Rough Country 633XN2 User Manual

921633XN200

84-01 4.5” XJ CHEROKEE LIFT 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 and make sure you
are confident about undertaking this installation. If you have any questions about the installation of this kit, call Rough
Country at 800-222-7023.

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, 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 features Rough Country’s adjustable joint design. Adjustable end tool is included in kit.

The 6.5” suspension system was developed for 33x11.50x15 tire on 15 x 8 after market wheel with 3.75” of back spac­ing. This tire size may require the installation of aftermarket flares and due to variation in vehicles when manufactured
and the numerous options available, the amount of actual lift gained by this lift kit will vary. On models outfitted with ex­tra bolt-on equipment and accessories, Rough Country offers new coil spring isolator pads made from polyurethane to
boost ride height 3/4".

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.

Please verify before installation rear axle tube diameter is 2 ¾” or 3”. Both sets are included with this kit to accommodate
rear axle options of the vehicle.

Assemble the joints per the separate instruction sheet Part # 92RCJ120 provided

NOTICE TO DEALER AND VECHICLE OWNER

TOOLS NEEDED:

Spring Compressor
Silicone Spray
Drill Motor
Drill Assortment (1/8” to 1/2")
Torque Wrench
Hammer
½” Drive Ratchet and Sockets
Combination Wrenches

Allen Wrenches
Torx Key Socket
Tape Measure
File
Large “C” Clamps and/or Bench Vise
Hydraulic Floor Jacks
Heavy Duty Jack Stands
Wheel Chocks (Wooden Blocks)
Grease or Anti Seize Compound

If question exist we will be happy to answer any questions concerning the design, function, and correct use of our prod­ucts. Please call us at 800-222-7023. The required installation time for this kit is 6-8 hours.

KIT CONTENT

Kit Includes:

9269-Front Coil Springs
8047-Rear Springs
7572- Adj Track Rod
Tie-Rod End

Jam Nut
Cotter Pin

1633XN2 Kit Box Including:

Front Upr Adj Control Arms (2)
Front Lwr Adj Control Arms (2)
Front Disconnect Assemblies (2)
Front Disconnect Bracket (2)
Front Brake Lines (2)
Front Shock # 658693
Rear Shock # 658708

Rear Components:

Rear Brake Line
Rear U-bolts (4)
Transfer Case Drop Spacers (4)

For Transfer Case Spacers:

10mm x 60mm Bolts (4)

For Front & Rear Brake Lines
Fr Line Crush Washers (4)

Brake Line Brackets (3)
Brake Line Clip (3)

For Sway Bar Bracket:
3/8” x 1 1/4” Bolt (2)

3/8” Flange Lock nut (2)
3/8” Flat Washers (2)

For Sway Bar Disconnects:

5/16” x 1” Tap Bolts (4)
3/8” x 1 1/4” Bolts (2)
Thick Washers (2)
Disconnect Pins (2)
Hitch pins (2)
Rod Ends (2)
1/2” Nuts (2)
1/2” Flat Washer (2)
1/2” Flange Lock Nut (2)
1/2” Jam Nut (2)

Rear Leaf Springs—2

Front

Shocks (2)

U bolts (4)

Rear Brake Line

Rear

Shocks (2)

Transfer Case Spacers

Sway Bar

Disconnects 2

Lwr Adj

Ctrl Arms (2)

Frt Adj Track Bar

Front Brake Lines (2)

Upper Adj

Control Arms (2)

Frt Coil Springs—2

PRE-INSTALLATION INSTRUCTIONS

1. Layout product and confirm that you have all needed products and know where they install.

2. Verify before installation rear axle tube diameter is 2 ¾” or 3”. Both sets are included with this kit to accommodate
rear axle options of the vehicle.

INSTALLATION INSTRUCTIONS

1. Secure and properly block the tires on the vehicle on a level concrete surface.

2. Jack up the vehicle and place the front of the vehicle on jack stands.

3. Remove the front wheels and tires.

4. Support the axle with a floor jack.

5. Remove the stock shock absorbers using a 15mm wrench. The stock bolts and nuts on the bottom of the shock will
be reused. Note: Access to the upper shock studs will be obtained through the engine compartment. It also may be
necessary to temporarily remove the washer fluid reservoir to access the driver side upper shock mount nut.

6. Remove the sway bar links on both sides using a T-55 torx bit /19mm wrench and a 15mm for the upper nut . SEE
PHOTO 1.

7. Remove the track bar from the axle housing on passenger side using a 15mm wrench. SEE PHOTO 2. Retain fac­tory bolt and flag nut for re-use.

PHOTO 1

PHOTO 2

REMOVE THE SWAY BAR HARDWARE REMOVE THE TRACK BAR

8. Locate and remove the coil clip on the driver side lower coil spring seat using a 13mm wrench. Lower the axle to
allow for removal of the coil spring. Do not overextend the brake lines. The caliper can be removed from the rotor to
allow the axle to lower. Do not let the brake caliper hang from the brake line. Remove coil spring. SEE PHOTO 3.
Repeat for opposite side.

9. With the differential supported, remove the driver side lower control arm from the vehicle using a 21mm wrench.
SEE PHOTO 4. Retain factory hardware, as it will be reused. Repeat for opposite side.

10. Lower the axle using the floor jack. With the axle lowered, install coil springs on both sides, making sure the lower
coil wrap is seated in the lower spring cup. Install factory spring retainer and secure with factory hardware using a
13mm wrench.

PHOTO 3 PHOTO 4

REMOVE THE COIL CLIP ( IF EQUIPPED)

REMOVE THE STOCK CONTROL ARMS