92177400
07–UP TUNDRA 4 1/2” LIFT KIT
Thank you for choosing Rough Country for all your suspension needs.
This kit will fit both 4WD and 2WD models, all brackets will be used for 4WD models. On 2WD models the differential brackets will not be used. In this instruction sheet, the 4WD model is shown.
PRODUCT USE INFORMATION
As a general rule, the taller a vehicle is, the easier it will roll. Too offset, as much as possible, what is lost in rollover resistance by increasing tire track width. In other words, 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.
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 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.
We will be happy to answer any questions concerning the design, function, and correct use of our products by calling 1800-222-7023.
This 4 1/2” kit was developed to accommodate a Maximum tire size of 35x 12.5x 18” tire on a 18x 8.5 with a
maximum backspacing of 6 3/16”on a wheel. 18” or larger stock wheels can be used but no wider than a 11.5”
tire can be used. Larger tires or different wheel offsets will need to be verified to work with this kit prior to usage.
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
Tools Needed:
Floor Jack / Jack Stands
5mm Allen wrench
10mm socket / wrench
12mm socket / wrench
13mm socket / wrench
14mm socket / wrench
17mm socket / wrench
19mm socket / wrench
21mm socket / wrench
22mm socket / wrench
24mm socket / wrench
39mm socket / wrench
9/16 socket / wrench
5/8 socket / wrench
1 1/16 socket / wrench
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
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
1 3/16 socket / wrench
Pipe wrench
Needle nose pliers
Tin shears / cutters
Shop hammer
Reciprocating-Saw
TORQUE SPECS:
KIT CONTENTS
Rear Blocks & U/bolts
Sway Bar
Drop Brkts (2)
Pass Fr Diff Brkt
Strut Spacers (2)
Pass Knuckle
Kit Contents:
1775Box1:
Front Cross-member
Rear Cross-member
Sway Bar Drop Bracket (2)
Dr Side Steering Stop
Pass Side Steering Stop
1775Box2:
Driver Side Knuckle
Pass Side Knuckle
1774Box3:
Strut Spacer (2)
Rear RCX 2.2 Shock-660564
Rear 3” block (2)
Rear U-bolts (4)
1775Box4:
Driver Front Diff Bracket
Driver Rear Diff Bracket
Pass Diff Bracket
Skid Plate
Fr Crssmber Square Washer (4)
Rr Crssmber Square Washer(4)
Rear E-Brake Bracket (2)
Rear ABS Bracket
Front Brake Bracket (2)
Front Bump-stop Bracket (4)
Rear Cross-member
Fr Cross-member
Bump-stop Brkts (4)
Skid Plate
Steering Stops
Kit Bag:
For Rear Cross-member
18mm X 150mm Bolt (2)
18mm Lock Nut (2)
Square Washers (4)
For Front Cross-member
7/8” x 5” Bolt (2)
7/8” Lock Nut (2)
Square Washer (4)
For Front Driver Diff Bracket (4WD Model)
Bushing (2)
Sleeve
9/16” x 4” Bolt
9/16” Lock Nut
14mm x 60mm Bolt (3)
For Driver Rear Diff Bracket (4WD Model)
Bushing (2)
Sleeve
9/16” x 4” Bolt
9/16” Nut on Skid Plate
14mm x 25mm Bolt
For Pass Side Diff Bracket (4WD Model)
Bushing (4)
Sleeve (2)
9/16” x 4” Bolt (2)
9/16” Washer (1)
9/16” Nut on Skid Plate
9/16” Lock nut (1)
For Front Bump-Stops
10mm x 35mm Bolt (4)
10mm Washer (4)
10mm Lock Nut (4)
For Front Sway Bar Bracket
7/16” x 1 1/4” (4)
7/16” Washer (8)
7/16” Lock Nut (4)
Rear Shocks (2)
Brake Line Brkts
Dr Rr Diff Brkt
Dr Fr Diff Brkt
Dr Knuckle
For Strut Spacers
3/8” Studs (8)
3/8” Nut (8)
3/8” Lock Washer (8)
3/8” Washer (8)
For Front Brake Line Brackets
5/16” x 3/4” Bolt (2)
5/16” Washer (4)
5/16” Lock Nut (2)
For Front Skid Plate
3/8” x 1” Bolt (2)
3/8” x Washer (2)
3/8” Lock Nut (2)
For Rear Shock Mount
Shock Bracket (2)
10mm x 55mm Bolt (2)
Mounting Bushing (2)
Cup Washer (2)
10mm Lock Nut (2)
10mm Flat Washer (2)
12mm x 65mm Bolt (2)
12mm Flange Lock Nut (2)
For Rear E-Brake Bracket
5/16” x 3/4” Bolt (2)
5/16” Washer (4)
5/16” Lock Nut (2)
For Rear Brake Line Bracket
5/16” x 3/4” Bolt
5/16” Washer (2)
5/16” Lock Nut
For Rear ABS Wire Bracket
5/16” x 3/4” Bolt
5/16” Washer (2)
