Rough Country 592.20 User Manual

92159200

08-09 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. 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 8” and the back 7”. 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 8” suspension system was developed for 37x12.50x17 tire on an after market wheel w/ 4.5” 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:

9298 Diesel Coil Springs
1580Box1 Upper Control Arms
1580Box2 Lower Control Arms
1592Box2 Stabilizer Drop Brackets
Track Bar Bracket
Control Arm Bracket
Sway Bar Link
Hardware Bags
Pitman Arm
Stainless Front Lines
Carrier Bearing Drop Brkt
1580Box4 Fr Shocks
Rear Shocks
1592Box1 Rear block / U-Bolt Kit
Block Shims (4)

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

Size Grade 8.8 Grade 10.9
8MM 18ft/lbs 23 ft/lbs

FRONT INSTALLATION 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 using a 10mm wrench.

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.

6. Unbolt the brake line brackets from the axle, using a 10mm wrench. Remove the center disconnect vacuum lines
from the clamp on the axle.( If equipped with automatic hubs). Remove the stock brake line from the stock steel line
and install the supplied braided brake lines in the factory location with the factory hardware. Please note there is a
driver and passenger side brake hose . Photo 3 Shows the new line being installed. Bleed brake system.

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.

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. Support both radius arms with jack stands. Using a 24mm wrench, and socket remove the bolt holding the radius
arm to the frame. Using a 24mm wrench, and socket remove the 2 bolts each side holding the radius arm to the
axle. Retain stock hardware for reuse.

10. 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 4.

Using a

Photo 3

Disconnect Vacuum Line (Auto Hubs only)

Photo 4

Crush sleeve installs in bracket here

11. Insert bushings, and sleeves from kit bag into the upper control arm. See Photo 5.

12. Attach the upper control arm to the radius arm 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

14. Attach the lower control arm to the axle using the stock hardware. Do not tighten at this time.

15. Insert the end of the lower control arm into the radius arm drop bracket. Bolt into place using a 3/4” x4.75” bolt, nut
and washer provided in the kit bag. See Photo 7. Using a 1 7/8” wrench tighten the jam nut against the arm body.
Center of bushing to center hole of opposite bushing should be 36 1/8”

16. Reattach the ABS wire to the upper control arm. See Photo 8.

17. Repeat step 12-18 on the opposite side.

Photo 7

Photo 8