Rough Country 907S User Manual
92190600
Thank you for choosing Rough Country for your suspension needs.
97-06 JEEP TJ 4” SUSPENSION KIT
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 parts list. Be
sure you have all the needed parts and understand where they go. 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.
Post suspension system vehicles may experience drive line vibrations. Angles may require tuning, slider on shaft may
require replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced
The 4” suspension system was developed for 33x12.50x15 tire on an after market wheel with 3.75” of back spacing,
on an 8” wide wheel. Due to the inconsistency of vehicles when manufactured and the various options available, the
amount of actual lift gained by this lift kit will vary. On models outfitted with extra bolt-on equipment and accessories,
Rough Country offers new coil spring isolator pads made from polyurethane to boost ride height 3/4". These are
available for the front or rear.
With the installation of this kit and larger tires it is highly recommended that an aftermarket stabilizer be added.
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 to the vehicle owner for review and to be kept in the vehicle for its service life.
TOOLS NEEDED:
• Spring Compressor
• Silicone spray
• Drill assortment
• Hammer
• Combination wrenches
• Torx key socket
• File
• Floor jacks
• Wheel chocks
• 1/2” drill motor
• Torque wrench
• 1/2 drive ratchet and sockets
• Allen wrenches
• Large “C” clamps and /or bench
vise
• Heavy duty jack stands
• Safety glasses
• Anti-seize compound
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
KIT CONTENTS
Rear Track
Bar Brkt
Rear Coil Spring (2)
Rear
Shock
Rear Sway
Bar Link (2)
(2)
Transfer Case Spacer (2)
03-06 Auto Skid Spacers
Front
Shift Control Brkt
Shock
(2)
Front Sway
Bar Link (2)
Frt & Rear Lower Arm (4)
Front Coil Spring (2
Kit Contents
1906– Box Containing
Rear Track Bar Bracket
Front Offset Sway Bar Link (2)
Frt Sway Bar Bracket (2)
Rear Sway Bar Link (2)
Lower Control Arm w/Bushings (4)
658693– Front Shock (2)
658696– Rear Shock (2)
1668Bag1– Rear Track Bar Brkt
1668Bag3—Shock Bag
1668Bag4—Shift Control Brkt
1668Bag5—Instr Sheet
1668Bag6—Sway Bar Bag
1668CT– 97-02 Box
Front Coil Spring (2)
Rear Coil Spring (2)
Pas. Side Transfer Case Spacer
Dr Side Transfer Case Spacer
Transfer Case Bag
1669CT– 03-06 Box
Front Coil Spring (2)
Rear Pass. Coil Spring
Rear Dr Coil Spring
Pas. Side Transfer Case Spacer
Dr Side Transfer Case Spacer
Transfer Case Bag
or
)
Kit Bag Contents
1668Bag1: Rear Track Bar Brkt
5/16” x 1” Bolt (2)
5/16” Nut (2)
5/16” Lock Washer (2)
5/16” Washer (3)
12mm x 65mm Bolt (1)
12mm Flange Nut (1)
Sleeve
1906Bag2:
Stem Bushing (4)
Cup Washer (4)
3/8” Nut (2)
1668Bag4: Shift Control Brkt
1/4” x 3/4” Bolt (2)
1/4” Nut (2)
Shift Control Brkt (1)
1906Bag1:
Instruction Sheet
Warning to Driver Decal
1668Bag6: Sway Bar Bag
For Front Sway Bar Conv Brkt
3/8” x 1 1/4” Bolt (2)
3/8” Washers (2)
3/8” Flanged Nut (2)
For Front Sway Bar
12mm ID Sleeves (4) -
12mm x 65mm Bolt (2)
12mm Flanged Nut (2)
12mm Flat Washers (2)
For Rear Sway Bar
10mm ID Sleeves (4) -
10mm x 65mm Bolt (4)
10mm Lock Nuts (2)
10mm Flat Washers (6)
IN 1668CT or 1669CT
Plastic End Cap (4)
97-02 Transfer Case Bag
Transfer Case Bolts (6)
or
03-06 Transfer Case Bag
Transfer Case Bolts (8)
Frt Cross Member Spacer (2)
Cross Member Spacer (2)
FRONT INSTALLATION
1. The front-end components are installed first.
2. Place the vehicle on a level surface. Set the parking brake. Center front wheels and chock rear wheels. From
inside the engine compartment, remove the upper stud nut, retainer and bushings from both of the front shocks
using a 15mm socket.
