a hammer, strike the
knuckle as shown in Photo 3 until the ball joint is free. The nut will keep the knuckle from falling out. Remove nut.
12. Using a 18 mm deep well socket, loosen the upper ball joint nut . Using a hammer hit the knuckle until the ball joint
breaks free. Remove the nut and remove the knuckle from the vehicle. Repeat for opposite side.
13. Remove the four factory bolts that hold the wheel bearing. Remove the wheel bearing, dust cover & o-ring. Take
caution not to damage the o-ring when removing from the stock knuckle. Install o-ring in new knuckle.
14. Using lock tight install the dust cover and bearing on the new knuckle. As shown in Photo 4. Tighten Hardware.
PHOTO 3 PHOTO 4
15. Using a 9/16” wrench remove the sway bar link.
16. 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.
17. Using a 19mm wrench and a 24 mm socket remove the lower control arm nuts. Remove the bolts, lower control
arm, and torsion bar. Retain the hardware for reuse.
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