Rough Country 683X User Manual
921683X00
JEEP JK 6” 4 DR X-SERIES SUSPENSION KIT
Thank you for choosing Rough Country for 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. 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.
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.
This kit features Rough Country’s adjustable joint design. Adjustable end tool is included in kit.
This 6” suspension system was developed using a 37X12.50X17 tire with 4.5” to 4.75” of back spacing on aftermarket
wheels. Stock wheels can be used with this kit with up to a 35x12.5 tire, but different tire manufactures designs may result in a tire width that could result in contact with the lower control arm and/or front sway bar link in a sharp turn. Please
consult with your tire and wheel expert before purchasing. Also note that if wider tires are desired, offset wheels will be
required.
IMPORTANT NOTE : Upon completing the install of this kit the draglink must be adjusted to center the steering
wheel BEFORE the vehicle is driven. Failure to do so will cause a computer error, odd handling, and poor performance.
Drive-shafts are available from Rough Country. The stock drive-shafts DO NOT have enough range of motion,
thus the shaft joints bottom out and damage will occur. The stock shafts can NOT be used and new yoke style
shafts are necessary. Additionally on 2012 Models, additional exhaust modification on the passenger side
crossover pipe will be required for adequate clearance on the front driveshaft.
If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products by calling 1-800-222-7023.
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.
INSTALLING DEALER - it is your responsibility to install the warning decal and forward these installation instructions on
to the vehicle owner for review. These instructions should be kept in the vehicle for its service
10mm Wrench 21mm Socket Jack
21mm Wrench Jack Stand Grinder
18mm Wrench 7/16” Wrench 13/32” Drill Bit
18mm Socket 9/16” Wrench Drill
19mm Wrench 9/16” Socket Pitman arm puller
19mm Deep Well Socket Reciprocating Saw
33mm Socket 13/16” Socket
7/8” Wrench
Assemble the joints per the separate instruction sheet Part # 92RCJ120 provided
NOTICE TO DEALER AND VEHICLE OWNER
PRODUCT USE INFORMATION
Tools Needed:
Kit Includes:
9248 Fr Coil Springs
9249 Rr Coil Springs
1683XBox1:
2-Fr Upper Adj Arms
2-Fr Lwr Adj Arms
1-Rr Pass Upper Arm
1-Rr Dr Upper Arm
2-Rr Lower Adj Arm
4-Lower Arm Flex Joints
2-Rear Upper Flex Joints
2-Fr Upper Flex Joints
2-Rr Coil Shims
1683XBox2:
1-Fr Track Rod Bracket
1-Fr Stab Brkt
1-Rear Track Rod Bracket
2-Fr Brake Lines
2-Rr Brake Lines
1-Pitman Arm
2-Fr Sway Bar Links
1-Dr Fr Disconnect Bracket
1-Pass Fr Disconnect Bracket
2-Rear Sway Bar Links
1-1683Bag2
1-1681Bag3
1-1146Bag1
1168
1- Fr Adjustable Track Bar
1-Poly Bag
PERF2.26JK– RCX 2.2 Shock Absorbers
Poly Bags:
1683Bag2:
For Fr Track Rod Bracket:
3-3/8” x 1 1/4” Bolt
3-3/8” Flat Washer
5-3/8” Flange Lock Nuts
1-3/8” X 2 1/2” X 3 1/4” U-bolt
1-14mm x 80mm Bolt
1-14mm Lock Nut
2-14mm Flat Washer
1-Crush Sleeve
For Upper Pass Control Arm:
1-10mm x 80mm Bolt
1-10mm Lock Nut
For Fr Brake Lines:
2-Frame Brackets
2-Brake Clips
4-Crush Washers
For Rear Brake Lines:
2-Frame Brackets
2-Brake Clips
4-Crush Washers
For Rear Track Rod Bracket:
3-3/8” x 1” Bolt
3-3/8” Flat Washers
3-3/8” Flange Lock Nuts
1-14mm x 80mm Bolt
1-14mm x 75mm Bolt
2-14mm Lock Nuts
1-Crush Sleeve
1681Bag3:
For Rear Sway Bar Links:
4-Sleeves
4-1/2” x 2 3/4” Bolts
4-1/2” Lock Nuts
8-1/2” Flat Washers
1146Bag1:
For Fr Sway Bar Disconnects:
4-5/16” x 1” Self Tap Bolt
2-Link Ends
2-Mounting Pins
2-1/2” Nut
2-1/2” Flat Washers
2-12mm Jam Nuts
2-12mm Flange Lock Nut
2-Hitch Pin
1168Bag:
For Front Track Bar:
2-Spacers
1-Sleeve
2-Bushings
1-Heim End
1-Jam Nut
KIT CONTENT
Fr Brake Lines
Rear Coil Springs
Front Coil Springs
Rr Lwr Control Arms
Rr Track Bar Brckt
Rr Sway Bar Links
Pitman
Arm
Rr Upr Control Arms
Rear Performance 2.2 Shocks
Rr Brake Lines
Rr Coil Shims (2)
Front Performance 2.2 Shocks
Fr Upr Control Arms
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
Fr Sway Bar
Disconnects
Fr Trk Rod Brkt
Rr Lwr Control Arms
Fr Adj Track Rod
TORQUE SPECIFICATIONS
9/16” 95 ft/lbs 130 ft/lbs
5/8” 135 ft/lbs 175 ft/lbs
3/4” 185 ft/lbs 280 ft/lbs
Metric (Grade) 8.8 10.9 12.9
14MM 85ft/lbs 120ft/lb. 145ft/lbs
FRONT INSTALLATION INSTRUCTIONS
1. Prior to installing this kit, with the vehicle on the ground, measure the heights of your vehicle. This measurement can
be recorded from the center of the wheel straight up to the top of the inner fender lip. Record the measurements.
LF:__________ ,RF:___________,
LR:__________, RR:___________
2. Place vehicle in park and chock the rear wheels. Raise the front of the vehicle with a jack and secure a jack stand
beneath each frame rail behind the front control arms. Ease the frame down onto the stands.
3. Remove the front tires/wheels
, using a 19mm deep well socket.
4. Using a 21mm socket, remove bolt securing the front track bar to the frame. Retain stock hardware. See Photo 1.
5. Using a 18mm socket and wrench remove the bottom sway bar bolts. Using a 21mm socket and 21mm wrench, remove the top of the sway bar link. Retain hardware for later use. See Photo 2.
PHOTO 1
Remove the track rod from axle
6. Remove the lower shock bolt using a 18mm socket and
wrench. Using a 14mm wrench unbolt the top of the shock
Remove the front sway bar links
PHOTO 2
PHOTO 3
and remove. See Photo 3. Retain the lower stock hardware.
7. Using a 21mm socket and wrench loosen the upper and
lower control arm bolts at the axle and frame, but do not
remove.
8. On some models it will be necessary to remove the brake
line bracket from the frame to allow the coils to be removed. Using a 10MM socket, remove the brake line
bracket from the stock location.
9. Push down on the axle to allow room for the coils to be
removed. Remove stock coil springs. Retain coil isolators.
10. Using a 21mm wrench, remove the bolts that secure the
Remove the front shock absorbers
lower link arms to the axle.
11. Remove the drive shaft from the differential using a 15mm wrench. See Photo 4.
12. Remove the driveshaft from the transfer case by removing the 8-8mm bolts as shown in Photo 5. Remove the shaft
from the Jeep. Driveshaft install will be performed in a later step.
PHOTO 4 PHOTO 5
Remove the driveshaft hardware from axle
Remove the hardware from t-case
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