Rough Country 805N2 - Manual (Page 2)

INSTALLATION INSTRUCTIONS
1. Raise the front of the vehicle and support with jack stands on the frame rails.
2. Be extremely careful when loading and unloading the torsion bars, there is a tremendous amount of energy in them.
Keep your hands and body clear of the adjuster arm assembly in case anything breaks or slips.
3. Unloading the torsion bars is accomplished by loosening the adjuster arm bolts. Before loosening, measure the
length of the exposed threads for reference in a later step.
4. Stock upper control arm removal is performed one side at a time, beginning with the drivers side.
5. Support only, do not load , the lower control arm with a floor jack. Remove the 4 upper ball joint to upper control arm
bolts and separate the joint from the arm. Loosen, do not remove, the nut on the each end of the upper control arm
spindle. Inspect the ball joints. If the ball joints are loose or damaged replace with new ball joints.
6. Carefully remove the two upper control arm spindle to frame bolts. Note the positioning of the alignment shims, since
they may be reused with the new Rough Country arms.
7. Press the spindle bushing assembly out of the upper control arm. Retain the factory spindle washers for reuse. Do
not damage threads on control arm spindle.
8. Install a furnished sleeve into a upper control arm bushing and install in one side of new upper control arm. Install
the bushing with the flange outward.
9. Position the spindle with factory inner washers in the opposite leg of the control arm that the bushing was installed.
Install the bushing and sleeve on spindle. With factory washers in place torque spindle to 56-76 ft/lbs.
10. Prior to installing the 90 degree grease fittings coat the threads with the furnished thread locking compound to en-
sure fittings stay facing front on the front and rear on the rear.
11. Bolt the upper control arm assembly to frame.. If vehicle was equipped with alignment shims, reinstall shims at this
point. Torque to 80-108 ft/lbs. Note: If the vehicle was equipped with alignment shims because the vehicle was lifted
before, do not use shims.
12. Apply thread locking compound to the supplied 8mm bolts / lock nuts for the ball joints and attach the upper control
arm to the ball joint / knuckle assembly. Torque to 12-15 ft/lbs.
13. Install the new shock absorbers. It may be necessary to raise the upper / lower control arm assembly with a floor
jack to gain access for installation.
14. Grease the bushings in the new control arms.
15. Repeat steps for opposite side.
16. Again lubricate the torsion bar adjuster arm bolts and adjust to approximately 1.5” past the stock adjustment point
measured earlier. Lower the vehicle to the ground and bounce the front of the vehicle several times to normalize the
torsion bars. Continue to adjust the bolts until the desired ride height is achieved. Consider that after the vehicle is
driven, the bars will settle anywhere from .5” to 1”.
17. Depending on the bar type and condition, it may be necessary to re-index the adjuster arms, in relation to the torsion
bars, to increase bar rotation and achieve the desired lift. If this step is to be performed proceed to step 18-19. If not
proceed to step20.
18. To re-index the arm completely unload bar and remove the adjusting bolt. Prior to arm removal, scribe a line noting
the arms position in relation to the torsion bar. Slip the rubber dust boot, located just forward of the arm, towards the
front of the truck to access the c clip. With the c-clip removed the arm can be shifted rearward, beneath its housing,
and off of the bar.
19. The arms should be re-indexed one spline on the torsion bar. As viewed from the rear of the vehicle, looking for-
ward, the drivers side should be rotated clockwise, the passengers side counter clockwise. Carefully inspect the
splines for wear and deformations. Replace as necessary. Reinstall the adjuster bolt and lubricate bolt. Adjust bolt
to set ride height.
20. Reinstall the tires / wheels. Tighten lug nuts to factory specifications.
21. Recheck all steering components and lift components before removing jack stands and lowering vehicle to the
ground.