Rough Country PERF663 User Manual
92PERF166300
97-06 JEEP TJ/LJ 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 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, 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 8” wide wheel with 3.75” of back
spacing. The 6” kit was developed for 35x12.50x15 tire on an after market 8” wide wheel with 3.75” of back spacing.
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.
This kit features Rough Country’s adjustable joint design. Adjustable end tool is included in kit.
• With the installation of this kit and larger tires it is highly recommended that an aftermarket stabilizer(s) be added.
• A drive-shaft/SYE combination is highly recommended for the 4’ kit and a necessity on the 6” kit to correct rear
• Additionally, the exhaust system must be modified by an exhaust specialist to clear all components.
• On Rubicon models the air compressor for the air lockers on the frame by the rear of the skid plate will have to be
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.
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.
Assemble the joints per the separate instruction sheet Part # 92RCJ120 provided.
driveshaft angles and prevent vibration.
relocated. Refer to installation instructions for detail.
NOTICE TO DEALER AND VECHICLE OWNER
KIT CONTENTS
This kit is packaged in 8 boxes. Please makes sure you have all the need parts and understand where the y go prior
to beginning installation. Please use the attached picture to match parts to their descriptions shown below.
1661C-4” KIT / 1662C-6” KIT
Fr Coil Springs (A)
Rr Side Coil Spring
1085 Fr Adj Track Rod Kit
1-Track Rod Body (D)
1-Track bar Bracket (E)
1085Bag:
For Front Track Rod Bracket
2-Frame Crush Sleeves
1-1/2” x 1 3/4” Bolt
2-1/2 x 3 1/2” Bolt
7-1/2” Flat Washer
3-1/2” Lock Nuts
For Front 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”)
1-Heim Joint
2-Heim Spacers
1086-Rr Adj Track Rod Kit
1-Track Rod Body & Heim End (F)
1086Bag:
For Rear Track Rod
1-Sleeves
2-Bushings
1-Jam Nut
2-Heim Spacers
1663Box1:
1-Dr Side Control Arm Mount (G)
1-Pass Side Control Arm Mount (H)
1-Rear Track Bar Bracke(I)
1-Rubicon Compressor Bracket
2-Front Upper Adj Arms (J)
1663Box2:
2-Front Lower Adj Arms (K)
4-Large Arm Ends
4-Small Arm Ends
1663Bag1:
For Control Arm Mounts:
4-1/2” x 4” Bolts
8-1/2” Washers
4-1/2” Lock nuts
For Transfer Case Skid Plate
6-9/16 x 4 1/2” Bolts (97-02)
OR 6-12mm x 65mm Bolts (03-06)
6-Flat Washers
For Front Lower Control Arms
2-9/16” x 4” Bolts
4-9/16” Flat Washers
2-9/16” Lock Nuts
For Front Upper Control Arms
2-10mm x 80mm Bolts
4-10mm Flat Washer
2-10mm Lock Nuts
1663Bag5:
For Rear Lower Control Arm:
2-9/16” x 7” Bolts
4-9/16” Flat Washers
2-9/16” Lock Nuts
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
1-Crush Sleeve
For use with Rubicon Models:
For Compressor Bracket
4-5/16” x 1” Bolts
4-5/16” Lock Nuts
8-5/16” Flat Washers
4-Lower End Component Bag
4-Upper End Component Bag
1-Adjustable End Tool Bag
1663Box3
1-Dr Side Fr Mnt Disc Brkt (L)
1-Pass Fr Mt Disc Brkt (M)
2-Front Sway Bar Links (N)
2-Fr Bump Stop Pucks (O)
2-Front Stainless Brake Lines (P)
1-Pitman Arm (Q)
1-Rear Stainless Brake Line (R)
2-Rear Straight Sway Bar Links (S)
2-Rear Shock Re-locator (T)
1-Hardware Bag
1663Bag3:
For Front Bump Stop
2-3/8” x 3 1/2” Self Tapping Bolt
For Fr Brake Lines
4-3/8” Brake Washers
2-Frame Brackets
2-Brake Clips
For Rear Brake Line:
