Rough Country 770S User Manual
92177000
TOYOTA FJ CRUISER 6” SUSPENSION KIT
Thank you for choosing Rough Country for your suspension needs.
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. If questions exist please call 1-800-222-7023. Also
please review the tools needed list and make sure you have needed tools.
PRODUCT USE INFORMATION
As a general rule, the taller a vehicle is the easier it will roll. 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.
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 no 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, and/or combining body lift with suspension 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.
The 6” suspension system was developed for Maximum tire size of 35x12.50x17 on an after market wheel with 4.5/8” of
back spacing and 8” wide wheel. Clearancing the body mount is required. Failure to clearance mount could result in
tire and body damage. See body mount section.
A helpful tip is to leave all fasteners loose until the installation of all components is completed. This will allow the brackets to line up without using force. At that time tighten all fasteners to specs.
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 too the vehicle owner for review and to be kept in the vehicle for its service life.
Kit Contents
9294 Rear Coil Springs
1770Box1 Front and Rear Cross Member,
Bump-stop brackets,1770Bag1,
1770Bag2
1770Box2 Driver and Passenger Side Knuckle
1770Box3 Front and Rear Skid Plates
1770Bag2, hardware in 1770 Bag6
1770Box4 Pass Diff Bracket, Driver Diff Bracket
Strut Spacers, Sway Bar Brackets,
Sway Bar Links, Rear Upper Arms
Rear Shocks, 770Bag3, 1770Bag4, 1
770Bag5, 1770Bag6, 3/8” Bag
1770Box5 Rear Track Bar 1170Bag7
Tools Needed
10mm Wrench
12mm Wrench
12mm Socket
14mm Wrench
14mm Socket
17mm Wrench
17mm Socket
19mm Wrench
19mm Socket
22mm Socket
22mm Wrench
35mm Socket
5mm Allen Wrench
12mm Allen Wrench
Jack Stands
Floor Jack
Flat Screwdriver
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
Size Class 8.8 Class 10.9 Class 12.9
M6 5 ft/lbs 9 ft/lbs 12 ft/lbs
M8 18 ft/lbs 23 ft/lbs 27 ft/lbs
M10 32 ft/lbs 45 ft/lbs 50 ft/lbs
M12 55 ft/lbs 75 ft/lbs 90 ft/lbs
M14 85 ft/lbs 120 ft/lbs 145 ft/lbs
M16 130 ft/lbs 165 ft/lbs 210 ft/lbs
M18 170 ft/lbs 240 ft/lbs 290 ft/lbs
Parts List
1770BOX1
Qty Part # Description
1 94003301 Front Cross member
1 94003302 Rear Cross member
1 1770Bag1 Front cross member kit bag
1 1770Bag2 Rear cross member kit bag
1770BOX2
Qty Part # Description
1 94003310 Driver side knuckle
1 94003303 Passengers side knuckle
1770BOX3
Qty Part # Description
1 94003304 Front skid plate
1 94003313 Rear skid plate
1770BOX4
Qty Part # Description
1 94003305 Passenger side diff bracket
1 94003306 Driver side diff bracket
2 94003307 Strut spacer
2 94003314 Sway bar bracket
2 94003012 Rear sway bar links
2 94003322 Rear upper control arms
1770BAG1
Qty Part # Description
2 90506002 .750-10 Lock nut
4 81051 .750 flat washer
2 90505810 .750-10 x4.5” Bolt
1770BAG2
Qty Part # Description
4 90500343 14mm Flat washer
2 90500339 14mm-2 x 130mm Bolt
2 90500392 14mm-2 Lock nut
1770BAG3
Qty Part # Description
2 90605907 .5625x .750 x2.41 Sleeve
4 90602105 Bushing
1 90500341 14mm-1.50 x 25mm Bolt
1 90500342 12mm-1.25 x 35mm Bolt
1 90500390 .562 Flat washer
1 970-0686 .50 Flat washer
2 90500378 .562-12 x3.5” Bolt
4 90500390 .562 Flat washer
2 90509301 .562-12 Lock Nut
1 81007 Bushing
2 660554 Rear shocks
2 94003312 Bump stop extensions
2 142973 Shock bushings (top)
2 140169 Shock bushings (bottom)
1 1770Bag3 Diff mounting bag
1 1770Bag4 Sway bar bracket bag
1 1770Bag5 Brake line bag
