Rough Country PERF689 User Manual
92PERF1689
84-01 4.5” & 6”XJ CHEROKEE LONG ARM 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.
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 and make sure you
are confident about undertaking this installation. If you have any questions about the installation of this kit, call Rough
Country at 731-285-9000.
PRODUCT USE INFORMATION
As a general rule, the taller a vehicle is the easier it will roll. We strongly recommend that 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.
The 4.5” Long Arm Kit system was developed for 32x11.50x15 tire on 15 x 8 after market wheel with 3.75” of back spacing. The 6” kit was developed for 33x12.50x15 tire on 15 x 8 after market 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".
Please verify before installation rear axle tube diameter is 2 1/2” or 3”. Both sets are included with this kit to accommodate rear axle options of the vehicle.
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 too the vehicle owner for review and to be kept in the vehicle for its service life.
TOOLS NEEDED:
Jack Stands
Floor Jack
Transmission Jack or comparable jack
Wheel Chocks
T-55 Torque Bit
T-30 Torque Bit
13mm Socket / Wrench
14mm Socket / Wrench
15mm Socket / Wrench
17mm Socket / Wrench
18mm Socket / Wrench
19mm Socket / Wrench
21mm Socket / Wrench
1/2” Socket / Wrench
9/16” Socket / Wrench
3/4” Socket / Wrench
1 1/8’ Wrench
17/32” Drill Bit
25/32” Drill Bit
23/64” Drill Bit
Drill Motor
Torque Wrench
Brake Fluid
Catch Pan
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
Class 8.8 Class 10.9
12MM 55ft/lbs 75ft/lbs
14MM 85ft/lbs 120ft/lbs
16MM 130ft/lbs 165ft/lbs
18MM 170ft/lbs 240ft/lbs
9278-4” Front Coil Springs
OR
9275-6” Front Coil Springs
1689Box1 OR
1601Box1 (2.8L Engine)
Dr Lower Long Arm& Joint (A)
Pass Lower Long Arm& Joint (B)
Dr Upper Arm (C)
Pass Upper Arm (D)
Cross member Side Plates (E)
Pitman Arm (F)
1/2” Flag Nut-For Frt Crssmbr (2)
1689Box2-For NP231 Transfer Case
Transfer Case Skid Plate (G)
OR
1616Box1-For NP242 Transfer Case
Transfer Case Skid Plate (G)
1689Box3
Long Arm Cross-member (H)
1689Box4
Fr Sway Bar Disconnects (I)
Fr Stainless Steel Brake Lines (J)
U-Bolts (2 3/4” x 6 3/4” or 3” x 8”)
For either axle size
Rear Stainless Steel Brake Line
1079 Adjustable Track Bar Kit
Front Adjustable Track Bar (K)
Track Bar Bracket (L)
Perf2.2Shocks:
Fr RCX 2.2 Series Shocks (M)
RR RCX 2.2 Series Shocks (N)
Lift Options for 4” Kit
Lifted Shackles (1077) (O)
& Add-a-Leaf (6123) (P)
OR
Lifted Springs
Lift Contents for rear of 6” Kit:
Rear Leaf Springs
& Shackles (1077)
KIT CONTENTS
Fasteners List:
1689Bag1-In 1689Box1 /1601Box1
For Front Cross member
10mm x 35mm Bolt (6)
10mm Flat Washer (6)
Crush Sleeve (2)
1/2” x 4 1/2” Bolt (2)
1/2” Flat Washer (6)
1/2” Lock nut
For Front Lower Control Arms
9/16’ X 4” Bolt (2)
9/16” Flat Washer (4)
9/16” Lock Nut (2)
For Front Upper Control Arms
10mm x 80mm Bolt (4)
10mm Lock Nut (4)
10mm Flat Washer (8)
For Transfer Case Skid Plate
3/8” x 1” Bolt (2)
3/8” Flat Washer (2)
3/8” Lock Washer (2)
3/8” Self Tapping Bolt (2)
1689Bag2– In 1689Box4
For Fr Sway Bar Disconnect:
4-5/16” x 1” Self Tap Bolts
2-3/8” x 1 1/4” Bolts
2-Thick Washers
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
For Rear Brake Line
Brake Line Clip
Brake Line Bracket
1079 Adj Track Rod:
For Fr Adj Track Rod Part
Bushings (2)
7/16” ID Sleeve
Heim End
Heim Spacers (2)
7/16” Flat Washer (2)
7/16” Lock Nut
3/4” Jam Nut
For Front Brake Lines
Bracket (2)
Brake Line Clip (2)
3/8” Crush Washers (4)
1077 Rear Shackles:
For Rear Shackles
(If purchased with 4 1/2” & 6” kit)
Bushings (4)
Sleeves (2)
9/16” x 4” Bolt (2)
9/16” Lock Nut (2)
14mm x 110mm Bolt (2)
14mm Lock Nut (2)
9/16” Flat Washer (8)
KIT CONTENTS
P
J
O
G
O
N
M
B
E
N
E
H
A
M
F
I
I
L
D
C
K
ADD-A-LEAF AND SHACKLES SHOWN IN PICTURE FOR 4” KIT. OPTIONAL SPRING KIT PART #8047 IS AVAILABLE FOR THIS VEHICLE.
6” KIT INCLUDES NEW LIFTED REAR SPRINGS AND SHACKLES.
1. Secure and properly block the tires on the vehicle on a level concrete surface.
INSTALLATION INSTRUCTIONS
2. Jack up the vehicle and place the front of the vehicle on jack stands.
3. Remove the front wheels and tires.
4. Support the axle with a floor jack.
5. Remove the upper mount of the stock shock absorbers using a 15mm wrench. Remove the lower stock hardware
using a 13mm wrench. Retain the hardware for reuse.
6. Remove the sway bar links on both sides using a T-55 torx bit /19mm wrench and a 15mm for the upper nut . See
Photo 1.
7. Remove the track bar from the axle housing on passenger side using a 15mm wrench. See Photo 2. Retain factory
bolt and flag nut for re-use.
PHOTO 1
PHOTO 2
Remove upper sway bar link from sway bar
Remove the track bar from the axle.
8. Locate and remove the coil clip on the driver side lower coil spring seat using a 13mm wrench. Lower the axle to
allow for removal of the coil spring. Do not overextend the brake lines. Remove the caliper from the rotor to allow
the axle to lowered using a 13mm socket. Do not let the brake caliper hang from the brake line. Remove coil spring.
See Photo 3. Repeat for opposite side.
9. With the differential supported, remove the driver side lower control arm from the vehicle using a 21mm wrench. See
Photo 4. Retain factory hardware, as it will be reused. Repeat for opposite side.
10. Lower the axle using the floor jack.
PHOTO 3 PHOTO 4
Remove the coil clip from the coil spring Remove the lower control arm
Loading...