5/16” Lock Nut
INSTALLATION INSTRUCTIONS
1. Park the vehicle on a level surface and chock the rear wheels.
2. Jack up the front of the vehicle and place jack stands under the frame rails. Lower the vehicle onto the jack stands
letting the front suspension hang at full droop. Remove tires and wheels with a 21mm socket.
3. Take ABS wire loose from upper control arm using a 10mm wrench & ABS/ brake line on the knuckle using a 12mm
wrench. Retain the stock hardware. Photo 1 & 2.
Photo 1
4. Remove the sensor as shown in Photo 3 using a 5mm allen wrench.
5. Remove the ABS bracket from the knuckle and remove the wire from the bracket. Cut the bracket as shown to install
on the new knuckle. Retain the stock hardware for reuse. See Photo 4.
Photo 3
Photo 2
Photo 4
6. Using a 1 1/16 and a 1 3/16 wrench loosen the tie-rod end from inner tie-rod as shown in Photo 5. Remove cotter
key from tie-rod end. Using a 24mm wrench remove nut as shown in Photo 6. Use a hammer to break loose tie-rod
from knuckle.
7. Remove brake caliper using a 17mm wrench. Tie caliper out of way, but do not let the caliper hang by the brake line.
Next remove the rotor and check for wear on brake pads and rotor. Any worn parts should be replaced before reinstalled.
Photo 5
Photo 6
8. Remove the dust shield and remove cotter key from axle and remove axle nut (4WD Model) using a 39mm socket
as shown in Photo 7.
9. Remove cotter key from upper ball joint. Using a 19mm wrench remove nut. Using a hammer as shown in Photo 8,
loosen ball joint from knuckle. Support the lower arm with jack stand.
Photo 7 Photo 8
10. With a dead blow hammer loosen the axle from hub bearing. (4WD Model) Using a 22mm wrench remove the 2
lower ball joint bolts as shown in Photo 9. Remove knuckle from vehicle. Do not let axle hang down and tie up out
of the way. (4WD Model)
Photo 9
11. Remove sway-bar bolt from lower control arm using a 19mm wrench as shown in Photo 10.
12. Remove lower strut bolt using 22mm wrench for both ends of bolt as shown in Photo 11. Use a 14mm wrench for
nuts on top of strut. Remove strut from vehicle.
13. With a 24mm wrench loosen lower control arm bolts and remove control arm from vehicle.
14. Repeat steps 3-12 on opposite side of vehicle.
15. With a pipe wrench remove all 4 bump-stops. See Photo 12
16. Remove sway-bar using a 17mm wrench.
Photo 11
Photo 10
Photo 12
17. Swap left and right outer tie-rod ends as shown in Photo 13. This is done for wheel clearance.
18. Trim rear lower control arm pocket front side only 1 inch from hole as shown in Photo 14.
Photo 13
Photo 14
1”
Passenger Side Shown
19. Support differential with jack stand and remove the 3 differential mounts using a 19mm wrench. There should be 10
bolts to remove. Remember too remove the nuts on top of frame from front diff mounts. (4WD Model)
20. Lower differential down being careful with vent hose and wiring. Let the diff rotate down slightly. (4WD Model) See
Photo 15.
21. Install rear cross-member using supplied 18mm x 150mm bolts square washers (4) and nuts as shown in Photo 16.
Do not tighten at this time. Please note, there is a front and rear cross-member square washer.
