92163600
Jeep Grand Cherokee 93-98 ZJ 3 1/2” Budget Kit
Thank you for choosing Rough Country for all 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 this page. 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. Always wear safety glasses.
As a general rule, the taller a vehicle is, the easier it will roll. 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.
Due to inconsistency of vehicles when manufactures and various options available, the amount of actual lift gained by
this lift kit could vary.
This suspension system was developed using a 31 x 10.50 x 15 tire with factory wheels. After market wheel will fit with 3
5/8” back spacing. Larger tire and wheel combinations may increase leverage on suspension, steering and related components. Consider the additional stress you could be adding on the OE components, when selecting combinations larger
than OE.
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 whoever is operating the vehicle of its unique handling characteristics.
PRODUCT USE INFORMATION
TORQUE SPECS:
Size Grade 5 Grade 8
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
Class 8.8 Class 10.9
12MM 55ft/lbs 75ft/lbs
13mm wrench
13mm socket
15mm wrench
15mm socket
16mm wrench
18mm socket
18mm wrench
21mm wrench
21mm socket
19mm wrench
19mm socket
Floor Jack
TOOLS NEEDED:
13/16” Socket
9/16” Socket
7/16” Drill Bit
T55 Torx Head
T50 Torx head
Jack stands
Safety Glasses
Drill
WD40
Coil Spring Compressor
KIT CONTENTS
Front Shocks
Front Coil Springs
Rear Lower
Control Arm
Kit Contents:
9270-Front Coil Springs
1636 Kit Box Including:
2-Lower Front Control Arms
2-Lower Rear Control Arms
2-Front Sway Bar Links
2-Front Sway Bar Link Brackets
1-Rear Track Bar Bracket
4-Crossmember Spacers
1-Poly Bag
1687Hydro Box containing:
Fr Shock-#651896BP
Rr Shock-#650328
For V8 Applications
3/4” Front Coil Spacer
Fr Sway Bar Links
Rear Track Rod
Bracket
Front Lower
Control Arm
Crossmember
Spacers
Rear Shocks
FRONT INSTALLATION
1. Place the vehicle on a level surface. Set the parking brake. Center the front wheels and chock the rear wheel s
2. From inside the engine compartment, using a 13mm deep well socket, remove the upper stu d nut, washer and bushings from the front shocks. See PHOTO 1.
3. Jack up the vehicle and place jack stands on the frame rail behind the lower control arm mount.
4. Remove the front tires/wheels, using a 13/16 deep well socket.
5. Place a floor jack underneath the axle for support and remove the lower shock bolts from the front shoc ks using a
13mm socket and wrench. Retain the factory lower bolts for reuse. See PHOTO 2.
PHOTO 1 PHOTO 2
REMOVE SHOCK FROM THE UPPER MOUNT REMOVE SHOCK FROM AXLE
6. Using a 15mm wrench and 18mm wrench for the upper bolt and a T55 torx head for the lower bolt, remove the sway
bar links. See PHOTO 3.
7. Remove the lower track bar bolt on the axle side using a 15mm socket. Retain the factory hardware for re use.
Measure over 3/4” mark and drill using a 7/16” drill bit. See PHOTO 4.
PHOTO 3 PHOTO 4
REMOVE THE SWAY BAR FROM THE AXLE
MEASURE OVER 3/4” AND DRILL
8. Using a 13mm wrench remove the driver and passenger side coil retainer. See PHOTO 5. Lower the axle and remove the coil spring. The front coil will be reused in the rear. A coil spring or strut compressor may be needed to
remove the stock coil. Pull the ABS sensor wire from the stock mount. Spray the line with WD40 to allow the mount
on the wire to slide, then re-attach.
9. Mark the original position of the eccentric cams on lower control arm. Using a 21mm socket & 18mm wrench remove
the stock lower bolt from the axle. Using a 21mm socket and wrench, remove the frame bolt from the lower control
arm. Retain the factory hardware for reuse. See PHOTO 6.
