Rough Country 909 User Manual
92PERF908
WJ JEEP LONG ARM KIT
W/ PERFORMANCE 2.2 SERIES SHOCK ABSORBERS
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. Also please review the tools needed list and make
sure you have needed tools. If you have any questions please call us at 800-222-7023.
PRODUCT USE INFORMATION
As a general rule, the taller a vehicle is the easier it will roll. We strongly recommend seat belts and shoulder
harnesses should be worn a t all times. Avoid situations where a side rollover may occur.
bilities 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 not 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, 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.
• With the installation of this kit and larger tires it is highly recommended
that an aftermarket stabilizer(s) be added.
• An upgraded drive-shaft is highly recommended for the 4’ kit if the vehicle has a front rizeppa joint (Shown Above)
on the transfer case or the front differential to prevent vibration and extend driveshaft longevity.
Due to differences in manufacturing, dimension and inflated measurements, tire and wheel combinations should be test
fit prior to installation. This suspension system w as developed us ing a 265 / 75R-16 tire with factory wheels. If bigger/wider tire are used with the factory wheels or factory offset wheels you must carefully check the clearance during
turning between the tires and the lower control arm and the front sway bar link before driving. Installing wider than recommended tires can cause the tire to come in contact with the rear shock. Always double check for clearance on all tire /
wheel packages.
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.
This kit features Rough Country’s adjustable joint design. Adjustable end tool is included in kit.
Assemble the joints per the separate instruction sheet Part # 92RCJ120 provided.
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. 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.
We hope installing your Rough Country lift kit is a positive experience. Please note that variations in construction and assembly in the vehicle manufacturing process will virtually ensure that some parts may seem difficult
to install. The use of pry bars and tapered punches for alignment is considered normal and usually does not
indicate a faulty product. However, if you are uncertain about some aspect of the installation process, please
feel free to call our tech support department at 800-222-7023. We do not recommend that you modify the Rough
Country parts in any way as this will void any warranty expressed or implied.
Braking performance and capa-
Rzeppa joint shown
KIT CONTENTS
This kit is packaged in 7 boxes. Please makes sure you have all the need parts and understand wh ere they go prior to
beginning installation. Please use the attached picture to match parts to their descriptions shown below.
1698C-4” KIT
Fr Coil Springs (A)
Rr Coil Spring (B)
1908BOX1:
1-Crossmember (C)
1908Box2:
2-Transmission Bracket (D)
1-Skid Plate (E)
4-Front Frame bracket flag nuts (F)
2-Fr Axle Brake Bracket (G)
2-Fr Bump Stop Brackets (H)
2-Front Sway Bar Links (I)
1-Rear L/A Axle Mount (J)
1-Dr Rear Frame Bracket (K)
1-Pass Rear Frame Bracket (L)
4-Rr Frame Bracket Flag Nuts (M)
2-Rear Sway Bar Brackets (N)
2-Rear Lower Shock Brackets (O)
1908Box3:
2-Rear Lower Long Arm (P)
2-Rear Lower Flex Joints
1-Flex Joint Tool
1908Box4:
1-Dr Front Lower Long Arm (Q)
1-Pass Front Lower Long Arm (R)
2-Front Lower Flex Joints
1-Dr Upper Adj Front Arm (S)
1-Pass Upper Adj Front Arm (T)
2-Fr Upper Flex Joints
1908Box5:
1-Rear Upper Y-Link (U)
1-Upper Y-Link Flex Joint
1084 Front Track Rod:
1-Track Rod Body (V)
1-Heim End
1084Poly Bag Containing:
Heim End Spacers (2)
Bushings (2)
Sleeve
12mm x 65mm Bolt
Flat Washer
12mm Lock nut
Jam Nut
1908Bag1:
Instruction Sheet Bag
1908Bag2:
For Front Cross-member:
4-10m x 80mm Bolts
4-10mm x 35mm Bolts
8-10mm Flat Washers
