Rough Country 735.20 - Manual (Page 2)

INSTRUCTION SHEET
Technical Assistance - (731) 285-9000 Page 2
5. Using the floor jack, lower the front axle down to the leaf springs. Be sure the tie bolts align and fit into the tie
bolt holes in the front axle housing. Install and tighten new u-bolts. Torque u-bolts to 75-90 ft.lbs.
6. Install new shocks and tires then lower the vehicle to the ground. Tighten spring eyebolts at this time. NOTE: The
drag link that goes along side of the frame from the gear box to the bell crank may require slight bending for
clearance of the new shock. Bending this drag link will not affect it, but do not kink the bar.
7. Raise the rear of the vehicle. Support securely with jack stands and block the front wheels. Remove the tires,
shocks, and u-bolts. (CAUTION: the rear axle will be free to move, so support securely on a floor jack.
8. Apply a thin coat of grease to the polyurethane bushings and insert into each eye of the new rear springs. Now
apply a thin coat of grease on outside of bushings. This will help you to insert the bushing into the spring mount.
9. With a floor jack supporting the rear axle, unbolt each end of the rear leaf spring and remove from both sides. (If
new shackle bushings were purchased, grease and install them in the frame at this time.) Install new springs, part
# 8042. When installing the rear springs the fat part of the shim on the bottom of the spring pack should be
pointing toward the front of the vehicle. Notice the tie bolt in the rear leaf springs is not in the center of the leaf
springs, but there is a long end and a short end. Install the springs with the short end towards the front and longer
end towards the rear bumper. Do not tighten spring eyebolts at this time.
10. Using a floor jack, lower the rear axle down to the leaf springs. Be sure tie bolts align and fit into the tie bolt
holes in the axle housing. Install and tighten new u-bolts, shocks and tires then lower vehicle to the ground.
Torque u-bolts to 75-90 ft.lbs. Tighten spring eyebolts at this time.
Installation is now complete. Check brake line length to make sure there is plenty of line left for free play. The steering wheel
can be adjusted by adjusting the drag link. Adjust each end of the drag link out making the link longer being sure that the drag
link ends do not come past the clamps.
POST INSTALLATION INSTRUCTIONS
1. 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. Test brake system.
2. 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.
3. Bump stops and extensions must be in place on all vehicles! Note: allowing suspension to over extend by neglecting to
install or maintain stops and extensions may cause serious damage to OE and related components.
4. 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
1000 miles. Wheel alignment steering system, suspension and driveline systems must be inspected by a qualified
Professional mechanic at least every 3000 miles.