Rough Country 478.20 User Manual

92147800

08-10 F250 4.5” SUSPENSION KIT

Thank you for choosing Rough Country for 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 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 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 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 kit is packaged as a leveling kit—raising the front 4.5” and the back 3”. 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 block / u-bolt options.

This 4.5” suspension system was developed for 35x12.50x17 tire on an after market wheel w/ 4.5” back spacing.

If equipped with factory rear contact overload springs, please note that they will need to be removed with the
addition of the block / or add-a-leaf combination on this kit.

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.

Kit Contents:

Coil Springs
Gas Coil Springs
1594Box1 Track Bar Bracket
Radius arm Drop Brkts
Sway Bar links
Pass Sway Bar Bracket
Driver Shim Plate
Carrier Drop Bracket
Pitman Arm
Bumpstop spacer
Dr & Pass Brake Lines
1580Box4 Shock Box
6578 3” Block and U-Bolt Kit

Tools Needed:
8mm Wrench 1 1/8” Wrench

10mm Wrench 1 13/16” Wrench
12mm Wrench Jack Stands
15mm Wrench Jack
17mm Wrench Drill
17mm Socket Drill Bits-13/16-7/8
18mm Wrench
18mm Socket
19mm Wrench
21mm Wrench
24mm Socket
30mm Socket

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

FRONT INSTALLTION INSTRUCTIONS

1. Block the rear wheels of the vehicle. 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

2. Disconnect the track bar from the driver side frame bracket, using a 30mm wrench.

3. Disconnect the sway bar end links from the axle and the sway bar using a 18mm wrench. Remove end links and
retain the hardware for reuse. See Photo 1.

4. Remove the bump stop from the cup shaped bracket. Remove the bracket from the frame rail. See Photo 2.

.

Photo 1 Photo 2

5. Disconnect the ABS sensor wire from the lower spring seat and the radius arm, using a 8mm wrench. See Photo 3.

6. Unbolt the brake line brackets from the spring seat, using a 10mm wrench. Remove the center disconnect vacuum
lines from the clamp on the axle.( If equipped with automatic hubs). See Photo 4.

7. Remove the stock brake line from the stock steel line on
the frame. See Photo 5.

8. Remove the stock line from the caliper and install the sup­plied braided brake lines in the factory location with the
factory hardware. To ease the removal of the coil springs,
do not install the brake line bracket to the spring seat.

Please note there is a driver and passenger side brake
hose .

9. Using a 19mm wrench, remove the nut, retaining washer
and rubber bushing from the both upper shock mounts.
Using a 18mm wrench remove the lower shock bolts. Re­tain hardware for re-use.

10. Carefully lower the jack until the coil springs are free. Re­move the coil springs from the vehicle. Note: use of a coil
spring compressor may be required for spring removal.

Photo 3

Photo 4

Disconnect Vacuum Line (Auto Hubs only)

Photo 5

11. Support both radius arms with jack stands. Using a 1 1/8” wrench, and socket remove the bolt holding the upper
control arm to the frame. Using a 24mm wrench, and socket remove the bolt holding the upper control arm to the
axle. Retain stock hardware for reuse. See Photo 6 & 7.

Photo 6

12. Insert the radius arm drop bracket into the stock location. See Photo 8. Bolt into place using the supplied spacer
sleeves and 3/4” x 4 3/4” bolts, nuts and washers provided in the kit bag. See Photo 9. Do not tighten at this time.

Photo 8

Photo 7

Photo 9

13. Install the radius arms to the new drop bracket with factory hardware. See Photo 10.

14. Attach the arm to the axle using the stock hardware. Note: it may be necessary to raise or lower the truck to align
the holes.

15. Reattach the ABS wire to the radius arm using a 8MM wrench.

16. Using a 21mm wrench and 19mm wrench socket remove the factory track bar bracket. Retain stock hardware for re­use.

17. Position the Rough Country track bar bracket on the frame in the same position as the original and secure using the
factory hardware. Tighten hardware. See Photo 11.

18. Using the nylon bump stop extension provided, place the extension between the frame and the bump stop cup. Bolt
back into the original location using the 8mmx95mm bolt supplied. Torque to 15 ft. lbs.

Photo 10

Photo 11