Photo 15 Photo 16
22. Install supplied bushings & sleeve into rear diff mount and using 22mm and 21mm wrench install on vehicle with
9/16 x 4” bolt Install the 14mm x 25mm bolt in the differential as shown in Photo 17.(4WD Model) Do not install
nuts on the 9/16” bolts, the nuts for this bolt are located on the skid plate.
23. Install front cross-member using 7/8 x 5” bolts and square washers (4) in Photo 18. Please note, there is a front and
rear cross-member square washer. Do not tighten at this time.
24. Install supplied bushings & sleeve into driver side diff mount and install on vehicle using 9/16 x 4” bolts & nut on the
cross-member and three 14mm x 60mm long bolts on the differential drop bracket as shown in Photo 18. Tighten
using a 19mm, 21mm and 22mm wrench. (4WD Model)
Photo 17
Photo 18
25. Install bushing into passenger side diff bracket. Using 2- 9/16 x 4” long bolts and 21 and 22mm wrench on vehicle.
Use stock bolts for bracket to diff with supplied 14mm nuts. (4WD Model) See Photo 19. Tighten using a 19mm
wrench. Do not install nuts on the 9/16” bolts on the rear cross member ,the nuts for this bolt are located on
the skid plate.
26. Install lower control arms with stock hardware as shown in Photo 20.Do not tighten.
Photo 19
9/16” Flat washer
installs here
27. At this time tighten all cross-member bolts using 1- 5/16” wrench on front cross-member and 1 -1/16” on rear.
Tighten all differential mounting bolts. Rear diff bracket bolt are not tighten because the nuts are welded to the skid
plate. (4WD Model) Do not tighten lower control arm bolts at this time.
28. Assemble supplied 1/4” coupler and hose and install new vent tube ext to differential as shown n Photo 21. (4WD
Model)
29. Install bump-stop to bump-stop ext. using 10mm x 1.25 nuts & washers and thread into factory location with 10mm
x1.25 bolts & washers. See Photo 22. Tighten hardware using a 17mm wrench.
Stock bolts install here
with supplied 14mm nuts
Photo 21
Photo 20
Photo 22
30. Install sway-bar drop brackets using factory hardware at top with a 17 mm wrench. Install sway bar to drop brackets
using supplied 7/16 X 1.25 bolts nuts and washers using a 5/8 wrench as shown in Photo 23. Attach sway bar links
to lower control arms with factory hardware using a 19mm wrench as shown in Photo 24.
Photo 23 Photo 24
31. Install the strut spacer on the strut with the factory hardware. Tighten using a 14mm wrench. See Photo 25.
32. Install the 3/8 studs into strut ext. using a 3/8 nut and a 9/16 socket torque the stud to 35-45 ft/lbs as shown in Photo
25, this will cause the stud to clinch.
33. Install strut onto vehicle using factory hardware for bottom and supplied 3/8” lock washers, flat washers & 3/8” nuts
for top. Tighten using a 22mm wrench & 14 mm wrench to tighten.
34. Remove hub bearing from stock knuckle using a 17mm wrench as shown in Photo 26. Remove seal and install seal
into knuckle.
Photo 25 Photo 26
35. Install bearing assemble into new knuckle Take care not to damage seals. See Photo 27. Tighten using a 17mm
wrench.
36. Install knuckle onto vehicle and install axle shaft in hub assembly. Tighten upper ball joint using 19mm.
37. Locate and install the steering stop bracket as shown in Photo 28 on lower ball joint with stock hardware using a
22mm socket.
Photo 27
38. Tighten the and axle nut with 39mm socket or equilavent. Make sure the cotter key is installed on the axle nut.(4WD
Model)
39. Install new brake line drop brackets on the frame as shown in Photo 29 using stock bolts. Secure the brake line to
the new bracket using the supplied 5/16 x 3/4” bolts, washers & nuts. Tighten using a 12mm and a 13mm wrench.
40. Install rotor and brake caliper using a 17mm wrench as shown in Photo 30.
Photo 29 Photo 30
Photo 28
41. Install the stock brake line bracket onto the knuckle as shown in Photo 31 using the stock hardware. Tighten using
12mm wrench.
