Rough Country 639P User Manual

92163900

WJ JEEP 4” Front and 3.5” Rear Lift Kit W/ Adj.

Lower Control arms & Fr Adj. Track Rod

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 kit content list. Be sure you
have all needed parts and know where they go. Also please review tools needed list and make sure you have the nec­essary tools to install this kit.

PRODUCT USE INFORMATION

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.
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.

Due to differences in manufacturing, dimension and inflated measurements, tire and wheel combinations should be test
fit prior to installation. This suspension system was developed using a 265 / 75R-16 tire with factory wheels. If bigger/
wider tire are used with the factory wheels or factory offset wheels you must carefully check the clearance during turning
between the tires and the lower control arm and the front sway bar link before driving. Installing wider than recom­mended tires can cause the tire to come in contact with the rear shock. Always double check for clearance on all tire /
wheel packages.

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

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

We hope installing your Rough Country lift kit is a positive experience. Please note that varia tions in construc­tion and assembly in the vehicle manufacturing process will virtually ensure that some parts may seem difficult
to install. If you are uncertain about some aspect of the installation process, please feel free to call our tech
support department at 800-222-7023. We do not recommend that you modify the Rough Country parts in any
way as this will void any warranty expressed or implied.

Prior to beginning this installation it is always good to use a penetrating oil and spray all fasteners that will be
removed. Typically the cross member, control arm bolts and the pitman arm are difficult to remove without hav­ing done this step.

Tools Needed:

• 13mm Socket / Wrench

• 14mm Socket / Wrench

• 15mm Socket / Wrench

• 18mm Socket / Wrench

• 19mm Socket / Wrench

• 21mm Socket / Wrench

• 22mm Socket / Wrench

• 33mm Socket

• 5/8” Wrench

IMPORTANT PRE—INSTALLATION INSTRUCTIONS

• Pitman Arm Puller

• Drill Motor

• 3/8” Drill Bit

• Pry Bar

• Floor Ja ck

• Jack Stands

• Spring Comp resso r

• Lithium Based Grease

Generally, braking performance and capability are decreased

Size Grade 5 Grade 8

Torque Specs:

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

Class 8.8 Class 10.9
8MM 18ft/lbs 23 ft/lbs
10MM 32ft/lbs 45ft/lbs
12MM 55ft/lbs 75ft/lbs
14MM 85ft/lbs 120ft/lbs

KIT CONTENTS

B

L

A

Kit Contents:

1698C Containing:

2-Front Coil Springs (A)
2-Rear Coil Springs (B)

1639 Kit Box Containing:

2-Front Adj Lower Control Arms (C)
4-Front Bump Stop Brackets (D)
2-Front Sway Bar Links (E)
4-Rear Sway Bar Brackets (F)
2-Rear Bump Stop Spacers (G)
1-Rear Upper Control Arm Bracket (H)
2-Rear Lower Shock Brackets (I)
1-1698Bag1-Hardware Bag
1-1698Bag2-Bushing Bag
1-1639Bag3 Inst Sheet Bag
Transfer Case hardware (J)
1084-Adjustable Fr Track Bar Kit:(K)
1-Track Bar Body
1-Heim End
2-Heim Spacers
1-12mm x 65mm Bolt
1-Flat Washer
1-Flange Lock Nut

Perf2.24WJ kit Containing:

2-Fr 2.2 Series Shocks (L)
2-Rr 2.2 Series Shocks (M)
1-1698Bag3-Rr Shock Hardware
2-Frt Upper Shock Hardware Bags

H

G

I

F

J

C

E

D

K

1639 Bag1:

For Front Bump Stops:
4-8mm x 95mm Bolt

4-8mm Washers

For Front Shock Absorbers:
4-5/16” x 1” Bolt

8-Flat Washers
4-Lock Nuts

For Front Sway Bar Disconnects:
2-1/2” Lock nuts

2-Hitch Pins
2-1/2” Flat washers
2-Disconnect Mounting Pins
2-12mm Flange Lock Nuts
2-12mm Jam Nuts
2-Rod Ends
2-Crush Sleeves
2-Frame Brackets

For Rear Upper Arm Bracket:
3-14mm x 75mm Bolts

3-Flat Washers
3-Crush Sleeves

For Rear Sway Bar Spacer:
4-10mm x 95mm Bolts
4-10mm Flat Washers
For Rear Bump stop Spacer

2-3/8” x 3 1/2” Self Tap Bolts
2—2” Body Blocks

For Rear Sway Bar Bracket:
4-10mm 90mm Bolts

4-Flat Washers

M

1639Bag1 Continued:

For Rear Shocks:

2-12mm x 100mm Bolts
2-Crush Sleeves
2-Flat Washers

1639 Bag2:

For Fr Lower Control Arms:

4-Control Arm Bushings
2-Sleeves
2-90 degree grease fittings

1698 Bag3:

For Rear Shocks:
4-Bushings
2-Lower Sleeves
2-Offset Sleeve/Washer

1639 Bag 4:

For Cross-Member Transfer Case Drop
4-10mmx 140mm Bolts

8-1 1/4” Spacers
4-10mm Flat Washers

FRONT INSTALLATION INSTRUCTIONS

1. Chock the rear wheels and jack up the front of the vehicle and support the vehicle with jack st ands.

2. Support the front axle with a floor jack.

3. Remove the lower sway bar link from the axle and the sway bar using a 15mm & 18mm wrench. See Photo 1.

4. Remove the shocks using a 15mm wrench/socket for the top mount and a 13mm wrench/socke t for the bottom
mount.

5. Lower the axle using the floor jack and remove the coil springs.

6. Remove the stock lower control arm using a 21mm wrench/socket. Retain factory hardware for re-use See Photo 2.

Photo 1

Remove Lower Sway Bar Link from Axle Mount Remove Lower Control Arm

Photo 2

7. Lubricate, using a lithium non-water soluble grease, the supplied control arm bushings and sleeves and install them
in the new lower control arms. Also install the supplied grease fittings at this time.

8. Adjust the lower control arm to a length of 16” from hole to hole and install the lower control arm on the vehicle with
the heim joint on the frame with the supplied U bracket.

Secure using the factory hardware. See Photo 3. Do

not fully tighten at this time.

9. Using a pry bar, remove the bump stop and remove the bump stop mounts using a 13mm wrench. See Photo 4 & 5.

Photo 3

Photo 4

Install New Lower Control Arm w/ U bracket

Remove Front Factory Bump Stop

10. Remove the track bar using a 19mm wrench/socket from the driver side mount as shown in Photo 6 and remove
from the axle using a 15mm socket. Retain the axle hardware for reuse.

Photo 5

Remove Factory Bump Stop Mount

Remove Track Rod from Driver Side

Photo 6