Rough Country 736.20 User Manual

92173600

1990-1995 TOYOTA 4-RUNNER KIT 5”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 product layout on the last page
on these instructions. 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.

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

This suspension system was developed using a Maximum tire size of a 33X12.50 on 8” wheel with 3.75” back spacing.

Note if wider tires are used, offset wheels will be required and/or trimming may be required.

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.

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 life.

Tools Needed:
22mm Wrench
21mm Wrecnch
12mm Wrench
19mm Wrench
17mm Wrench
24mm Wrench
15mm Wrench
13mm Wrench
14mm Wrench
19mm Wrench
1/2” Wrench
7/16” Wrench
3/4” Wrench
9/16” Wrench
Hammer
Floor jack
Jack stands
Pry bar
WD-40 or similar penetrating oil
Flat Head Screwdriver

PRODUCT USE INFORMATION

Torque Specs:

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
9/16” 95 ft/lbs 130 ft/lbs
5/8” 135 ft/lbs 175 ft/lbs
3/4” 185 ft/lbs 280 ft/lbs

Class 8.8 Class 10.9
6MM 5 ft/lbs 9 ft/lbs
8MM 18ft/lbs 23 ft/lbs
10MM 32ft/lbs 45ft/lbs
12MM 55ft/lbs 75ft/lbs
14MM 85ft/lbs 120ft/lbs
16MM 130ft/lbs 165ft/lbs
18MM 170ft/lbs 240ft/lbs

FRONT INSTALLATION INSTRUCTIONS

1. Chock the rear tires and lift the front of the truck with a floor jack. Place jack stands under the frame rails . Lower the
vehicle on the jack stands. Never work under an unsupported vehicle.

2. Remove the tires and wheels.

3. Remove the stock shock absorbers using a 21 & 22 wrench.

4. Remove the brake caliper bolts from the knuckle using a 17mm wrench and secure out of way. Do not let the brake
caliper hang by the brake line. Doing so could cause damage to the brake line.

5. Remove sway bar from the frame rail using a 12mm wrench and from the factory lower control arm using a 14mm
wrench. See Photo 1 & 2.Remove the front skid plate. (if equipped).

PHOTO 1

PHOTO 2

6. Remove the cotter pin on the tie rod and remove nut using a 19mm wrench. Strike the end of the knuckle to dislodge
the tie rod. Retain the hardware for reuse

7. Remove the cotter pins from the upper and lower ball joint castle nuts and loosen the lower ball joint nuts u sing a
22mm wrench, but do not remove. Using a hammer, strike the knuckle as shown in Photo 3 & 4 to dislodge the ball
joint on the upper and lower ball joints.

PHOTO 3 PHOTO 4

8. Using a 17mm wrench remove the 6 nuts that secure the front half shaft to the differential. See Photo 5.

9. Remove the tie rod mount from the knuckle by removing the two bolts as shown in Photo 6.Using a 19mm wrench.

10. Remove the axle/knuckle assembly from the vehicle.

PHOTO 5 PHOTO 6

11. Loosen and remove lower control arms using a 22mm & 24mm wrench as shown in Photo 7 & 8. Retain the hard-
ware for reuse. Remove the lower control arms from the vehicle.

PHOTO 7 PHOTO 8

12. On the front cross-member, remove the 4 bolts securing the cross-member to the frame using a 17mm wrench as
shown in Photo 9. Retain hardware for reuse.

13. Remove the differential bolt as shown in Photo 10 using a 15mm wrench. Retain hardware for reuse. Remove the
factory cross-member and retain for reuse.

PHOTO 9 PHOTO 10

14. Remove driveshaft from the differential as shown in Photo 11 using a 13mm wrench. Retain hardware for reuse.

Secure driveshaft out of harms way.

PHOTO 11

PHOTO 12

15. Remove the two factory bump-stops from the frame using a 14mm wrench as shown in Photo 12 & 13.

16. Support the differential with a floor jack and remove the hardware on the drivers side as shown in Photo 14 using a
17mm wrench.

17. Retain the bump-stops / hardware for reuse.

PHOTO 13

PHOTO 14

18. With the differential still supported, remove the passenger side hardware securing the differential to the frame as
shown in Photo 15 & 16 using a 17mm wrench. Retain hardware for reuse. Remove the differential from the vehicle.

PHOTO 15 PHOTO 16

19. Install the new Rough Country drop brackets on the differential as shown in Photo17 using the stock h ardware and
a 17mm wrench. Do not fully tighten at this time.

20. Reinstall the differential in the vehicle and install the supplied 2- 7/16” x 1 1/4” bolts on the driver side. Install the 1­7/16” x 1 1/2” & 1-7/16 x 1 1/4” bolt in the passenger side. See Photo 18. The longer 1 1/2” bolt will install on the
Passenger side upper bracket forward hole.

PHOTO 17

PHOTO 18

Longer 1 1/2” installs here

21. Install the 1– 7/16” x 1 1/4” bolt as shown in Photo 19 on the
passenger side bracket. Do not tighten at this time.

22. Install the new rear cross-member brackets as shown in PHOTO
20 in the stock mounts with the supplied 5/8” x 4” hardware /
square washers using a 24mm wrench.

23. Install the center tube in the drop down brackets using the sup­plied 14mm x 85mm bolts/washers & nuts. Tighten using a
19mm socket /wrench at this time. See Photo 21.

PHOTO 20

PHOTO 19

PHOTO 21