1 1770Bag6 Strut/Skid plate bag
1 3/8” Stud Bag Fr Strut Spacer Fasteners
1770BOX5
Qty Part # Description
1 94003309 Rear track bar
1 1770Bag7 Track bar bag
9294
Qty Part # Description
2 91929400 Rear coil spring
1770BAG4
Qty Part # Description
4 81055 .312 Flat washer
4 81072 .375-16 Nut
4 81057 .375 Lock washer
4 90500316 .375-16 x 1” Bolt
1770BAG5
Qty Part # Description
2 94004415 Brake line brackets
2 960-0559 .3125 Flat washer
2 90500324 .312-18 Lock nut
2 90500326 .312-18 x.75 Bolt
1 94003319 Rear brake line bracket
1 90500316 .375-16x1” Bolt
2 90500304 .375 Flat washer
1 90500314 .375-16 Lock nut
Parts List (cont)
1770BAG6
Qty Part # Description
6 81078 .375-16 Lock nut
2 90606703 .125 x 2” Cotter pin
4 90606701 .093 x 1” Cotter pin
6 90500302 .375-16 x 1.25” bolt
8 94003315 Upper control arm spacer
2 94003318 Bump stop stud
1770BAG7
Qty Part # Description
4 90601002 Track bar bushing
2 94003316 Track bar sleeve
1770BAG9
Qty Part # Description
6 90500270 3/8” x 1” Fr Bump-stop bolt
1770BAG11
Qty Part # Description
2 90500367 8MM Lock Nut
4 81083 Stud Bushings
4 403298 Cup Washers
2 403646 Sleeves
2 90504840 12mm x 65mm Bolts
2 90504750 12mm Flange Lock Nut
2 81046 Flat Washer
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 the vehicle in park on a smooth and level surface. Place the floor jack under the front cross member of the
vehicle and raise the vehicle. Place jack stands under the frame rails behind the front wheel wells and lower the
frame onto the stands. Remove the jack, set emergency brake and chock rear wheels.
3. Remove the front wheels.
4. Remove the front skid plate and skid plate support bracket using a 12mm socket. Retain stock hardware for reuseSee PHOTO 1.
5. Using a 12mm socket, unbolt the brake line bracket from the knuckle. Retain factory hardware for reuse. See
PHOTO 2.
PHOTO 1
6. Using a 12mm socket, unbolt the brake line bracket from the frame. Retain factory hardware for reuse. See PHOTO
3.
7. Remove the ABS bracket from the knuckle using a 12mm socket. Retain factory hardware for reuse. See PHOTO 4.
PHOTO 3
PHOTO 2
PHOTO 4
8. Using a 10mm socket remove the ABS bracket from the upper control arm.
9. Remove the ABS sensor from the knuckle using a 5mm allen wrench. Retain factory hardware for reuse. See
PHOTO 5.
10. Using a 19mm wrench, remove the outer tie rod end nut and separate from the knuckle. Retain stock nut for reuse.
See PHOTO 6.
PHOTO 5 PHOTO 6
11. Usi ng a 17mm socket, remove the sway bar links from the knuckle. See PHOTO 7
12. Using a 17mm socket, remove the brake caliper, and rotor. DO NOT let the caliper hang from the brake line. If allowed to hang, damage may occur to the brake lines. Use a zip tie or wire to hang the caliper to the frame, out of
harms way.
13. Usi ng a flat screwdriver remove the dust cap from the knuckle.
14. Remove the cotter pin and pal nut from the axle. Using a 35mm socket, remove the axle retaining nut. Retain stock
hardware for re-use. See PHOTO 8.
PHOTO 7
PHOTO 8
15. Usi ng 2 hammers as shown in PHOTO 9, remove the CV shaft from the knuckle. Do not directly strike the end of
the axle-shaft. Using zip ties or wire, be sure to support the CV axle before removing the lower control arm. Do not
allow the axle to hyper-extend or damage to the CV axle may occur.
16. Using a 17mm wrench, remove the 4 bolts that hold the hub flange and dust cover to the knuckle. Remove the hub,
and cover. Retain stock hardware. Note: You will not be able to remove the bolts from the hub assembly after the
hub is removed from the knuckle. See PHOTO 10.
PHOTO 9
PHOTO 10
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