3. Place jack stands on the frame rail behind the lower control arm mount on the frame and jack up the vehicle. Installation is done one side at a time.
4. Remove the front tires and wheels.
5. Remove both of the front sway bar end links from the axle using a 18mm wrench and the sway bar using a 15mm
socket. The upper link can be dislodged by striking the link as shown. See Photo 1 & 2.
PHOTO 1
PHOTO 2
REMOVE THE LINK FROM AXLE REMOVE LINK FROM THE SWAY BAR
6. Place a floor jack underneath the axle for support and
complete the removal of the front shock absorbers us-
PHOTO 3
ing a 13mm socket. See Photo 3. Retain the stock
lower hardware for reuse.
7. Mark the position of the lower control arm cam bolt and
axle brackets for installation reference. See Photo 4.
8. If equipped with ABS brakes, remove the sensor wires
and clamps for the inside of the lower arms and save
clamps for re-use.
9. Remove the track rod bolt from the axle on the passenger side only using a 18mm wrench. It may be
necessary to pry bar loose.
10. Remove the coil spring clip located on the bottom coil
seat on the driver side of the vehicle using a 13mm
MARK STOCK CAM LOCATION
socket. Lower the axle and remove the coil spring. A
coil spring or strut compressor may be needed to remove the stock coil spring.
11. Remove the stock lower control arm by removing the nut, cam, and cam bolt (if equipped) from the axle bracket
and then removing the nut and bolt from the frame bracket using a 21mm socket / wrench, one side at a time.
12. Install the new Rough Country control arm on the frame and axle using factory hardware. See Photo 5. – DO
NOT tighten control arm bolts until vehicle is on the ground.
PHOTO 4
REMOVE LOWER SHOCK HARDWARE INSTALL NEW LOWER CONTROL ARM
PHOTO 5
13. If applicable, drill a 23/64” hole into each lower link and reinstall the ABS sensor wires. Use the original clamps.
14. A coil spring or strut compressor will be needed for the new coil spring installation. Install the new spring into the
upper and lower spring pockets and carefully remove the compressor. Make sure the coil is seated properly in
the coil seat by rotating the spring so the pig tail end fits in the spring pocket. See Photo 6.
15. Install the coil spring clamp and torque the spring clip bolt to 16ft.-lbs using a 13mm wrench.
16. Repeat steps on other side.
17. On the front track bar mount. From center of stock track bar hole measure directly over 3/4” and mark using a
punch as shown in Photo 7. Drill the new track bar hole using a 7/16” drill bit making sure to keep drill level. Do
not reinstall the track rod at this time. This will be preformed in a later step with the vehicle on the ground. Note:
This step will not be performed if the optional Adjustable Track Rod was purchased. If installing the optional track
PHOTO 6
INSTALL NEW COIL SPRINGS
MARK AND DRILL USING A 7/16” BIT
rod, please wait until the vehicle is on the ground to center the front end.
18. Install new front shock absorber part #658693 in the factory lower mount
using stock hardware with the body side down. See Photo 8.
19. Install the new upper stud bushings and tighten the upper mounting
point only until bushing bulges slightly. Tighten the bar pin on the bottom
of the shock with the stock hardware.
20. Repeat this on the opposite side of the vehicle.
21. Install the tires, wheels and lug nuts. Lower the vehicle to the ground
and tighten the lug nuts to the factory specifications (80-110 ft. lbs) using
crossing pattern..
22. Install the sway bar hoop (u-shaped bracket) on the bottom side of front
sway bar where the stock link was secured using the supplied 3/8” x
1.25” bolt, washer, and flanged lock nut. Run bolt from inside to outside
23. Lightly grease and install the 12mm sleeves (larger ID sleeves in bag)
provided on the bottom and top of the bent sway bar link. Use the factory hardware to install lower end of link. Place large face washer between bushing and nut. See Photo 9.
24. Install the upper part of the new link in the hoop bracket with the 12mm
bolts & flanged nut. See Photo 9 and 10. Note: The bolt must be in-
stalled with the nut to outside of vehicle to provide adequate clearance to the frame.
PHOTO 7
PHOTO 8
.
Note:
Direction of bolt
on uppers sway
bar mount. Nut
goes to the outside.
PHOTO 9
Note: The offset
of the sway bar
link goes toward
the frame.
PHOTO 10
TIGHTEN LINK ON AXLE MOUNT
Loading...