Rough Country PERF644 User Manual
92PERF1641
97-06 JEEP TJ 3 1/4”PROGRESSIVE COIL/SPACER KIT
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.
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.
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 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, 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.
This 3 1/4” suspension system was developed for 33 x 12.5 tire on an after market 15x 8” wide wheel with 3.75” of
back spacing. The use of stock wheels with larger than stock tires may cause the tire to come in contact with the
lower control arm at full turn. The use of aftermarket wheels is recommended to avoid this. Due to the inconsistency
of vehicles when manufactured and the various options available, the amount of actual lift gained by this lift kit may
vary slightly. Longer shocks are needed on this kit. For optimum performance RCX 2.2 Series shocks are
highly recommended for full suspension articulation and optimum ride quality.
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.
Please read all the in structions before beginning the installation. Check the kit hardware against the parts
PRODUCT USE INFORMATION
NOTICE TO DEALER AND VECHICLE OWNER
Tools Needed:
Spring Compressor
Silicone spray
T-55 Torx Head Bit
Floor jacks
Wheel chocks
Drill Motor
5/16” Drill Bit
7/16” Drill Bit
Torque wrench
T-55 Torx Head Bit
1/2” Socket / Wrench
9/16” Socket / Wrench
3/4” Socket / Wrench
13mm Socket /Wrench
15mm Socket / Wrench
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
Size Class 8.8 Class 10.9 Class 12.9
M8 18 ft/lbs 23 ft/lbs 27 ft/lbs
M10 32 ft/lbs 45 ft/lbs 50 ft/lbs
M12 55 ft/lbs 75 ft/lbs 90 ft/lbs
M14 85 ft/lbs 120 ft/lbs 145 ft/lbs
18mm Socket / Wrench
21mm Socket / Wrench
Heavy duty jack stands
Safety glasses
KIT CONTENT
Front Coil Springs
Front 2.2 Shock
Front Sway Bar Links
Front Poly Isolators
And Sway Bar Brackets
Kit pic
Rear Sway Bar Links
Rear Coil Springs
Rear 2.2 Shock
03-06 KIT SHOWN W/ RCX PERFORMANCE 2.2 SHOCK ABSORBERS
Kit Contents
4 Cylinder:
9239-Fr Coils
9237-RR Coils
Poly Spring Isolators (4)
Transfer Case Spacers
Transfer Case Bolts
Rear Track Rod
Front Sway Bar Links
Front Sway Bar Link Brackets
Rear Sway Bar Links
6 Cylinder:
9238-Fr Coils
9237-Rr Coils
Transfer Case Spacers
Transfer Case Bolts
Rear Track Rod
Front Sway Bar Links
Front Sway Bar Link Brackets
Rear Sway Bar Links
Rear Track Bar Bracket
For Front Sway Bar Links
12mm x 65mm Bolt (2)
12mm Flange Lock nut (2)
3/8” x 1 1/4” Bolt (2)
3/8” Flat Washer (2)
3/8” Lock Nut (2)
Sway Bar Sleeves-12mm (4)
For Rear Sway Bar Links
10mm x 60mm Bolt (4)
10mm Lock Nut (2)
10mm Washer
For Rear Track Rod
Crush Sleeve
5/16” x 1” Bolt (2)
5/16” Lock Washer (2)
5/16” Flat washer (4)
5/16” Lock Nut (2)
12mm x 65mm Bolt
12mm Flange Lock Nut
For Transfer Case Drop
FRONT INSTALLATION INSTRUCTIONS
1. The front-end components are installed first.
2. Place the vehicle on a level surface. Set the parking brake. Center the front wheels and chock rear wheels.
3. Remove the upper stud nut, retainer and grommet from both of the front shocks using a 15mm socket
4. Jack up the vehicle and place jack stands on the frame rail behind the lower control arm mount on the frame. Installation is done one side at a time.
5. Remove the front tires and wheels.
6. Remove the sway bar links from the axle using a 18mm wrench / T55 torx head and a 15mm for the upper and
remove the links. See Photo 1.
7. Place a floor jack underneath the axle for support and complete the removal of the front shock absorbers. Using
a 13mm socket & wrench remove the lower shock hardware. Retain factory lower mounting hardware for re-use.
8. Remove the track rod from the axle using a 15mm wrench. Retain the hardware for reuse.
9. Remove the coil spring clip located on the bottom coil seat as shown in Photo 2 using a 13mm wrench on the
driver side of the vehicle. Lower the axle and remove the coil springs.
PHOTO 1 PHOTO 2
10. With the front axle lowered, install the new front progressive rate coil spring with the supplied 3/4” poly isolator
spacer on top as shown in Photo 3. A coil spring or strut compressor may be needed for the new coil spring installation. Install the new progressive coil spring (with the coil wraps that are closer together to the top) 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.
11. Install the coil spring clamp with the stock hardware using a 13mm wrench. Torque the spring clip bolt to 16ft.-lbs.
12. Install the front shock absorber in the factory upper & lower mounts with the stock hardware using a 13mm
wrench on the lower mount and a 9/16” on the upper. (RCX 2.2 shocks are highly recommended f o r this lift).
13. Install the supplied sway bar hoop (u—shaped bracket) on the bottom side of front sway bar where the stock link
was secured with the supplied 3/8” x 1.25” bolt, washer, and flanged lock nut using a 9/16” wrench. See Photo 4.
The bolt will install from bottom to top.
PHOTO 3 PHOTO 4
Loading...