Rough-country PERF689 User Manual download pdf

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 spac-

ing. 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 accommo-

date 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 character-

istics. INSTALLING DEALER—It is your responsibility to install the warning decal and to forward these installation in-

structions on too the vehicle owner for review and to be kept in the vehicle for its service life.

92PERF1689

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

TOOLS NEEDED:

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

1 2 3 4 5 6 ... 11 12

Summary of Contents

Page 1

84-01 4.5” & 6”XJ CHEROKEE LONG ARM KIT Thank you for choosing Rough Country for your suspension needs. Rough Country recommends a certifi

Page 2

54. Remove the front brake line from the frame rail hard line as shown in Photo 33 and remove the brake line from the frame using

Page 3

REAR INSTALLATION This section will be used as reference when the add a leaf and shackle are installed. If leaf springs are used pro-ceed to th

Page 4

POST INSTALLATION INSTRUCTIONS 1. Check all fasteners for proper torque. 2. Check to ensure there is adequate clearance betwe

Page 5

9278-4” Front Coil Springs OR 9275-6” Front Coil Springs 1689Box1 OR 1601Box1 (2.8L Engine) Dr Lower Long Arm& Joint (A)

Page 6

B D E F G H I J K L M N A C E I M N O O P ADD-A-LEAF AND SHACKLES SHOWN IN PICTURE FOR 4” KIT. OPTIONAL SPRING KIT PART #8047 IS AVAIL-ABLE FOR

Page 7

PHOTO 2 PHOTO 1 INSTALLATION INSTRUCTIONS 1. Secure and properly block the tires on the vehicle on a level concrete surface. 2

Page 8

11. Using a reciprocating saw, cut the stock lower control arm mounts even with the frame. See Photo 5. 12. After cutting , grind the edges d

Page 9

18. Install the side plates with the supplied 10mm x 35mm bolts as shown. Snug but do not fully tighten at this time See Photo 1

Page 10

24. Secure the transmission mount to the new cross member with the stock hardware. Tighten using a 1/2” wrench. 25. Adjust the lower arm to a me

Page 11

36. Place the new track rod bracket in place on the studs on the side of the frame rail and tighten using a 18mm socket. See Photo

Page 12

45.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 was

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Rough-country PERF689 User Manual

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