Rough Country 735.20 User Manual

92756702

64-80 TOYOTA LANDCRUISER INSTALLATION

Rough Country recommends a certified technician install this system. In addition to these instructions, professional knowledge
of disassemble/reassemble 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.

With the installation of all lift kits and larger tires it is important to check the condition of your steering stabilizer. If the
stabilizer is worn or is leaking it should be replaced. Steering stabilizers are designed to restrain “bump steering” and front-end
vibration, giving added life to tires, ball joints, and other steering components. A multiple stabilizer kit is recommended for
vehicles equipped with a snowplow, winch, or larger tires

As a general rule, the taller a vehicle is, the easier it will roll. Offset, as much as possible, what is lost in rollover resistance by
increasing tire track width. In other word s, go "wide" as you go "tall". Many sportsmen remove their mud tires after hunting
season and install ones more appropriate for street driving; always use as wide a tire and wheel combination as possible to
enhance vehicle stability.
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
Generally, braking performance and capability are decreased when significantly 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 t h e Rough
Country product purchased. Mixing com po nent b ran ds is not recommended.
Rough Country makes no claims regarding lifting devices and excludes any and all implied claims. We will not be respon sible
for any product that is altered.

If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products.

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

1. Park the vehicle on a level surface. Check the vehicle height from side to side and front to back. This is done by

measuring from the ground up to the fender using the hub as a centering point.

2. Apply a thin coat of grease to the polyurethane bushings and insert into each eye of the new front springs. Now

apply a thin coat of grease on outside of bushings. This will help you to insert the bushing into the spring mount.

3. Raise the front of the vehicle and support securely with jack stands under the frame behind the front springs, and

block the rear wheels. Remove the tires, shocks, u-bolts, and loosen the sway bar bolts. (Caution: the front axle
will now be free to move, so support securely on floor jack.)

4. With a floor jack supporting the axle, unbolt each end of leaf springs and remove from both sides. (If new shackle

bushings were purchased, grease and install them in the frame at this time.) Install new front springs, part # 8041.
When installing the front springs that the fat part of the shim on the bottom of the spring pack should be pointing
toward the rear of the vehicle. Notice the tie bolt in the front leaf springs is not in the center of the leaf spring, but
there is a long end and short end. Install the springs with the short end towards the rear, and long end towards the
front bumper. Do not tighten spring eyebolts at this time.

PRODUCT USE INFORMATION

NOTICE TO DEALER AND VEHICLE OWNER

INSTALLATION INSTRUCTIONS

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INSTRUCTION SHEET

5. Using the floor jack, lower the front axle down to the leaf springs. Be sure the tie bolts align and fit into the tie

bolt holes in the front axle housing. Install and tighten new u-bo lts. Torque u-bolts to 75-90 ft.lbs.

6. Install new shocks and tires then lower the vehicle to the ground. Tighten spring eyebolts at this time.

drag link that goes along side of the frame from the gear box to the bell crank may require slight bending for
clearance of the new shock. Bending this drag link will not affect it, but do not kink the bar.

7. Raise the rear of the vehicle. Support securely with jack stands and block the front wheels. Remove the tires,

shocks, and u-bolts. (CAUTION: the rear axle will be free to move, so support securely on a floor jack.

8. Apply a thin coat of grease to the polyurethane bushings and insert into each eye of the new rear springs. Now

apply a thin coat of grease on outside of bushings. This will help you to insert the bushing into the spring mount.

9. With a floor jack supporting the rear axle, unbolt each end of the rear leaf spring and remove from both sides. (If

new shackle bushings were purchased, grease and install them in the frame at this time.) Install new springs, part
# 8042. When installing the rear springs the fat part of the shim on the bottom of the spring pack should be
pointing toward the front of the vehicle. Notice the tie bolt in the rear leaf springs is not in the center of the leaf
springs, but there is a long end and a short end. Install the springs with the short end towards the front and longer
end towards the rear bumper. Do not tighten spring eyebolts at this time.

10. Using a floor jack, lower the rear axle down to the leaf springs. Be sure tie bolts align and fit into the tie bolt

holes in the axle housing. Install and tighten new u-bolts, shocks and tires then lower vehicle to the ground.
Torque u-bolts to 75-90 ft.lbs. Tighten spring eyebolts at this time

Installation is now complete. Check brake line length to make sure there is plenty of line left for free play. The steering wheel
can be adjusted by adjusting the drag link. Adjust each end of the drag link out making the link longer being sure that the drag
link ends do not come past the clamps.

POST INSTALLATION INSTRUCTIONS

1. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and

heated members. Check steering gear for interference and proper working order. Test brake system.

2. Perform steering sweep. Check to ensure brake hoses have sufficient slack and will not contact rotating, mobile, or fixed

members, adjust lines/brackets to eliminate interference and maintain proper working order. Failure to perform
inspections may result in component failure.

3. Bump stops and extensions must be in place on all vehicles! Note: allowing suspension to over extend by neglecting to

install or maintain stops and extensions may cause serious damage to OE and related components.

4. Re torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during routine vehicle service.

MAINTENANCE INFORMATION
It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 100 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.

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NOTE: The

Technical Assistance - [phone] Page 2