921633XN200 84-01 4.5” XJ CHEROKEE LIFT 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 800-222-7023. 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. 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. 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 The 6.5” suspension system was developed for 33x11.50x15 tire on 15 x 8 after market wheel with 3.75” of back spacing. This tire size may require the installation of aftermarket flares and due to variation in vehicles when manufactured and the numerous 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". 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. Please verify before installation rear axle tube diameter is 2 ¾” or 3”. Both sets are included with this kit to accommodate rear axle options of the vehicle. TOOLS NEEDED: Spring Compressor Silicone Spray Drill Motor Drill Assortment (1/8” to 1/2") Torque Wrench Hammer ½” Drive Ratchet and Sockets Combination Wrenches Allen Wrenches Torx Key Socket Tape Measure File Large “C” Clamps and/or Bench Vise Hydraulic Floor Jacks Heavy Duty Jack Stands Wheel Chocks (Wooden Blocks) Grease or Anti Seize Compound If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products. Please call us at 800-222-7023. The required installation time for this kit is 6-8 hours. KIT CONTENT For Transfer Case Spacers: 10mm x 60mm Bolts (4) For Front & Rear Brake Lines 9269-Front Coil Springs Fr Line Crush Washers (4) 8047-Rear Springs Brake Line Brackets (3) 7572- Adj Track Rod Brake Line Clip (3) Tie-Rod End Jam Nut For Sway Bar Bracket: 3/8” x 1 1/4” Bolt (2) Cotter Pin 3/8” Flange Lock nut (2) 1633XN2 Kit Box Including: 3/8” Flat Washers (2) Front Upr Adj Control Arms (2) For Sway Bar Disconnects: Front Lwr Adj Control Arms (2) 5/16” x 1” Tap Bolts (4) Front Disconnect Assemblies (2) 3/8” x 1 1/4” Bolts (2) Front Disconnect Bracket (2) Thick Washers (2) Front Brake Lines (2) Disconnect Pins (2) Front Shock # 658693 Hitch pins (2) Rear Shock # 658708 Rod Ends (2) Rear Components: 1/2” Nuts (2) Rear Brake Line 1/2” Flat Washer (2) Rear U-bolts (4) 1/2” Flange Lock Nut (2) Transfer Case Drop Spacers (4) 1/2” Jam Nut (2) Kit Includes: Rear Leaf Springs—2 Rear Brake Line Front Shocks (2) Rear Shocks (2) U bolts (4) Transfer Case Spacers Sway Bar Disconnects 2 Lwr Adj Ctrl Arms (2) Frt Adj Track Bar Upper Adj Control Arms (2) Frt Coil Springs—2 Front Brake Lines (2) PRE-INSTALLATION INSTRUCTIONS 1. Layout product and confirm that you have all needed products and know where they install. 2. Verify before installation rear axle tube diameter is 2 ¾” or 3”. Both sets are included with this kit to accommodate rear axle options of the vehicle. INSTALLATION INSTRUCTIONS 1. 2. 3. 4. 5. Secure and properly block the tires on the vehicle on a level concrete surface. Jack up the vehicle and place the front of the vehicle on jack stands. Remove the front wheels and tires. Support the axle with a floor jack. Remove the stock shock absorbers using a 15mm wrench. The stock bolts and nuts on the bottom of the shock will be reused. Note: Access to the upper shock studs will be obtained through the engine compartment. It also may be necessary to temporarily remove the washer fluid reservoir to access the driver side upper shock mount nut. 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 REMOVE THE SWAY BAR HARDWARE PHOTO 2 REMOVE THE TRACK BAR 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. The caliper can be removed from the rotor to allow the axle to lower. 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. With the axle lowered, install coil springs on both sides, making sure the lower coil wrap is seated in the lower spring cup. Install factory spring retainer and secure with factory hardware using a 13mm wrench. PHOTO 3 REMOVE THE COIL CLIP ( IF EQUIPPED) PHOTO 4 REMOVE THE STOCK CONTROL ARMS 11. Adjust new lower control arm to 16.5” from center to center and install using factory hardware. SEE PHOTO 5. 