Rough Country 488.20 User Manual

92148800
99-04 F250/F350 8” 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.
PRODUCT USE INFORMATION
As a general rule, the taller a vehicle is the easier it will roll. 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 with its new heavy duty track bar only fits trucks produced after 03/01/99—2000 models forward. If you have a truck produced prior to this date this kit will not fit the vehicle. A difference of bolt size on the stock track bar bracket does not allow the installation of the new track rod.
This 8” suspension system was developed for 38x13.50x17 tire on an after market wheel with 4. 5” of back spacing.
Front driveshaft modification may be necessary and must be checked prior to driving the vehicle. Lengthening and bal­ancing must be performed by a drive line specialist. Failure to perform driveshaft modifications may result in driveshaft damage.
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 to the vehicle owner for review and to be kept in the vehicle for its service life.
Kit Contents: 8073-Front Spring 8072-Rear Spring 1488 Kit Box Containing:
1-FR Track Rod
Tools Needed: Assorted Metric Wrenches Assorted standard wrenches Jack stands
Floor jack 1-FR Track Rod Bracket 1-Steering Adj. Sleeve 2-FR Shock-650341 Hydro / 650377 Nitro 2-RR Shock-658049 Hydro / 658048 Nitro 2-Fr Brake Line 1-Rr Brake Line 1-Pitman Arm 1-Carrier Bearing Drop Bracket
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 3/4” 185 ft/lbs 280 ft/lbs
Class 8.8 Class 10.9 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
INSTALLATION INSTRUCTIONS
1. Park the vehicle on a level, hard surface. Block the rear wheels.
2. Remove the front anti-sway bar links from the frame mount and the sway bar using a 19 mm wrench. Retain the
upper and lower mount hardware for re-use. See Photo 1 & 2
Photo 1
Photo 2
3. Disconnect the track bar on driver side from the frame bracket and axle using a 30mm wrench and remove. See
Photo 3 & 4. Remove the stock track rod bracket using a 15mm wrench. Retain the track rod hardware for reuse.
Photo 3
Photo 4
4. Remove the front shock absorbers from the upper mount and the lower mount from the axle using a 19mm wrench .
Retain the hardware for re-use. Remove the shock absorber.
5. Using a 13mm socket remove the bolts that secure the bumper to the front hanger bracket. Retain hardware for
reuse. See Photo 5. Remove the 4 bolts that secure the front bumper to the frame using a 18mm socket. See Photo
6. Retain the hardware for re-use. Remove the bumper from the vehicle. It may be necessary to remove the rubber lower dust shroud between the bumper and the lower cross-member.
Photo 5
Photo 6
6. Position a floor jack under the front axle and jack up the vehicle. Place jack stands under the frame rails directly be-
hind the rear stock shackles. Lower the vehicle onto the jack stands. Do not remove the jack at this time. The jack will be used to support the axle later in the step
7. Remove the wheels and tires using a 7/8 deep socket.
8. The radiator cooler lower mounts will have to be removed to allow the cooler to move outward to gain access to the
front spring bolts. Remove bolts on both sides of cooler as shown in Photo 7 (Passenger Side Shown). Retain the factory hardware for reuse.
9. Remove the leaf spring bolts from the shackle and frame mount using a 21mm and 24mm wrench and retain hard-
ware for re-use. Reattach the transmission cooler to the factory location using the factory hardware.
10. Remove the brake line bracket from the axle using a 1/2” wrench to allow slack in the line.
11. Remove the sway bar links from the frame and sway bar using a 18mm & 15mm wrench. Retain the stock hardware
for reuse.
12. Remove the axle u-bolts using a 22mm socket and lower the axle /springs & brackets down. Do not lower beyond
the limit of the brake lines. Lower the axle down and remove the stock springs. Retain the stock leaf spring bolt / hardware.
Photo 7
Photo 8
13. Locate the new Rough Country front leaf springs part # 8073and install in the stock frame mount location and the
shackle mount with the factory hardware. See Photo 8. Do not tighten at this time.
14. Jack up the front axle to meet the leaf springs making sure the center pin is aligned and install the supplied 9/16” x 3
1/8” x 11 1/2” u-bolts.
15. Install the new track bar bracket in the original track bar bracket location. Reuse the factory fasteners. Torq ue to fac-
tory specs. See Photo 9.
16. Using a 30mm socket, attach the upper end of the track bar to the new bracket in the lower hole using the factory
hardware. See Photo 10. Insert the bolt from the front to the rear and hand tighten only, it will be tightened in a later step. Do not install the track rod on the axle at this time..
Photo 9
Photo 10
Install track rod bolt here
17. Using a 18mm socket and wrench, install the front shock absorbers in the factory location, part # 650328 hydraulic/
650380 gas charged shock using hardware included in kit. Tighten the upper shock nut and lower bolt to 75 ft/lbs.
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