PHOTO 5 PHOTO 6
REMOVE COIL CLIP REMOVE THE LOWER CONTROL ARM
10. Using a 21mm wrench & socket install the control arms in the frame mount using stock h ardware. See PHOTO 7.
11. Using a 21mm socket and 18mm wrench install the new lower control arm in the axle mount. Do not fully tighten at
this time. See PHOTO 8.
PHOTO 7 PHOTO 8
INSTALL THE LOWER CONTROL ON FRAME
INSTALL THE ARM ON THE AXLE
12. Install the new coil spring. A coil spring or strut compressor may be needed to install the new coil spring. Install the
new spring into the upper and lower coil spring seat. Make sure the coil spring is seated properly on the coil seat, by
rotating the spring until the pigtail end fits into the spring pocket. See PHOTO 9. Install the coil spring clip using a
13mm wrench. Torque to 16ft/lbs. Important note: If equipped with 8 cylinder motor a 3/4’ spacer kit for the
front will be installed at this time on the top of the coil spring to level the vehicle and is included with the
kits for 8 cylinder vehicles.
13. Install the new sway bar hoop on the sway bar where the stock link was secured, using the supplied 3/8” x 1 1/4” bolt
and flange lock nut. See PHOTO 10. Tighten using a 9/16” socket & wrench.
INSTALL THE COIL SPRING
PHOTO 9
INSTALL THE UPPER SWAY BAR BRACKET
PHOTO 10
14. Install the bushings and 12mm sleeves on the top and bottom of the sway bar link. Install the upper link in the hoop
bracket with the 12mm bolts and nuts with the head of the bolt toward the frame and threads facing outward.
Install the lower link using the stock axle hardware. Tighten using a 18mm and 19mm wrench. See PHOTO 11.
15. Assemble the front shock absorbers, part # 651896 hydro / 651997 Nitro and install using the factory hardware on
the bottom of the shock. Torque to 20 ft/lbs .Install the upper stud bushings and tighten the upper mounting point
until bushing swells slightly Repeat for opposite side.
16. Install the tires/wheels and lug nuts, using a 13/16” deep wheel socket. Lower the vehicle to the ground.
17. Tighten the lower control arms, using a 21mm socket and 21mm /18mm wrench. Torque to 130 ft/lbs.
18. Install the track bar in the axle mount location as shown in PHOTO 12 and tighten with stock hardware. Turning the
steering wheel either left and right will align the hole.
PHOTO 11
INSTALL THE LINK ON THE AXLE
REINSTALL THE TRACK ROD
PHOTO 12
REAR INSTALLATION
1. Chock the front wheels. Jack up the rear of the vehicle and support the vehicle with jack stand s, so that the rear
wheels are off the ground.
2. Remove the rear tires/wheels, using a 13/16” deep well socket. Place a floor jack under the differential.
3. Remove the rear track bar from the frame mount on the passenger side using a 18mm wrench and T55 torx head.
4. Using a 18mm socket and a 15mm wrench, remove the rear shocks. It may be necessary to temporarily remove
the fender wheel inner shroud. If so remove and retain the hardware for reinstallation. Retain the shock hardware for reuse.
5. Using a 13mm wrench remove the coil spring retainer. Retain factory hardware.
6. Lower the axle and remove the stock coil spring. A coil spring or strut compressor may be needed to remove the
stock coil.
7. Using a 21mm socket and wrench remove the lower control arm. Retain the factory hardware.
8. Using a 21mm socket and wrench install the new lower control arm using facto ry hard wa re. See Photo 1. Do not
tighten at this time.
9. It may be necessary to loosen the upper control arm to ease coil spring installation. If so using a 15mm socket ,
wrench and a T50 torx head, loosen the upper control arm hardware.
