Rough Country 591.20 User Manual
92159000
05-07 F250 8” 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 and the kit
contents on the back of these instructions. 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 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 8” and the back 7 with new leaf springs”. 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.
The 8” suspension system was developed for 37x12.50x17 tire on an after market 17x9” wheel with 4” 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.
Kit Contents:
Diesel Coil Springs
Upper Control Arms (2)
Lower Control Arms (2)
Stabilizer Drop Brackets
Track Bar Bracket
Control Arm BracketBrake Line Drop
Bracket
Sway Bar Link Extension
Pitman Arm
Carrier Bearing Drop Brkt
Front and Rear Shocks
7” Rear Spring
Rear 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
17mm Socket
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
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 bracket using a 21mm wrench. Remove end links See Photo 1.
4. Remove the bump stop from the cup shaped bracket. Remove the bracket from the frame rail using 10mm wrench.
See Photo 2.
.
Photo 1
5. Disconnect the ABS sensor wire from the lower spring seat and the radius arm, using a 8mm wrench.
6. Unbolt the brake line brackets from the axle, using a 10mm wrench, to ensure brake line free play during the suspension system installation. Mark the coil springs and the coil spring seats on the axle with a grease pencil to ensure
proper spring position during installation. Remove the center disconnect vacuum lines from the clamp on the axle.( If
equipped with automatic hubs).
7. Using a 19mm wrench remove the nut, retaining washer and rubber bushing from the upper shock mounts.
18mm wrench remove the lower shock bolts. Retain hardware for re-use. See Photo 3.
8. 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.
9. Using a 24mm wrench and socket remove the bolt holding the radius arm to the frame. Using a 24mm wrench, and
socket remove the bolts holding the radius arm to the axle. Retain stock hardware for reuse.
10. Insert bushings, and sleeves from kit bag into both ends of the upper radius arm. See Photo 4.
Photo 2
Using a
Photo 3
Photo 4
11. Insert the radius arm drop bracket into the stock location. Bolt into place using a 3/4” x4.75” bolt, crush sleeve, nut
and washer provided in the kit bag. Do not tighten at this time. See Photo 5.
12. Attach the upper control arm to the radius arm drop bracket in the top hole. Bolt into place using a 3/4” x4.75” bolt,
nut and washer provided in the kit bag. Do not tighten at this time.
13. Attach the control arms to the axle using the stock hardware. See Photo 6. It may be necessary to use the rear
nut from the frame mount due to some models having the radius arm nut welded to the radius arm.
Photo 5
Photo 6
Crush sleeve installs in bracket here
14. Insert the adjustable end of the lower radius arm into the radius arm drop bracket as shown in Photo 7. Bolt into
place using a 3/4” x4.75” bolt, nut and washer provided in the kit bag. Using a 1 7/8” wrench tighten the jam nut.
Center of end to center hole of opposite end should be 36 1/8”. Reattach the ABS wire to the upper radius arm. See
Photo 8.
15. Repeat step 12-15 on the opposite side.
Photo 7
Photo 8
16. Using a 21mm wrench and 19mm wrench socket remove the factory track bar bracket from the frame. Retain stock
hardware for re-use
17. Position the Rough Country track bar bracket on the frame in the same position as the original and secure using the
factory hardware. See Photo 9. The track rod will be installed later.
Photo 9
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