Rough Country 576.20 User Manual
92157600
04-08 FORD F150 6” 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 parts list on the next 2 pages.
Be sure you have all needed parts and know where they go. Also please review 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
seat belts and shoulder harnesses should be worn at all times. Avoid situations where a side rollover may occur.
Generally, braking performance and capability are decreased when 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 to increase vehicle height
over the intended height of the Rough Country product purchased. Mixing component brands is not recommended.
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. If questions exist we will be happy to answer them concerning the design, function, and correct use of our products.
This suspension system was developed using a 35X12.50/17, tire on aftermarket 17” wheels with 4 1/2-5” backspace.
The lift was designed to lift the front 6” and the rear 5-5 1/2” to level the vehicle. Due to manufacturing, dimension variances, and inflation all tire and wheel combinations should be tested prior to installation on all oversized / wider then
stock tires We recommend a wheel not exceeding 8" in width be used with a minimum backspacing of 4.5" to a maximum of 5".
Rough Country recommends not operating the vehicle in 4 wheel drive abov e 40 mph. Doing so may result in a
low frequency front driveshaft vibration. See Driveshaft Re-clocking Instructions.
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 whoe ver is operating the vehicle of its unique handling characteristics.
Tools Needed:
5mm wrench /socket
8mm wrench /socket
10mm wrench /socket
11mm wrench /socket
12mm 12 point wrench
14mm wrench /socket
15mm wrench /socket
16mm wrench /socket
18mm wrench /socket
19mm wrench /socket
21mm wrench /socket
22mm wrench /socket
24mm wrench /socket
30mm wrench /socket
Floor Jack
Jack stands
Hammer
7/16” wrench /socket
9/16 wrench /socket
5/8” wrench /socket
3/4” wrench /socket
1 1/16 socket
Drill
17/32” Drill Bit
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
KIT CONTENTS
1576 BOX 1
PART # DESCRIPTION QTY
94003702 REAR CROSSMEMBER 1
94003703 DIFF DROP 2
94003710 BRAKE LINE BRACKET 1
94003709 PASS DIFF BRACKET 1
94003035 STRUT SPACER 2
94003713 RACK & PINION BRACKET 2
1576 BOX 2
PART # DESCRIPTION QTY
94003701 FRONT CROSSMEMBER 1
337403 PASS SIDE BRAKE LINE 1
337303 DR SIDE BRAKE LINE 1
94003705 SWAY BAR DROP BRKT 2
94003706 SKID PLATE 1
94003715 REAR BRAKE LINE BRKT 1
1576 BOX 3
PART # DESCRIPTION QTY
94003712 DRIVER KNUCKLE 1
1576 BOX 4
PART # DESCRIPTION QTY
94003711 PASS KNUCKLE 1
1576 BOX 5
PART # DESCRIPTION QTY
90906000 9/16” x 3 X 13” U-BOLT 4
94003718 5” REAR BLOCK 2
1576 BAGS (IN BOX 5)
For the Skid Plate:
3/8” X 1” SELF TAPPING BOLT
For the Rack and Pinion Brackets:
16MM X 130MM BOLT
16MM FLAT WASHER
16MM NUT
SPACERS
For Sway Bar Brackets:
3/8” NUT
3/8” X 1” BOLT
3/8” WASHERS
For Driver Side Diff Bracket:
12MM x 90MM BOLT
12MM FLANGE LOCK NUT
12MM FLAT WASHER
For Pass Side Diff Bracket:
12MM X 100MM BOLT
12MM FLANGE LOCK NUT
For Strut Spacers:
3/8” STUDS
3/8” NUT
3/8” LOCK WASHER
3/8” FLAT WASHER
For Differential:
DIFF HOSE COUPLER
DIFF HOSE
For E-Brake Bracket:
5/16” X 1” BOLT
