How it Works
Rough Country
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790
User Manual
14 pgs974.73 Kb0

Rough Country 790 User Manual

92179000
JEEP JK LONGARM UPGRADE
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.
PRODUCT USE INFORMATION
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 suspension system was developed using a 35X12.50X17 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. 2012 and newer JK will have to have exhaust modifications. An aftermarket 180 degree exhaust pipe is required.
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.
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.
Torque Specs:
Size Grade 5 Grade 8 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 12MM 55ft/lbs 75ft/lbs 14MM 85ft/lbs 120ft/lbs 16MM 130ft/lbs 165ft/lbs 18MM 170ft/lbs 240ft/lbs
• 10mm thru 22mm Sockets and Wrenches
• 5/8” thru 7/8” Sockets and Wrenches
• Adjustable Wrench
• Gloves
• Safety glasses
• Hand grinder
• Plasma cutter
• Resipiciating saw
• Tape measure
• 1 1/4” hole saw
• 3/8”, 17/64”, 13/32” drill bit
• Drill Motor
Tools Needed:
N
Q
O
C
E
A
D
L
B
J
E
O
P
M
K
G
•
Crossmember (A)
•
Crossmember brace driver (B)
•
Crossmember brace passenger (C)
•
Front bumpstop ext. (D)
•
Rear bumpstop ext. (E)
•
Driver front lower control arm (F)
•
Passenger front lower control arm (G)
•
Driver upper control arm (H)
•
Passenger upper control arm (I)
•
Front swaybar disconnects (J)
•
Front brake lines (K)
•
Rear brake lines (L)
J
K
I
•
Driver rear lower control arm (M)
•
Passenger rear lower control arm (N)
•
Rear upper control arms (O)
•
Driver rear control arm bracket (P)
•
Passenger rear control arm bracket (Q)
•
4-Door skid plate bracket (R)
•
Skid plate (S)
H
F
1. Place vehicle in park and chock the rear wheels. Using a 21mm socket, remove bolt securing the front track bar to the frame. Retain stock hardware. See Photo 1. 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. Support the axle with a floor jack.
2. Remove the front tires/wheels, using a 19mm deep well socket.
3. 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. See Photo 2.
PHOTO 1
4. Remove the front factory skid plate with a 19mm socket.
5. Remove the lower shock bolt using a 18mm socket and wrench. Using a 14mm wrench unbolt the top of the shock and remove. See Photo 3. Retain stock hardware.
6. 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.
7. Lower the axle with the floor jack to allow room for the coils to be removed. Remove stock coil springs. Retain upper coil isolators.
PHOTO 3
PHOTO 2
PHOTO 4
8. Remove the bolts securing the upper control arms to the axle and frame using a 18mm wrench/socket. It may be necessary to cut out the passenger side upper bolt as shown in Photo 4 to remove the control arm. A new bolt is supplied in the hardware bag to replace this factory bolt. Retain factory axle end hardware.
9. Using a 21mm wrench, remove the bolts that secure the lower controls to the axle and frame then remove the con­trol arm. Retain factory axle end hardware.
12. Next the upper and lower factory control arm pocket have to be removed to make clearance for the longer arms. This will be done using a plasma cutter or cut off wheel in a die grinder. Always uses gloves and safety glasses.
13. First cut half of the lower control arm pocket on the passenger side as shown in Photo 5. Follow around the bottom edge where the bracket tapers down to the frame. Be careful not to cut through the frame. In Photo 6 you can see where the first cut is made.
14. Next cut the other half of the control arm pocket as shown in Photo 6. Follow around the bottom edge where the bracket tapers down to the frame, then cut the bottom side of the bracket flush with the bottom of the frame.
PHOTO 5
15. Finally cut the upper control arm pocket as shown in Photo 7. Follow around the bottom edge where the bracket tapers down to the frame.
16. Using a hand grinder clean up any sharp burrs or jagged edges left from cutting off the control arm pockets. Paint the frame with a durable spray paint to prevent rusting. See Photo 8
PHOTO 7
PHOTO 6
PHOTO 8
17. Repeat steps 13-16 on the driver side control arm pockets.
18. Steps 19 & 20 are only used if you have a 2012 or newer JK that has a 180 degree exhaust loop on the driver side.
19. Measure back 2 inches as shown in Photo 9 and mark the exhaust, next cut the exhaust pipe with a saw as shown in Photo 10. Using a 13mm wrench remove the exhaust flange bolts so the cut section of exhaust can be removed.
20. An aftermarket 180 degree exhaust pipe will have to be installed for added clearance.
PHOTO 9 PHOTO 10
21. Support the transmission with a jack stand and remove the three factory bolts from the bottom of the crossmember that holds the transmissions with a 15mm socket. Next remove the two factory bolts that connect the skid plate to the crossmember using 15mm socket. Retain factory bolts.
22. Remove four factory bolts holding the crossmember with a 18mm socket and wrench, then remove the crossmeber. Retain factory hardware.
23. Next install the supplied new crossmember as shown in Photo 11 with the control arm pockets facing forward. Insert the four factory bolts from the back side of the crossmember with the thread side forward. Do not tighten at this time.
24. Using a transfer punch or a old bolt knock the factory thread insert out of the frame where the factory skid plate bolted to the bottom side of the passenger side frame rail. See Photo 12
PHOTO 11
25. Slide the passenger side crossmember support bracket over the factory crossmember bolts as shown in Photo 13. Hand tighten with the factory nuts.
26. Next insert the crossmember brace threaded tab through the frame hole in Photo 14. Align the holes in the tab and bracket, using the supplied 7/16” x 1.5” long bolts, washers, and lock washers out of 1787bag1. See Photo 15 Tighten with a 5/8” socket.
PHOTO 13
PHOTO 12
PHOTO 14
27. Finally tighten the crossmember bolts with a 18mm socket and wrench.
28. Repeat steps 24-27 on the driver side.
29. Remove the jack stand holding the transmission and let the transmission studs drop into the crossmember. Using a 15mm socket insert and tighten the three nuts holding the transmission to the crossmember.
30. Insert two of the crossmember flag nuts into the slotted holes in the crossmember and align the flag nuts with the two factory holes in the skid plate. Tighten factory bolts with a 15mm socket.
PHOTO 15
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