Rough Country PERF662X User Manual
921661X00
97-06 JEEP TJ 4”/ 6” X-SERIES SUSPENSION KIT
Thank you for choosing Rough Country for your suspension needs.
Rough Country recommends a certified technician to 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 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 wo rn at all times. Avoid situations where a side rollover may occur.
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.
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. And the 6” kit was developed for a 35x12.50x15 tire. 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. Part # 7596
With the installation of this kit and larger tires it is highly recommended that an aftermarket stabilizer be added. This
kit assumes the installation of a SYE and a CV drive shaft. If a SYE and a CV driveshaft are not installed a transfer
case drop and a shift control bracket will be required.
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. 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.
Braking performance and
TOOLS NEEDED:
• Spring Compressor
• Silicone spray
• 23/64” Drill Bit
• 17/32” Drill Bit
• 29/32” Drill Bit
• Hammer
• 13mm Socket /Wrench
• 15mm Socket / Wrench
• 18mm Socket /Wrench
• 19mm Socket /Wrench
• 21mm Socket / Wrench
• 33mm Socket
• 9/16” Wrench
• 1 1/8” Wrench
• 1 1/2” Wrench
• 1 13/16” Wrench
• T40Torx bit
• T55 Torx Bit
• Floor jacks
• Wheel chocks
• 1/2” drill motor
• Torque wrench
• Allen wrenches
• Heavy duty jack stands
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
10mm 33ft/lbs 50 ft/lbs
12mm 60ft/lbs 85ft/lbs
TORQUE SPECS:
Rear Coil Spring (2)
KIT CONTENTS
Rear Track Bar Brkt
Rear Lwr Shock Brkts
Rear Sway Bar
Links (2)
Adj Fr & Rr
Upper & Lower Arms
Pitman Arm
Rough Country
Front Nitro
Absorbers
Shock
Kit Contents
1661C:
Fr Coil Springs
Rr Coil SpringS
1085 Fr Adj Track Rod Kit
1-Track Rod Body
1-Track bar Bracket
1-Heim End
1661XBox1:
2-Front Lower Adj Arms
2-Rear Lower Adj Arms
2-Front Upper Adj Arms
2-Rear Upper Adj Arms
4-Front/Rear Lower Adjustable End Bags
2-Front Upper Adj End Bags
2-Rear Upper Adj End Bags
1668XNITRO
Rough Country Nitro Front Shock (2)
Rough Country Nitro Rear Shock (2)
Rear Lwr Shock Relocation Bracket (2)
1661XBox2 (4)” OR 1662XBox2 (6”)
1-Dr Side Frame Mount Disconnect Brkt
1-Pass Side Frame Mt Disconnect Brkt
2-Front Bent Sway Bar Links
2-Rear Straight Sway Bar Links
2-Front Stainless Brake Lines
1-Pitman Arm
1-Rear Track Bar Bracket
Front Sway Bar Links & Brackets
Fr Brake Lines
Fastener Breakdown:
1085Bag
For Front Track Rod Bracket
1-Track Bar Frame Sleeves
1-1/2” x 1 3/4” Bolt
2-1/2 x 3 1/2” Bolt
1-1/2” Flat Washer
3-1/2” Lock Nuts
For Adjustable Track Rod
2-7/16” x 2 3/4” Bolt
4-7/16” Flat Washers
2-7/16” Lock Nut
1-3/4” Jam Nut
2-Track Bar Bushings
1-Track Bar Sleeve (ID 7/16”)
2-Heim Spacers
1661XBag1
8-Lwr Control Arm Bushings
4-Lwr Control Arm Sleeves
4-Rr Upr Control Arm Bushings
2-Rr Upr Control Arm Sleeves
1668XBag3:
For Rear Shock Reloc Bracket
2-12mm x 65mm Bolts
2-12mm Flange Lock nuts
2-5/16” x 3/4” Bolts
2-5/16 Lock Nuts
2-Crush Sleeves
4-Flat Washers
Front Adj Track Rod & Bracket
1661XBag2:
For Fr Sway Bar Disconnect:
2-Upper Sway Bar Mounts
4-1/4” x 3/4” Bolts
4-1/4” Flat Washers
2-1/2 Lock nut
2-3/8” x 1 1/4” Bolts
2-3/8” Flat Washers
2-3/8” Lock Washers
2-Disconnect Pins
2-Moutnting Pins
2-1/2” Lock nut
2-1/2” Flat Washers
2-Rod Ends
2-1/2” Jam Nut
For Fr Brake Lines
4-3/8” Brake Washers
2-Frame Brackets
2-Brake Clips
1661XBag3:
For Rear Track Bar Bracket
2-5/16” x 1” Bolt
4-5/16” Flat Washers
2-5/16” Lock Nuts
1-12mm x 65mm Bolt
1-12mm Flange Lock nut
For Rear Sway Bar
4-10mm ID Sleeves
4-10mm x 65mm Bolts
2-10mm Lock Nuts
4-10mm Flat Washers
For Rr Brake Line
1-Frame Brackets
1-Brake Clips
Rough Country
Rr Nitro Shocks
Front Coil Spring (2)
FRONT INSTALLATION
1. The front-end components are installed first.
2. Place the vehicle on a level surface. Set the parking
PHOTO 1
brake. Center front wheels and chock rear wheels. Remove the upper stud nut, retainer and grommet from
both of the front shocks using a 15mm socket.
3. Jack up the front of 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.
3. Remove the front tires and wheels.
4. Remove both of the front sway bar end links using a
18mm wrench & T55 torx bit from the axle and a 15mm
for the upper stud. Place a floor jack underneath the
axle for support and complete the removal of the front
Mark location of Eccentric Bolt
shock absorbers using a 13mm wrench. Retain the
stock lower hardware for reuse.
5. Do not reuse the original factory shocks.
6. If your axle is equipped, mark the position of the lower control arm cam bolt and axle brackets for installation reference. See Photo 1. If equipped with ABS brakes, remove the sensor wires and clamps from the inside of the
lower arms and save clamps for re-use.
7. Remove the track rod from the axle and from the frame using a 15mmwrench for the axle and a 19mm wrench for
the frame..
8. Install the track rod bracket as shown with the 1/2” x 1 3/4” bolt, washer & nut in the stock track rod mount. Make
sure the bracket is flat against the frame. Snug but do not fully tighten at this time. Photo 2.
9. Using the bracket as a guide, mark and drill the two side holes through the inner and outer frame as shown in
Photo 3 using a 17/32” drill bit. Make sure to keep the drill level when drilling.
PHOTO 2 PHOTO 3
PHOTO 2
10.Remove the bracket and enlarge the outside holes only using a 29/32” bit.
11.Install the supplied crush sleeves as shown in Photo 4 and reinstall the bracket.
12.Secure to the frame using the supplied 1/2” x 3 1/2” bolts, washers and nuts & 1/2” x 1 3/4” bolts & nuts. Tighten
the 1/2” x 1 3/4” bolts to 65ft/lbs and the 1/2” x 3 1/2’ bolts to 80ft/lbs. Tighten using a 3/4” wrench & 3/4 socket.
See Photo 5.
PHOTO 4
PHOTO 5
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