1-Brake Line Bracket
1-Brake Line Clip
For Rear Shock Bracket
2-12mm x 65mm Bolts
2-12mm Flange Lock Nuts
2-5/16” x 3/4” Bolts
4-5/16” Flat Washers
2-5/16” Lock Nuts
2-Crush Sleeve
4-7/16” Flat Washers
For Rear Sway Bar
4-10mm ID Sleeves
4-10mm x 60mm Bolts
2-10mm Lock Nuts
2-10mm Flat Washers
Sway Bar Disconnect Bag:
For Fr Sway Bar Disconnect:
4-1/4” x 3/4” Bolts
4-1/4” Flat Washers
2-3/8” x 1 1/4” Bolts
2-3/8” Flat Washers
2-Fr Disconnect Mounts
2-Disconnect Pins
2-Hitch pins
2-Rod Ends
2-1/2” Nuts
2-1/2” Flat Washer
2-1/2” Flange Lock Nut
2-1/2” Jam Nut
1663Box4
2-Rear Lower Adj Arms (U)
2-Rear Upper Adj Arms (V)
Perf2.24TJ:
2-2.2 Series RCX Front Shock (W)
2-2.2 Series RCX Rear Shock (X)
KIT CONTENTS
P
E
D
X
N
J
K
O
A
G
L
Q
M
T
N
A
O
J
K
H
X
W
U
I
V
B
B
V
U
T
W
S
R
F
T
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. Typically the transfer case bolts and the pitman arm are difficult to remove without having done this step.
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 key socket
• File
• Floor jacks
• Wheel chocks
• 1/2” drill motor
• 11/32” Drill bit
• 17/32” Drill bit
• 29/32” Drill bit
• 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:
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
1. Place the vehicle on a level surface. The vehicle will need to be placed on jack stands front and rear to install the
long arm kit.
2. Remove the front tires and wheels.
3. From inside the engine compartment, remove the upper stud nut, retainer and grommet from both of the front
shocks using a 15mm socket.
4. Remove both of the front sway bar end links using a 15mm wrench for the upper and a 18mm wrench for the
lower. Retain lower link hardware for re-use.
5. Place a floor jack underneath the axle for support and complete the removal of the front shock absorbers from the
lower mount using a 13mm Socket. Retain the stock lower hardware for reuse.
6. Do not reuse the original factory shocks.
7. 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 for the inside of the lower
arms and save clamps for re-use. See Photo 2.
PHOTO 1
PHOTO 2
Mark the location of eccentric bolt.
Remove ABS wire from arm if equipped
8. Remove the track rod from the axle and from the frame using a 15mm (axle) & 18mm wrench (frame). Retain the
axle hardware for reuse.
9. Remove the coil spring clip located on the bottom coil seat on the driver side of the vehicle using a 13mm socket.
Retain the clip and hardware for reuse.
10.Remove the brake caliper from the axle using a 13mm socket and secure out of harms way.
11.Lower the axle and remove the coil spring. A coil spring or strut compressor may be needed to remove the stock
coil spring.
12.Support the front axle and 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 doing one side at a
time using a 21mm socket & wrench. Retain the stock hardware.
13.Remove the upper arm from the mount using a 15mm wrench. Do not retain stock hardware.
14.Cut the stock lower control arm mounts from the frame as shown in Photo 3 by cutting the weld that secures the
bracket to the frame using a cutting wheel or similar cutting tool. Take care not to cut in to the frame rail.
15.After the bracket is removed, grind the surface smooth as shown in Photo 4 and paint the area to prevent rusting
PHOTO 3
PHOTO 4
Remove lower control arm mount. Cut along line
Grind frame smooth and paint exposed surface
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