Rough Country 663U User Manual
921663U00
97-06 JEEP TJ/LJ LONG ARM UPGRADE KIT
Thank you for choosing Rough Country for your suspension needs.
This kit is an upgrade kit only. This kit includes frame mounting points and adjustable long arms for the front
and rear.
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 kit contents. 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. If you have any questions please call us at 800-222-7023.
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 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.
• With the installation of this kit and larger tires it is highly recommended that an aftermarket stabilizer be added.
• A drive-shaft/SYE combination is highly recommended for the 4’ kit and a necessity on the 6” kit to correct rear
driveshaft angles and prevent vibration.
• Additionally, the exhaust system must be modified by an exhaust specialist to clear all components.
• On Rubicon models the air compressor for the air lockers on the frame by the rear of the skid plate will have to be
relocated. Refer to installation instructions for detail.
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 to the vehicle owner for review and to be kept in the vehicle for its service life.
TOOLS NEEDED:
• Spring Compressor
• Silicone spray
• Drill assortment
• Hammer
• Combination
wrenches
• Floor jacks
• Wheel chocks
• 1/2” drill motor
• 11/32” Drill bit
• 17/32” Drill bit
• Torque wrench
• 1/2 drive ratchet and sockets
• Allen wrenches
• Large “C” clamps and /or bench vise
• Heavy duty jack stands
• Safety glasses
• Anti-seize compound
TORQUE SPECS:
Size Grade 5 Grade 8
5/16” 15 ft/lbs 20 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
• T55 torx bit
1663Box1:
1-Dr Side Control Arm Mount (A)
1-Pass Side Control Arm Mount (B)
1-Rear Track Bar Bracket (C)
2-Front Upper Adj Arms (D)
2-Large Arm Ends
2-Small Arm Ends
1663Box2:
2-Front Lower Adj Arms (E)
2-Rear Lower Adj Arms (F)
2-Rear Upper Adj Arms (G)
2-Large Arm Ends
2-Small Arm Ends
D
KIT CONTENTS
Fastener Breakdown:
1663Bag1:
For Control Arm Mounts:
4-1/2” x 4” Bolts
8-1/2” Washers
4-1/2” Lock nuts
For Transfer Case Skid Plate
6-9/16 x 4 1/2” Bolts (97-02)
OR 6-12mm x 65mm Bolts (03-06)
6-Flat Washers
For Front Lower Control Arms
2-9/16” x 4” Bolts
4-9/16” Flat Washers
2-9/16” Lock Nuts
For Front Upper Control Arms
2-10mm x 80mm Bolts
4-10mm Flat Washer
2-10mm Lock Nuts
For Rear Lower Control Arm:
2-9/16” x 7” Bolts
4-9/16” Flat Washers
2-9/16” Lock Nuts
For Rear Track Bar Bracket
2-5/16” x 1” Bolt
4-5/16” Flat Washers
4-5/16” Lock Nuts
1-12mm x 65mm Bolt
1-12mm Flange Lock
1-Crush Sleeve
For use with Rubicon Models:
For Compressor Bracket
4-5/16” x 1” Bolts
4-5/16” Lock Nuts
8-5/16” Flat Washers
1663Bag2
12-Control Arm Bushings
6- Control Arm Sleeves
8-Grease Fittings
D
E
E
F
A
G
F
B
C
G
FRONT INSTALLATION
1. Place the vehicle on a level surface. The vehicle will need to be placed on jack stands front and rear to install the
long arm kit.
2. Remove the front tires and wheels.
3. From inside the engine compartment, remove the upper stud nut, retainer and grommet from both of the front
shocks using a 15mm socket.
4. Remove both of the front sway bar end links using a 15mm wrench for the upper and a 18mm wrench for the
lower. Retain lower link hardware for re-use.
5. Place a floor jack underneath the axle for support and complete the removal of the front shock absorbers fro m the
lower mount using a 13mm Socket. Retain the stock lower hardware for reuse.
6. Do not reuse the original factory shocks.
7. If your axle is equipped, mark the position of the lower control arm cam bolt and axle brackets for installation reference. See Photo 1. If equipped with ABS brakes, remove the sensor wires and clamps for the inside of the lower
arms and save clamps for re-use. See Photo 2.
Mark location of Eccentric Bolt
PHOTO 1
Remove ABS wire from arm if equipped
PHOTO 2
8. Remove the track rod from the axle and from the frame using a 15mm (axle) & 18mm wrench (frame). Retain the
axle hardware for reuse.
9. Remove the coil spring clip located on the bottom coil seat on the driver side of the vehicle using a 13mm socket.
Retain the clip and hardware for reuse.
10.Remove the brake caliper from the axle using a 13mm socket and secure out of harms way.
11.Lower the axle and remove the coil spring. A coil spring or strut compressor may be needed to remove the stock
coil spring.
12.Support the front axle and remove the stock lower control arm by removing the nut, cam, and cam bolt (if
equipped) from the axle bracket and then removing the nut and bolt from the frame bracket doing one side at a
time using a 21mm socket & wrench. Retain the stock hardware.
13.Remove the upper arm from the mount using a 15mm wrench. Do not retain stock hardware.
14.Cut the stock lower control arm mounts from the frame as shown in Photo 3 by cutting the weld that secures the
bracket to the frame using a cutting wheel or similar cutting tool. Take care not to cut in to the frame rail.
15.After the bracket is removed, grind the surface smooth as shown in Photo 4 and paint the area to prevent rusting
PHOTO 3
PHOTO 4
Remove lower control arm mount. Cut along line
Grind frame smooth and paint exposed surface
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