4-7/16” x 1 1/4” Bolts
4-7/16” Flat Washers
For Transmission Mount:
4-7/16” x 1 1/4” Bolts
For Skid Plate:
4-5/16” x 1 1/4” Bolts
4-5/16” Flat Washers
For the Front Lower Control Arm:
2-9/16” x 4 1/2” Bolts
2-9/16” Lock Nuts
4-9/16” Flat Washers
For Front Bump stop:
2-8mm x 95mm Bolts
2-8mm Flat Washers
For Front Axle Brake Line Brackets:
2-1/4” x 1” Bolt
2-1/4” Lock Nuts
4-1/4” Flat Washers
For Lower Shock Bolts:
4-5/16” x 1” Bolts
4-5/16” Lock Nuts
8-5/16” Flat Washers
1131Bag:
For Front Sway Bar Disconnects:
2-1/2” Lock nuts
2-Hitch Pins
2-1/2” Flat washers
2-Disconnect Mounting Pins
2-12mm Flange Lock Nuts
2-12mm Jam Nuts
2-Rod Ends
2-Crush Sleeves
2-Frame Brackets
1908Bag3:
For Rear Control Arm Mounts:
8-1/2” x 1 1/2” Bolts
8-1/2” Flat Washers
For Rear Arm Axle Mount:
3-14mm x 50mm Bolts
3-14mm Flat Washers
For Rear Lower Control Arm:
2-9/16” x 4 1/2” Bolts
2-9/16” Lock Nuts
4-9/16” Flat Washers
For Rear Upper Y-Link:
1-9/16” x 4 1/2” Bolt
1-9/16” Lock Nut
2-9/16” Flat Washers
For Rear Upper Brake Brackets:
4-1/4” x 3/4” Bolts
4-1/4” Lock Nuts
8-1/4” Flat Washers
For Rear Sway Bar Brackets:
4-10mm x 90mm Bolts
4-10mm Flat Washers
For Rear Bump stop:
2-3/8” x 3 1/4” Self Tap Bolts
1908Bag4: Containing
For Rear Lower Shock Mount:
2-12mm x 100mm Bolts
2-12mm Sleeves
2-12mm Flat Washers
Perf2.24WJ:
2-2.2 Series RCX Front Shock (W)
2-2.2 Series RCX Rear Shock (X)
KIT CONTENTS
A
B
O
N
K
J
H
G
I
P
M
S
Q
X
W
B
O
A
L
G
N
U
D
C
H
F
E
I
P
M
X
R
T
W
V
IMPORTANT PRE—INSTALLATION INSTRUCTIONS
Prior to beginning this installation it is always good to use a penetrating oil and spray all fasteners that will be removed.
TOOLS NEEDED:
Prior to beginning installation please re-read the instructions and make sure you have all the tools needed to complete installation. Listed below are the minimum tools required.
• Spring Compressor
• Silicone spray
• Drill assortment
• Hammer
• Combination wrenches
• Torx bit socket
• File / Grinder
• Floor jacks
• Wheel chocks
• 1/2” drill motor
• 15/32” Drill bit
• 17/32” Drill bit
• 1/2 drive ratchet and sockets
• Allen wrenches
• Large “C” clamps and /or bench vise ( For Joint Assembly)
• Heavy duty jack stands
• Safety glasses
• Anti-seize compound
TORQUE SPECS:
Listed below are generic torque specs that are to be used when no specific spec is listed in the instructions. Please
note it is extremely important to tighten all fasteners to the proper 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
FRONT INSTALLATION INSTRUCTIONS
1. Chock the rear wheels and jack up the front of the vehicle and support the vehicle with jack stands.
2. Support the front axle with a floor jack.
3. Remove the lower sway bar link from the axle and the sway bar using a 15mm & 18mm wrench. See Photo 1.
4. Remove the shocks using a 15mm wrench/socket for the top mount and a 13mm wrench/socket for the bottom
mount.
5. Lower the axle using the floor jack and remove the coil springs.
6. Remove the stock lower control arm using a 21mm wrench/socket. Retain factory hardware for re-use See Photo 2.
7. Remove the stock upper control arms using a torx bit and a 18MM wrench.
Photo 1
Remove Lower Sway Bar Link from Axle Mount Remove Lower Control Arm
Photo 2
8. Remove the track bar using a 19mm wrench/socket from the driver side mount as shown in Photo 3 and remove
from the axle using a 15mm socket. Retain the axle hardware for reuse.
9. Remove the brake line bracket from the driver and passenger side frame using a 10mm socket. Retain the hardware
for reuse. See Photo 4.
Photo 3
Photo 4
Remove Track Rod from Driver Side
Remove Brake Line Bracket
10. Remove the lower control arm mount from the driver and passenger side flush with frame using a cut off wheel or
reciprocating saw. See Photo 5.
11. Grind smooth and paint to prevent rusting. See Photo 6.
Photo 5 Photo 6
Remove the lower front control arm mounts Grind and paint the area
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