12. Remove the stock upper control arm by removing the factory hardware from the axle bracket and then removing the nut and bolt from the frame bracket doing one side at a time. Do not remove the factory bushing in the axle mount –it is reused. Lubricate bushings with a lithium grease or equivalent and install the new bushings and sleeves in the Rough Country control arm. Adjust the upper Rough Country adjustable control arm to a measurement of 15 ½” from center to center and install on the vehicle using factory hardware – do not tighten at this time. SEE PHOTO 6. PHOTO 5 INSTALL NEW LOWER ADJ ARM PHOTO 6 INSTALL NEW UPPER ADJ ARM 12. PHOTO 7 shows the caster adjustment bolts on the lower control arms. These bolts can be adjusted in or out if needed for additional caster alignment. Final alignment should be performed by a professional. 13. Install the Rough Country adjustable track rod in the factory location axle mount using factory hardware. Do not attach the frame end of the new track rod at this time. Installation is done after the vehicle is on the ground and axle is centered. SEE PHOTO 8. 14. Install the new shock absorbers Part # 658693 and tighten the factory bottom bolts using a 13mm wrench and the upper with a 9/16 wrench . Reinstall the wiper reservoir if removed. PHOTO 7 NOTE THE ADDITIONAL CASTER ADJ BRKT PHOTO 8 INSTALL THE NEW ADJ TRACK BAR 15. Install the front wheels and tires. Jack up the vehicle, Remove jack stands and lower the vehicle to the ground. 16. Check to make sure the body is centered over the axle. Unlocking the steering wheel and turning the wheel to move the body, do this until the track rod hole lines up. Install the track rod with the stock bolt /flag nut and using a 15mm wrench. Torque to factory specs. FRONT SWAY BAR DISCONNECT INSTRUCTIONS 1. Install the upper sway bar mount on the top of front sway bar where the stock link was secured, using the supplied 3/8” x 1.25” bolt lock washer and thick washer. Tighten using a 9/16” wrench making sure the mount is straight. See Photo 1. 2. Using a hammer, remove the lower stock sway bar link mounting bolt from the axle mount. 3. Install supplied pin on the axle. See Photo 2. Hold using a screwdriver & tighten 1/2” lock nut using a 3/4” wrench. PHOTO 1 INSTALL BRACKET USING THICK WASHER PHOTO 2 INSTALL THE PIN ON THE AXLE 4. Assemble the sway bar link with the link body, the jam nut and rod end Adjust the sway bar to a length of 11 1/4” from top to bottom. Tighten the jam nut against the rod end using a 5/8” & 3/4” wrench. 5. Install the sway bar link on the upper sway bar mount with the supplied 1/2” flange lock nut. See Photo 3. Tighten using a 5/8” & 3/4” wrench. 6. With the sway bar link installed on the supplied frame bracket, swing the bracket and sway bar link up and position the bracket on the frame as shown in Photo 4. PHOTO PHOTO 293 INSTALL THE LINK ON THE MOUNT PHOTO 4 POSITION THE MOUNT ON THE UNI-BODY 7. While holding the bracket in place, remove the sway bar link from the bracket. Mark and drill the holes using a 1/4” drill bit. 8. Install the supplied 5/16” x 1” self tapping bolt in the drilled holes and tighten using a 1/2” socket. See Photo 5. Do not over tighten the self tapping bolts. 9. Install on the lower axle mounting pin. Install the disconnect pin. See Photo 6. Note: When disconnected the hitch pin will be used on the upper mount to secure the sway bar link to the mount. PHOTO 5 TIGHTEN HARDWARE PHOTO 6 INSTALL LINK ON THE AXLE AND SECURE FRONT BRAKE LINE INSTALLATION INSTRUCTIONS 1. Inspect the brake system and repair / replace components as necessary. 2. Remove the stock hoses from the frame rail and from the brake calipers. Be sure that the stock crush washers are removed. New washers are supplied. 3. Thoroughly clean and inspect all mating surfaces. 4. Install the new Rough Country hoses in the stock location using the stock hardware on the axle. 5. Using the supplied brake line mounting bracket and brake clip install in the stock location on the frame rail. See Photo 1 & 2. PHOTO 2 PHOTO 1 Install clip INSTALL BRAKE LINE BRACKET ON FRAME INSTALL BRAKE LINE IN BRACKET 6. With the suspension supporting the vehicle weight and the tires / wheels installed, cycle the steering lock-to-lock and check for adequate hose length and clearance. 