Rough Country 3592 User Manual

92359200

02-05 1500 Dodge Torsion keys

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.

PRODUCT USE INFORMATION

As a general rule, the taller a vehicle is, the easier it will roll. Offset, as much as possible, what is lost in rollover
resistance by increasing tire track width. In other words, go "wide" as you go "tall".

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, 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.

Braking performance and capability are decreased when significantly larger/heavier tires a nd wheels are used. Take this
into consideration while driving.

The required installation time for this system is approximately 2 hours. This suspension system was developed using
285x75R16 tire on an 8” wide wheel. To ensure proper fitment, please consult your local tire and wheel specialist.

If questions exist on the design, function, and correct use of our products please contact us at 800-222 -7 023.

NOTICE TO DEALER AND VEHICLE OWNER

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.

INSTALLING 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.

RECOMMENDED TOOLS

• Floor jack

• Heavy duty jack stands

• Safety glasses

• Wheel chocks

• Ball Joint Remover like

OTC7249

FRONT INSTALLATION INSTRUCTIONS

1. Place the vehicle in neutral. Raise the front of the vehicle with a
jack to slightly raise the tires of the ground and support the frame
with jack stands beneath each frame rail behind the lower control
arms. Installation is done one side at a time, starting with the driver
side. The torsion bar adjusters are under the cab of the vehicle at
the rearward end of the torsion bars.

2. Measure or make a note of how much thread is remaining on the
torsion bar adjuster bolt. You will reset the bars at this same
location with the new adjusters. See Photo 1.

• Impact gun

• 18 mm socket

• 21 mm socket

Photo 1

3. Use extreme caution when loading and unloading the torsion bars;
there is a tremendous amount of energy stored in them. Keep your
hands and body clear of the adjuster arm assembly and the puller
tool in case anything slips or breaks. Note: Because of the extreme
loads generated by the torsion bars on these vehicles, a standard
tow-jaw puller may bend the “lips” of the cross member and may
pop out of place. For best results use a c-clamp type puller tool. If
you cannot find one locally, this tool (J-22517-C) is available from
Kent Moore Tools in Roseville, Michigan (800-345-2233) or a Ball
Joint Remover like OTC7249 can be used.

4. On the driver side, using a torsion bar removal tool, remove the
stock torsion bar adjuster by loading the torsion bar using the tool
and removing the bolt and nut block. Slide the torsion bar forward
allowing the OE torsion key to fall out. See Photo 2.

5. Install the new torsion bar adjuster using the torsion bar tool as
shown in Photo 3. Reinstall the threaded block and adjuster bolt.

6. Repeat steps for passenger side. Making sure the driver and
passenger side torsion bar adjuster bolts are adjusted the same
amount. Fine-tuning is done in a later step.

7. Remove the factory shock absorbers and discard if new shock
absorbers were purchased. If purchased; install new shock
absorbers with factory hardware.

8. Jack up the front of the vehicle and remove the jack stands. Lower
the vehicle to the ground to where the torsion bars are supporting
the weight of the vehicle.

POST INSTALLATION INSTRUCTIONS

After the torsion bar adjusters have been installed and tightened to the factory measurement taken in step #2. addition al
adjustment may need to be performed to level the vehicle. This is done by either tightening or loosening the torsion bar
adjuster bolts. Use a floor jack to support the side of the vehicle that is being adjusted, raising the tires slightly of the
ground and only adjusting the bolt 1-2 turns at a time to ensure the leveling of the truck. After adjustment lower the vehicle
to the ground and recheck for level. This may take several attempts.

headlights is required after installation. Note – the air dam on the front may need to be trimmed for additional clearance,
depending on the tire size.

As with any lift installed, adjustment of the front

A front-end alignment should ALWAYS be checked after installing ANY vehicle suspension lift. This kit typically requires a
slight toe-in adjustment. Record the ride height measurement at the time of alignment. If, in the future the torsion bars
settle excessively, alignment can be restored by adjusting-up the bars to their original ride height.

Photo 2

Photo 3

Thank You for choosing Rough Country for your suspension needs.