5/16” WASHER
5/16” NUT
For the Front Brake Lines:
BRAKE CRUSH WASHER
BRAKE LINE CLIP
For the Rear Brake Line Bracket:
5/16” X 3/4” BOLT
5/16” NUT
5/16” WASHER
4
2
4
2
2
4
4
8
1
1
2
1
1
6
6
6
6
1
1
1
2
1
4
2
1
1
2
1263BAG2 BLOCK BAG 1
9/16BAG U-BOLT NUT BAG 1
94003714 RACK & PINION SPACER 2
84164W STICKER 1
658048 REAR SHOCK 2
For the Front and Rear Cross member:
18MM X 150MM CAM BOLTS
18MM WASHERS
18MM NUTS
For the rear blocks:
7/16” x 3” x 3” U-BOLTS
7/16” NUTS
7/16” WASHERS
4
4
4
4
8
8
1576 BAG 2 (IN BOX 5) SHOCK BAG
PART # DESCRIPTION QTY
81019 REAR SHOCK BUSHING 4
404739 SHOCK SLEEVE 4
KIT CONTENTS
Rear Brake Line Bracket
Rear Blocks (2)
Diff Drop Brackets (2)
Knuckles (2)
E Brake Line Brkt
Front Brake Lines
Rear RC Shocks (2)
Rear Cross Member
Rack & Pinion Brkts (2)
Dif Skid Plate
Sway Bar Drop Brkts (2)
Front Cross Member
Strut Spacer (2)
Please make sure you have all the needed parts and fully understand where they go before starting installation. If there
are any questions about these instructions or this product please call your sales tech at 800-222-7023.
INSTALLATION INSTRUCTIONS
1. Chock the rear wheels and jack up the front of the vehicle.
2. Place jack stands under the frame rails and lower onto jack stands.
3. Remove the wheels/tires.
4. Remove tie-rod end using a 21mm wrench. Using a hammer hit the side of the knuckle to pop tie-rod out. Photo 1.
5. Using a 18mm socket remove brake caliper as shown in Photo 2. Hang caliper out of way. Do not let caliper hang
by brake hose as this will damage hose. Remove rotor.
PHOTO 1
PHOTO 2
6. Using a 5mm Allen-wrench remove ABS wire from wheel bearing and remove vacuum hoses from knuckle. Retain
factory hardware. See Photo 3.
7. Remove the dust cap from the knuckle and remove the 13mm axle nut.
8. Remove the upper ball joint nut on the knuckle using a 21mm wrench. Use a hammer as shown in Photo 4 to sepa-
rate the ball joint from the knuckle.
PHOTO 3
PHOTO 4
9. Remove the lower ball joint nut from the knuckle using a 24mm wrench. See Photo 5. Use a hammer as shown in
Photo 6.
PHOTO 5 PHOTO 6
10. Remove the knuckle from the vehicle. Be sure not to overextend or pull out the CV axle shaft.
11. Repeat steps 4-10 for opposite side of the vehicle.
12. Remove the upper strut mounting nuts as shown in Photo 7 using a 15mm wrench and retain the nuts for reuse.
13. Remove the lower strut mount bolt from the lower control arm using a 30mm socket and 1 1/16” wrench as shown in
Photo 8 and remove the strut from the vehicle.
PHOTO 7 PHOTO 8
14. Remove the axle shaft bolts using a 12mm 12point socket as shown in Photo 9 and remove the axle shaft. Retain
the hardware for reuse.
15. Remove the nut from the sway bar link using a 21mm wrench and retain the factory nut. It may be necessary to use
a hammer as shown in Photo 10 to separate the sway bar link from the sway bar.
PHOTO 9 PHOTO 10
16. Remove the bolts on the lower control arm using a 21mm and a 1 1/16” wrench and remove the lower control arm.
17. Repeat steps 12-16 for the opposite side.
18. Remove the center cross-member bolts as shown in Photo 11 using a 18mm and a 13mm wrench. Remove the
cross-member as shown in Photo 12.
PHOTO 11 PHOTO 12
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