Rough Country 501P User Manual

92758200

99-04 Ford F250 Super Duty 4”-6” 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, profes-

sional 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, because of rollover possi­bility, that the vehicle be equipped with a functional roll-bar and cage system. 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 is packaged as a leveling kit—raising the front 4” and the back 2” or raising the front 6” and the back 4”. If
you desire a different look or if your truck has a tool box or something else that is going to bring the rear end
down, please consult with your sales repetitive about option higher block and u-bolt options or the use of an add­a-leaf.

The 4” suspension system was developed for 35x12.50x17 tire on an after market wheel with 4.5” of back spac­ing. The 6” suspension system was developed for 37x13.50x17 tire on an after market wheel with 4.5” of back
spacing.

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.

Tools Needed
13mm Socket 22mm Socket
13mm Wrench 24mm Socket
15mm Socket 30mm Socket
15mm Wrench 32mm Wrench
16mm Wrench 34mm Socket
18mm Wrench 4 Ton Floor Jack
18mm Socket 2 Jack Stands
19mm Wrench
19mm Socket
21mm Wrench
7/8 Deep Well Socket

Torque Specs:

Size Grade 5 Grade 8
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
12MM 55ft/lbs 75ft/lbs
14MM 85ft/lbs 120ft/lbs
16MM 130ft/lbs 165ft/lbs
18MM 170ft/lbs 240ft/lbs

FR LEAF SPRINGS

PITMAN ARM-6” KIT ONLY

KIT CONTENTS

TRACK BAR

BRACKET

SWAY BAR BRKTS FOR VEHICLES

PRODUCED 3/1 AND LATER

REAR BLOCK AND

U-BOLTS

PART #7595 KIT-SWAY BAR LINKS FOR VEHICLES PRODUCED ON OR BEFORE 02/28/99.

Kit Contents
Fits trucks made on or after 3-1-99
4” Kit 6” KIT

8057– Front Leaf Springs 8061– Front Leaf Springs
7582- Front Kit Box 7582– Front Kit Box
6557- 2” Block & U-Bolt Kit 7638– Rear U-Bolts
8113– Front Shocks 6593– 4” Block
8181– Rear Shocks 8113– Front Shocks
8181– Rear Shocks

` 6111-Pitman Arm
Fits trucks made on or before 02/28/99

4” Kit 6” Kit

8057– Front Leaf Spring 8061– Front Leaf Springs
7595– Front Kit Box 1493– Kit Box
6557– 2” Block and U-Bolt Kit 7638– U-Bolt Kit
8113– Front Shocks 6593– 4” Rear Blocks
8181– Rear Shocks 8113– Front Shocks
8181– Rear Shocks
6111-Pitman Arm

FRONT INSTALLATION INSTRUCTIONS

1. The tools needed , and parts for this installation are on the front cover. Make sure you have all of the proper
tools an understanding of these directions before you proceed.

2. Place the truck on a clean level surface and set the parking brake. Chock the rear wheels and using a floor
jack raise the front of the truck and support the frame rails with approved jack stands. NEVER WORK UN-
DER AN UNSUPPORTED VEHICLE, Using a 7/8 deep well socket remove the front wheels.

3. Using a 18mm and 13mm socket, remove the front bumper. Using a clip tool or a large flat head screwdriver,
disconnect the rubber valance panel from underneath the front bumper. Disconnect the block heater plug from
the bumper. (if equipped).

4. Using a 21mm socket, remove front crash bar. ( if equipped).

5. Using a 30mm socket, unbolt the track rod from the frame mount and let the bar hang. Using a 15mm wrench,
unbolt the track rod bracket from the frame

6. Using a 18mm socket and 15mm wrench, remove the sway bar links from the sway bar, and the frame
mounts on the frame rail.

7. Using a 18mm socket and wrench, remove the factory shock absorbers.

8. Leaf spring removal is done one side at a time starting with the drivers side. Position the floor jack under the
driver side knuckle. Slightly load the jack so that it supports, not raises the axle. Make sure the frame rails are
still secure on the frame stands.

9. Using a 22mm socket, remove the leaf spring u-bolts that secure the spring to the axle. Now remove the
spring plate/ shock plate and the bottom u-bolt cradle. See PHOTO 1

10. Using a 21mm and a 24mm wrench, remove the spring shackle bolt and swing the shackle back away from
the spring. See PHOTO 2.

Photo 1

11. Using a 15mm socket remove the front spring hanger to allow the spring bolt to come out.

12. Using a 24mm socket and wrench, unbolt the spring’s front eye from the hanger, then lower the jack enough
to allow the spring to be removed. See PHOTO 3.

13. Install the new springs, with the double wrap end towards the front of the truck. Insert the spring from the front
of the vehicle and position the front spring eye in the spring hanger and install the factory bolt from the inside
facing outward. Install the factory nut, do not install at this time. Using a 15mm socket re-install the spring
hanger. See PHOTO 4.

Photo 2

Photo 3 Photo 4 Photo 4