Rough Country 477.20 User Manual
92147700
1997-2003 Ford F150 4WD 4”-5” Suspension Kit
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. Check the kit hardware against the kit contents list. Be sure you
have all needed parts and know where they go, separating parts according to where they go and placing hardware with
the brackets before you begin with save on installation time. If you are missing any components, are unsure where they
go, or have a question about the installation please call Rough Country at 800-222-7023.
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". Many sportsmen remove their mud tires
after hunting season and install ones more appropriate for street driving; always use as wide a tire and wheel combination as possible to enhance vehicle stability.
Braking performance and capability are decreased when significantly larger/heavier tires and wheels are used. Take this
into consideration while driving.
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. Missing 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 will not work on all wheel drive—AWD F150 or Expeditions.
This suspension system was developed for 315/75 R16 tire on an after market wheel with 4.5” of back spacing. A
16”,17” or 20” wheel that is 8” wide is recommended at 5” of lift. Additionally we recommend the use of a quality tire of
redial design not exceeding 35x12.50”. This lift is determined from the front while only lifting the rear to a position level
with the front. If you want the rear to set higher order part # 6574.
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 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.
KIT CONTENTS
Torsion Bar Drop Brkt. –2
Rear
Shock –2
Pass.
Knuckle
Rear Blocks & u-bolts—2
Front Cross Member
Cr. Mbr
Spreader Bar
Diff Skid Plate
Rear Cross Member
Front Skid Plate
Drop Brkt –4
Pass Axle Brkt
Bump Stop Brkt—2
Front
Shock –2
Dr & Pass Knuckles
Driver Side Cross Member Brackets (2)
Pass Side Cross Member Bracket (2)
Front Cross Member
Rear Cross Member
Passenger Diff Drop Bracket
Sway Bar Links (2)
Sway Bar Link Brackets (2)
Bump stop Brackets (2)
Lower Skid Plate
Front Skid Plate
Cross Member Spreader Bar
Rear Blocks
Rear U-bolts
Front Shocks (650346)
Rear Shocks (650333)
Hardware Poly Bag
Front Sway Bar Link—2
Kit Contents:
Driver
Knuckle
PRE-INSTALLATION
Prior to beginning installation, carefully inspect the vehicle’s steering and driveline system paying close attention to the
tie rod ends, ball joints, and wheel bearings. Additionally, check steering to frame and suspension to frame attaching
points for stress cracks. The overall vehicle must be in excellent working condition before beginning installation. Repair
or replace all worn or damaged parts.
8mm socket 10mm socket
12mm socket 13mm socket
14mm socket 15mm socket
18mm socket 21mm socket
22mm socket 24mm socket
36mm socket 8mm wrench
10mm wrench 10mm wrench
12mm wrench 13mm wrench
15mm wrench 18mm wrench
21mm wrench 22mm wrench
24mm wrench Torque Ratchet
Torsion Bar Tool 17/64 drill bit
5/64 drill bit Sawsall
Drill Grinder
Jack stands (2) Floor jack
Tool Required List:
Torque Specs:
Size Grade 5 Grade 8
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
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
Safety Glasses and Gloves
FRONT INSTALLATION
1. With the truck sitting on a level surface measure the distance from the center of the wheel to the bottom of the
fender. Record these Measurements. See Photo 1 & 2.
Front Driver ______ Front Passenger ______
Rear Driver ______ Rear Passenger ______
Photo 1
Photo 2
2. With the truck parked on a clean, dry, and level surface set the parking brake. Chock the rear wheels. Using a floor
jack raise the front of the truck and support the frame rail
with approved jack stands. NEVER WORK UNDER AN
Photo 3
UNSUPPORTED VEHICLE.
3. Using a 22 mm socket remove the lug nuts on the front
wheels and remove the front wheels
4. Measure the amount of thread showing on the torsion bar
adjuster bolts. See Photo 3. Drivers Side ______
Passenger Side ______ Using a 18mm socket remove the
adjuster bolt.
5. Using a Ford approved torsion bar tool, remove the torsion bar adjuster nuts and adjusters. Set aside, these will
be reused.
6. Using a 18 mm wrench and 18 mm socket remove the
upper shock nuts. Using a 13 mm wrench and 18 mm
socket remove the lower shock bolt. Retain the lower
hardware for reuse.
7. Using a 16 mm wrench and 15 mm socket remove the
stock sway bar links. See Photo 4.
8. Using a 13 mm wrench remove the brake caliper. Tie the
caliper up and out of the way. Do not let the caliper hang
from the brake line. Using a 18 mm socket remove the
brake caliper bracket.
9. Using a 8 mm socket remove the brake dust cover. This
will be reinstalled on the new knuckle.
10. Using a 8 mm socket remove the ABS hold down from the
knuckle. Using a 3/16 allen wrench remove bolt and
the sensor. Route this up to the frame rail. The allen bolt
will be reused.
11. Using side cutters remove the cotter pin from the tie rod castle nut. Using a 21 mm socket remove the nut from the
tie rod. Using a hammer tap the knuckle as shown until the tie rod pops out. See Photo 5. Never hit the tie rod
itself.
12. Using side cutters remove the cotter key from upper ball joint. Using a 21 mm socket loosen the nut. Hit the knuckle
as shown until the ball joint pops loose. See Photo 6.
Photo 4
Photo 5
13. Using side cutters remove the cotter pin from the lower ball joint. Using a 24 mm socket remove the castle nut from
the ball joint. Using a hammer hit the knuckle as shown in Photo 7 until the ball joint pops free.
14. Using side cutters remove the cotter pin from CV shaft. Using a 36 mm socket remove the nut. See Photo 8.
Photo 7 Photo 8
Photo 6
15. Remove the nut from the upper ball joint and remove the knuckle from the truck. Using a 15 mm socket remove the
wheel bearing from the knuckle. Using a blunt punch and hammer remove the rear seal from the knuckle. Retain
hardware for reuse.
16. Using a 15 mm socket remove the six bolts that attaches each CV shaft to the front differential. Retain the bolts,
they will be reused.
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