PHOTO 1
INSTALL THE REAR LOWER CONTROL ARM
INSTALL THE TRACK ROD BRACKET
PHOTO 2
10. Install the stock front coil spring in the rear mount. A coil
spring or strut compressor will be needed to install the
PHOTO 3
coil spring. Make sure the coil spring is seated properly
into the coil seat, by rotating the spring until the pigtail
end fits the spring pocket. Install the coil spring clip using
a 13mm wrench, Torque to 16ft/bs.
11. Assemble the new shocks. Part 650328 hydro / 650380
Nitro with bushings /sleeves. Install the shock into the
factory location using the stock hardware. Tighten using a
15mm and 18mm socket. Tighten the upper to 25 ft/lbs
and the lower to 55 ft/lbs.
12. Install the new track bar bracket into the stock frame
mount on the passengers side. Using the supplied 7/16” x
1” bolt, washers and nut. Tighten using a 16mm socket
INSTALL TRACK ROD IN BRACKET
and wrench.
13. Insert the supplied crush sleeve into the new bracket and insert the 12mm x 65mm bolt, washer through the bracket
and sleeve where the track bar was bolted stock. See PHOTO 2. Tighten using a 19mm wrench and socket.
14. Install the tires/wheels and lug nuts. Using a 13/16” deep well socke t. Lower the vehicle to the ground.
15. Tighten the lower control arms to 130ft/lbs using a 21mm socket and wrench.
16. Install the stock track rod into the new frame bracket using the stock track bar bolts. Tighten using a T55 and 18mm
wrench torque to 50ft/lbs. See PHOTO 3. The vehicle may have to be raised up to align the track rod hole.
T-CASE LOWERING INSTRUCTIONS
1. Position a floor jack under the transfer case cross-member and lightly support it.
2. Remove the transfer case bolts using a 15mm wrench. See PHOTO 1.
3. Slightly lower the jack and install the supplied spacers as shown In PHOTO 2 with the supplied 10mm x 55mm bolts
and washers.
4. Tighten hardware using a 17mm wrench and remove the floor jack.
PHOTO 1
REMOVE THE CROSS-MEMBER HARDWARE
4WD SHIFTER ADJUSTMENT INSTRUCTIONS
1. From the front of the vehicle locate the 4wd shifter linkage.
2. The shifter adjuster linkage will need to be adjusted to
allow the shifter to be placed in all range of gears on the
transfer case.
3. As shown loosen the adjuster bolt using a 13mm wrench.
See Photo 1.
4. Leaving the adjuster bolt loose, slide the shifter rod
through the adjuster bolt, lengthening the shifter linkage.
5. Tighten adjuster bolt and place the 4wd shifter in all
ranges. If all ranges cannot be engaged, Loosen the adjuster bolt and fine tune as needed.
PHOTO 2
INSTALL THE SPACERS AND TIGHTEN BOLTS
PHOTO 1
LOOSEN ADJ BOLT AND ADJUST LINKAGE
POST INSTALLATION
1. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile,
fixed and heated members. Check steering for interference and proper working order. Test brake system.
2. Perform steering sweep. The distance between the tire sidewall and the brake hose must be chec ked closely. Cycle
the steering from full turn to full turn to check for clearance. Ensure there is adequate clearance between exhaust
and brake line, fuel lines, fuel tank, and wiring harnesses. Failure to perform inspections may result in component
failure.
3. Check clearance between the inner side wall of tires and links. It may be necessary to adjust steering stop s
4. Re torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during routine vehicle
service.
5. Readjust headlights to proper settings.
6. Vehicle will have to have an alignment.
7. Some vehicles may experience drive line vibrations. Angles may require tuning, shafts may need to be lengthened
or trued, and u-joints may need to be replaced.
It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 500 miles and then every
1000 miles. Wheel alignment steering system, suspension and driveline systems must be inspected by a qualified professional mechanic at least every 3000 miles.
MAINTENANCE INFORMATION
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Thank You for Purchasing a Rough Country Suspension System
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