Rough Country 8595 User Manual

92859500

02-10 HD TORSION ADJUSTERS

W/SHOCK BRACKETS

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. 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".

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, 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.

Braking performance and capability are decreased when significantly larger/heavier tires a nd wheels are used. Take this
into consideration while driving.

The required installation time for this system is approximately 2 hours. This suspension system was developed using
285x75R16 tire on an 8” wheel. Before installing other combinations, please consult your local tire and wh eel specialist.

A front-end alignment should ALWAYS be checked after installing ANY vehicle suspension lift. This kit typically requires
a slight toe-in adjustment. Record the ride height measurement at the time of alignment. If, in the future the torsion bars
settle excessively, alignment can be restored by adjusting-up the bars to their original ride height.

If questions exist on the design, function, and correct use of our products please contact us at 800-222 -7 023.

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.

RECOMMENDED TOOLS

• Floor jack

• Heavy duty jack stands

• Safety glasses

• Wheel chocks

• Ball Joint Remover like

OTC7249

• Impact gun

• 18 mm socket

• 15 mm socket

• 21 mm socket

1. Place the vehicle in neutral. Raise the front of the vehicle with a jack to slightly raise the tires of the ground and
support the frame with jack stands beneath each frame rail behind the lower control arms. Installation is done one
side at a time, starting with the driver side. The torsion bar adjusters are under the cab of the vehicle at the rearward
end of the torsion bars.

2. Measure or make a note of how much thread is remaining on the torsion bar adjuster bolt. You will reset the bars at
this same location with the new adjusters. See Photo 1.

3. Use extreme caution when loading and unloading the torsion bars; there is a tremendous amount of energy stored in
them. Keep your hands and body clear of the adjuster arm assembly and the puller tool in case anything slips or
breaks. Note: Because of the extreme loads generated by the torsion bars on these vehicles. A torsion bar tool is
recommended for the safe installation of these torsion bar keys. Rough Country offers a torsion bar key. Call Rough
Country or your local dealer to purchase.

4. On the driver side, using a torsion bar removal tool, remove the stock torsion bar adjuster by loading the torsion b ar
using the tool and removing the bolt and nut block. Slide the torsion bar forward allowing the OE torsion key to fall
out. See Photo 2.

5. Install the new torsion bar adjuster using the torsion bar tool.

FRONT INSTALLATION INSTRUCTIONS

Photo 1

Reinstall the threaded block and adjuster bolt.

6. Repeat steps for passenger side. Making sure the driver and passenger side torsion bar adjuster bolts are adjusted
the same amount. Fine-tuning is done in a later step.

7. Remove the shock from the lower mount using a 21mm wrench and remove the bracket as shown in Photo 3 using a
15mm wrench. Retain the factory hardware.

8. Install the new bracket as shown in Photo 4 in the stock location and reinstall the factory shock absorber on the lower
control arm with factory hardware and using a 15mm wrench.

9. Jack up the front of the vehicle and remove the jack stands. Lower the vehicle to the ground to where the torsion bars
are supporting the weight of the vehicle.

Photo 3 Photo 4

Photo 2

POST INSTALLATION INSTRUCTIONS

After the torsion bar adjusters have been installed and tightened to the factory measurement taken in step #2. addition al
adjustment may need to be performed to level the vehicle. This is done by either tightening or loosening the torsion bar
adjuster bolts. Use a floor jack to support the side of the vehicle that is being adjusted, raising the tires slightly of the
ground and only adjusting the bolt 1-2 turns at a time to ensure the leveling of the truck. After adjustment lower the vehicle
to the ground and recheck for level. This may take several attempts.

headlights is required after installation. Note – the air dam on the front may need to be trimmed for additional clearance,
depending on the tire size.

As with any lift installed, adjustment of the front