Rough-country PERF663 User Manual download pdf

97-06 JEEP TJ/LJ LONG ARM KIT

W/ PERFORMANCE 2.2 SERIES SHOCK ABSORBERS

92PERF166300

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 prod-

uct 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 of-

fers 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.

Assemble the joints per the separate instruction sheet Part # 92RCJ120 provided.

• 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

driveshaft angles and prevent vibration.

• 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

relocated. Refer to installation instructions for detail.

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 in-

stallation 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 con-

struction 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 proc-

ess, 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.

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Summary of Contents

Page 1

97-06 JEEP TJ/LJ LONG ARM KIT W/ PERFORMANCE 2.2 SERIES SHOCK ABSORBERS 92PERF166300 Thank you for choosing Rough Country for your suspension ne

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47.Swing the sway bar link down and install on the lower axle mounting pin. Install the disconnect pin. See Photo 28. It may be necessary to inst

Page 3

54. Remove the bracket and enlarge the outside holes only using a 29/32” bit. 55. Install the supplied crush sleeves as shown in Photo 34 and reins

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63.Install the upper arm on the axle using the stock hardware. Do not tighten at this time. See Photo 40. 64.Locate the new track rod bracket and

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69. Install the supplied brake line bracket with the factory hardware on the frame. Install the brake line to the bracket on the frame and secure w

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79. Assemble the new sway bar links with the supplied 10mm sleeves. 80. Install the new sway bar links on the sway bar with the supplied 10mm x 60

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NOTES:

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POST INSTALLATION 1. Rotate driveshaft and check for interference at differential yoke and u-joint. If necessary, lightly dress casting(s) and/

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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 Br

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KIT CONTENTS A A B D E F G H I J K L M T O P Q R U W V T T W X X J K U N V S N O B

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IMPORTANT PRE—INSTALLATION INSTRUCTIONS Prior to beginning this installation it is always good to use a penetrating oil and spray all fasteners t

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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

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16. On the rear of the vehicle, remove the stock shocks from the vehicle using a 13mm socket on the upper and a 18mm socket / wrench on the lower

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25. Align the holes in the frame with the new control arm bracket and install the factory skid plate bolts. Clamp in place using a large c-clamp. S

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31. Adjust the lower front arm to a length of 29 3/4” from center of end to center of bushing. Tighten jam nut using an adjustable wrench. 32. Ins

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38.Tighten the bump stop extension bolt with a 9/16 wrench. Do not over torque the bolt. See Photo 22. 39.Remove the cotter pin and nut from the d

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Rough-country PERF663 User Manual

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