7. Now raise the vehicle and check length / clearance with the suspension hanging at full extension travel. 8. Bleed the air from the system as instructed by the factory service manual. Avoid getting brake fluid on painted surfaces. REAR LIFT INSTALLATION 1. Remove rear factory shocks using a 13mm wrench on top and a 3/4” wrench on bottom and retain hardware. 2. Chock the front wheels and jack up the rear of the vehicle and place the vehicle on jack stands. Remove the wheels and tires. 3. Working from the drivers side, remove the factory u-bolts and lower the axle with a floor jack. Repeat for passenger side. 4. Remove the spring from the shackle and from the frame using a 21mm wrench. SEE PHOTO 3. 5. Locate and grind off the excess from the bolt pictured in PHOTO 4. This will allow the shackle to move rearward. PHOTO 3 REMOVE SPRING FROM SHACKLE & FRAME PHOTO 4 GRIND BOLT 6. Install new rear springs at this time with factory hardware using 21mm wrench and skip to Step 10. The larger spring eye will bolt back in the stationary mount 7. This kit includes 2 3/4” & 3” diameter u-bolts for rear axle options on the Jeep. Confirm axle diameter and use appropriate u-bolt. Install the u-bolts and torque to factory specs using 3/4” wrench. 8. Install the new shocks Part # 658708 with factory hardware. Torque the upper using a 13mm wrench and lower bolts using 3/4” wrench to factory specs. Repeat for other side. 9. Install the tires and wheels. Jack up the vehicle and remove the jack stands. Lower the vehicle to the floor. 10. Torque the frame bolts, and shackle bolts to factory specs using a 21mm wrench. 11. Install the rear brake line on the axle and the frame with the supplied c-clip. TRANSFER CASE DROP INSTALLATION INSTRUCTIONS 1. Position the floor jack under the transfer case cross member and lightly apply pressure. 2. Loosen and remove the bolt and the nut on stud on the driver side transfer case cross member. 3. Loosen and remove the bolt and nut on the drivers side cross member. 4. Carefully lower the transfer case down to the point it clears the stud. 5. Using 2 nuts to form a jam nut on the stud, remove the stud from the cross member on both sides. 6. Carefully lower the transfer case cross member to allow clearance for installation of transfer case spacer and sleeve. 7. Place the spacer between the frame and cross member; install the new 10mm x 60m bolts through cross member, spacer and into uni-body. Raise the transfer case and tighten bolts to 35 ft/lbs. See PHOTO 1. PHOTO 1 INSTALL TRANSFER CASE SPACERS POST INSTALLATION INSTRUCTIONS 1. 2. 3. 4. 5. 6. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and heated members. Check steering gear for interference and proper working order. Before driving the vehicle, check to make sure brakes are operating properly and do not need to be blead. Perform steering sweep. Check to ensure brake hoses have sufficient slack and will not contact rotating, mobile, or fixed members. Adjust lines/brackets to eliminate interference and maintain proper working order. Failure to perform inspections may result in component failure. 7. Have headlight readjusted to proper settings. 8. Take the vehicle to be aligned to factory specifications by a certified alignment shop. 9. Re torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during routine vehicle service. MAINTENANCE INFORMATION It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 100 miles and then every 100 miles. A qualified mechanic must inspect wheel alignment steering system, suspension and driveline systems at least every 3000 miles. We have most of the additional accessories you need for your Cherokee. We have Rock Sliders, Diff Guards, Slip Yoke Eliminator, Drive Shafts, Steering Stabilizers, Adjustable Controls Arms, Etc. $59.95 Diff Guard $49.95 Stabilizer $269.00 SYE Kits $9.95 RC Hat $159.95 Adj Arms Drive-Shafts Call For Price$ $129.95 Adj Track Bar Thank you for purchasing a Rough Country Suspension System.
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