42. Install the ABS sensor into the knuckle using a 5mm allen wrench and install the factory bracket back onto the upper
a-arm using a 10mm wrench and stock bolt . It may be necessary to slightly pull the ABS wire to create slack .
WD-40 can be used to lube the line to allow it to slide in the upper control arm mount. Reinstall the ABS
bracket on the knuckle as shown using the stock hardware. Tighten using a 12mm wrench. See Photo 32.
Photo 31 Photo 32
43. Install the tie-rod end into the knuckle using a 24mm wrench to tighten in Photo 33. Make sure the cotter key is
installed. Tighten the jam nut on the tie-rod end using a 1 1/16” and a 1 3/16” wrench.
44. Install skid plate as shown in Photo 34 using the previously installed 9/16” rear diff. bracket bolts and supplied 3/8” x
1” bolts and nuts and 2 washers. (4WD Model) Use a 9/16” wrench for the front bolts and a 21mm for the rear diff
bolts that secure the skid plate.
Photo 33
45. Install the wheels and tires. Jack up the front of the vehicle and remove the jack stands. Lower the vehicle to the
ground and tighten lower control arm bolts using a 21mm wrench.
Photo 34
REAR INSTALLATION INSTRUCTIONS
1. Chock the front tires. Jack up the rear of the vehicle and place jack stands under the frame rails, remember to raise
the rear high enough so the axle can be lowered to install the blocks. Lower the jack and let the vehicle rest on the
jack stand, keep the jack under the axle this will be used to move the axle up and down during installation.
2. Remove the bolts from the 4 factory brake line and ABS wire brackets. Also remove the emergency brake cable
bolts from brackets. Use 12mm wrench to remove bolts. See Photo 1.
3. Remove shocks using a 17mm for both top and bottom bolts. See Photo 2.
Photo 1
4. Using a 19mm socket remove the factory U-bolts and lower the axle with the jack. Be careful not to over extend the
brake lines or ABS wires. Install lift blocks and new U-bolts. See Photo 3. Tighten with a 22mm socket.
5. Insert the new rear shock relocation bracket in Photo 4 through the frame with a 10mm x 55 bolt and a male stem
shock bushing.
Photo 3 Photo 4
Photo 2
6. Using a 17mm wrench tighten the 10mm nut and cup washer to hold the shock relocation bracket in Photo 5.
7. Install the supplied Rough Country 2.2 series shock Part # 660564 to the shock relocation bracket with supplied
12mm x 65mm bolt and flange lock nut. See Photo 6. Tighten using a 18mm socket and 19mm wrench.
Photo 5
Photo 6
8. Install the shock on the lower shock mount with factory
hardware and tighten using a 17mm wrench. Note: The
RCX 2.2 Series Shock Absorber is designed to run the
piston down as shown. See Photo 7.
9. Install new brake line brackets in Photo 8 using stock and
supplied 5/16 x 3/4” bolts. Tighten using 12mm wrench
and 13mm wrench to tighten.
10. Install new emergency brake cable brackets on the driver
and passenger side as shown in Photo 9 using stock
hardware to secure the new bracket to the stock location.
Secure the new bracket to the stock brake bracket using
5/16 x 1” bolts . Tighten using a 12mm wrench and 13mm
wench to tighten.
11. Install tires and wheels.
12. Jack up the rear of the vehicle and remove the jack stand.
13. Lower the vehicle to the ground and check to make sure that all ABS and brake lines are clear from any moving
parts.
Photo 7
Photo 8
Driver Side Shown
POST INSTALLATION INSTRUCTIONS
1. Check and recheck all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and heated members. Check clearance between upper control arm and sidewall of tire for proper
clearance. Check steering for interference and proper working order. Test brake system.
2. Perform steering sweep. Cycle the steering from full turn to full turn to check for clearance. Failure to perform inspections may result in component failure.
3. Re torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during routine vehicle
service.
4. Adjust headlights to proper settings given increased vehicle height.
5. An alignment will need to be performed on this vehicle to set proper alignment.
Photo 9
Thank you for choosing Rough Country for all your suspension needs and don't forget
to visit us on the web @ www.roughcountry.com for your off road needs.
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