Rough Country RC617 User Manual

92RC60500

97-02 JEEP TJ BODY LIFT KIT INSTRUCTIONS

Congratulations on your purchase of a new Rough Country 2”/3” Body Lift. We are committed to providing you
with the best product available for the best value. Your satisfaction is our highest priority! This instruction
sheet addresses both 2” and 3” body lifts for Jeep TJ

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. 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 list and make sure you have needed tools.

PRODUCT USE INFORMATION

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.

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. We will not be responsible for any product that is altered.

This 2”or 3” combination body lift / replacement body bushing kit can be used with Rough Country’s lift kit if desired to
allow the fitment of larger tires for off road use.

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.

BODY LIFT PRE INSTALLATION NOTES:

To ensure the SRS system (Air bag system) is not accidentally deployed during installation, always ground yourself and
the vehicle. Exercise extreme caution when working near SRS sensors and wiring. DO not allow anyone n ear air bags
during the lift kit installation. Accidental deployment can result in serious injury or death. As a precaution, the negative
and positive wire should be disconnected from the battery with the negative wire being removed first. Also the air bag
fuse can be removed from the fuse panel behind the glove box. Check hoses and wiring before and reche c k during
installation taking caution to not overextend them.

Torque Specs:
Size Grade 5 Grade 8

(SHOWING LOCATIONS OF BODY MOUNTS)

DIAGRAM 1

7/16” 45 ft/lbs 60 ft/lbs
1/2” 65 ft/lbs 90 ft/lbs
1/4” 12 ft/lbs 18 ft/lbs

Tools Needed:

Floor jacks, Wood Blocks, Wheel chocks, Torque wrench, 1/2 drive ratchet

5/8” socket/wrench, 3/4” socket /wrench, Safety glasses, Thread locker

INSTALLATION INSTRUCTIONS

1. Disconnect negative battery cable using 13mm wrench. See Photo 1.

2. Open glove box and remove strap from glove box door. Put door out of way. remove both 10 amp airbag fuses. See
owners manual. See Photo 2.

PHOTO 1

REMOVE THE NEGATIVE BATTERY WIRE REMOVE ALL AIRBAG FUSES

3. Remove plastic jeep sway-bar cover using 10mm socket. See Photo 3.

4. If equipped with fog light on the bumper remove push pin from fender and unplug light.

5. Remove air intake hose from air filter housing and throttle body using a screwdriver. See Photo 4.

PHOTO 3

PHOTO 2

PHOTO 4

REMOVE THE SWAY BAR COVER REMOVE THE AIR INTAKE HOSE

6. Remove coolant overflow hose and bottle from fan shroud and radiator. See Photo 5.

7. Remove the four nuts from radiator fan then remove the 4 bolts holding fan shroud to the radiator using a 11mm
socket. See Photo 6. Do not drop or let the fan rest again the radiator as this may cause damage to the cooling fins.

PHOTO 5

PHOTO 6

REMOVE THE OVERFLOW CONTAINER REMOVE THE FAN SHROUD

8. Remove clip holding transmission line to shroud. Remove both shroud and fan from vehicle.

9. Remove the six bolts from radiator using 10mm socket. See Photo 7.

10. Unplug vacuum hose from brake booster. See Photo 8.

PHOTO 7

REMOVE THE RADIATOR

11. Remove heater hoses from clip on side of valve cover. See Photo 9.

12. Unplug or unclip the black and grey wiring harness connectors and any other harness present in this location. See

Photo 10.

PHOTO 9 PHOTO 10

REMOVE VACUUM HOSE

PHOTO 8

REMOVE THE HEATER HOSES FROM CLIP REMOVE THE CONNECTORS FROM MOUNT

13. On driver side front fender well remove the clips from gap guard. See Photo 11.

14. Then using a 15mm wrench remove the two bolts on steering carrier bearing bracket. See Photo 12.

PHOTO 11 PHOTO 12

REMOVE THE DRIVER INNER FENDER COVER REMOVE THE TWO STEERING BRCKT BOLTS

15. Remove gas cap. Remove the four screws from fuel filler assembly. See Photo 13.

16. Remove the screws for fuel filler bezel. See Photo 1 4.

PHOTO 13 PHOTO 14

REMOVE THE FUEL FILLER NECK REMOVE THE FUEL FILLER BEZEL

17. Depending on the year of jeep if your EVAP canister or ( charcoal canister ) is under hood on drivers fender skip to
step 23.

18. If the EVAP canister is located on the passenger side rear wheel well, proceed with step 19.

19. Remove wheel from passenger rear using a 19mm socket then remove the 7 push clips from inner fender well. See
Photo 15.

20. Remove fender well. See Photo 16.

PHOTO 15 PHOTO 16

REMOVE REAR PASS INNER FENDER COVER REMOVE THE INNER FENDER

21. Using a 13mm socket, remove EVAP canister plate. See Photo 17.

22. Unclip the black clamp around hose just above the white connector. See Photo 18.

PHOTO 17

REMOVE THE EVAP CANNISTER COVER

MOVE BLACK CLAMP UP

PHOTO 18