Rough Country 394.24 User Manual

923934000

2008-10 2500 Dodge 5” Lift Kit with Adj. Arms

Thank you for choosing Rough Country Suspension for your Off Road 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. Average professional install time for this kit is 4-6 hours.

Please read all the instructions before beginning the installation. Check the kit hardware against the kit contents list on
the last page. Be sure you have all the needed parts and understand where they go.

Product Use Information

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, 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 suspension system was developed for 37x12.50 tire on the stock 17” x 9” or 20” wheels at 5” of lift. On an after­market wheel you will need to purchase a 8” wide wheel with minimum of 4-5/8” of backspacing. When larger tires are
installed, speedometer recalibration is necessary. Due to ride height inconsistencies from the factory you may need to
slightly trim the front plastic valance for proper tire clearance.
This kit can also be used a 3500 single rear wheel truck. Use of this kit on a dual rear wheel pickup is not rec­ommended. Block and u-bolt combinations may vary with 3500 models.

On vehicles equipped with a two piece driveshaft & carrier bearing as on the Mega Cab, there is the potential
for take off vibration, depending on the severity this can be corrected with shimming down the carrier bearing.
Carrier bearing drop kit Part # 1110 is available from Rough Country. Also 2500/3500 trucks with factory over­load springs the overload will have to be removed for the new block and u-bolt installation.

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 to the vehicle owner for review and to be kept in the vehicle for its service life.

Tools and Supplies Needed to Install Kit

1. Torque Wrenches 8. Pitman Arm Puller

2. ½” Drive Ratchet and Sockets 9. Hammers

3. Assorted Combination Wrenches 10. C-Clamps

4. Heavy Duty Jack Stands 11. Center Punch

5. Hydraulic Floor Jacks 12. Rubbing Alcohol

6. Channel Locks 13. Safety Glasses

7. Anti-Seize Compound 14. Non- Water Soluble Grease

FRONT SUSPENSION INSTALLATION

1. Secure and block the rear tires of the vehicle on a level concrete or asphalt surface

2. Open the hood and remove the shock nuts, retaining washers and rubber bushings from both upper shock mounts
located inside the engine compartment. The shocks will be removed when the coils are removed.

3. Raise the front of the vehicle and support the frame with jack stands. Remove the front wheels and tires and set
aside. Position a hydraulic jack under the front axle and raise the jack until the front suspension begins to com­press

4. On both sides of the vehicle, scribe alignment marks on the adjustment cam and axle bracket at the lower link to
axle attachment point for later reference. See Photo 1.

5. Unbolt the brake line brackets from the control arm mount on the axle using a 13mm wrench to ensure brake line
free play during the suspension system installation.

6. Remove the stock front upper sway bar links from the sway bar as shown in Photo 2 using a 15mm wrench.

PHOTO 1

7. Remove the lower link from the axle using a 21mm wrench. See Photo 3.

8. Remove the track bar from its upper mounting point on
the frame using a 24mm wrench and rest it on the axle.
It may be helpful to loosen the lower track bar bolt on the
axle. Retain hardware for reuse.

9. Remove the cotter pin, and castle nut from the drag link
on the pitman arm. A pitman arm tool may be needed to
separate the drag link from the pitman arm.

10. Remove the stock nut, and lock washer from the sector
shaft on the steering box. Save hardware for later instal­lation. Using a pitman arm puller carefully remove arm.

11. Remove the lower suspension arm nut, cam, and cam
bolt from the axle. Remove the nut and bolt from the
frame attachment point and remove the lower suspen­sion arm from the vehicle. Repeat this step for the oppo­site side of the vehicle. Retain hardware for reuse

12. Adjust the arms to a length of 20” from center to center of the eye. Note: The arms may need to be readjusted
for the alignment. This measurement is a starting point.

13. Install the new Rough Country lower suspension arms in place of the stock lower suspension arms. See PHOTO 4
& 5. Slight prying of the mounts apart may be necessary for arm installation. Install the original rear suspension
arm bolt and slightly tighten the nut. Install the original front suspension arm bolt and slightly tighten the nut. Re­fer to the reference mark on the cam bolt and the axle when installing the cam bolt. Repeat on the other side.

PHOTO 2

PHOTO 3

PHOTO 4

PHOTO 5