Owner's manual

ManualsBrandsRough Country ManualsCar323S

Thank you for choosing Rough Country for all your suspension needs.

Rough Country recommends a certified technician install 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 instructions before beginning installation. Check the kit hardware against the kit contents list. Be sure you

have all needed parts and know where they go. Also please review tools needed list and make sure you have the tools

needed to install the kit.

Seat belts and shoulder harnesses should be worn at all times. Avoid situations where a side rollover may occur.

Generally, braking performance and capability are decreased when larger/heavier tires and wheels are used. Take this

into consideration while driving. Do not add, alter, or fabricate any factory or after-market parts to increase vehicle height

over the intended height of the Rough Country product purchased. Mixing component brands is not recommended.

Rough Country makes no claims regarding lifting devices and excludes any and all implied claims. We will not be re-

sponsible for any product that is altered.

We will be happy to answer any questions concerning the design, function, and

use of our products.

This 4” suspension system was developed using a 35 X 12.5 tire with aftermarket wheels. 20” wheels with 5 1/2” back-

space or an 18” wheel with 5” of backspace will be required to maintain adequate clearance. Stock wheels can be used

with this lift with the addition of a 1/4” wheel spacer. As with any tire and wheel combination it is recommended to trial fit

the tire / wheel to assure there are no clearance problems.

Please note, this lift kit is not recommended for AWD (All Wheel Drive) Models.

TRX models will achieve aproximately 1" of additional lift. This lift is not recommended for use on the TRX mod-

els due to possible CV shaft vibration caused by the additional lift. Instead, consider our 4" lift system for about

5" of lift or replace the TRX struts with standard struts for use with this system.

NOTICE TO DEALER AND VEHICLE OWNER

Any vehicle equipped with any Rough Country product should have a “Warning to Driver” decal installed on the inside of

the windshield or on the vehicle’s dash. The decal should act as a constant reminder for whoever is operating the vehi-

cle of its unique handling characteristics.

INSTALLING DEALER - it is your responsibility to install the warning decal and forward these installation instructions on

to the vehicle owner for review. These instructions should be kept in the vehicle for its service life.

92132300

2012 DODGE 1500 4” LIFT KIT

WD-40

Loc-Tite

Reciprocating Saw

Hammer

Dead Blow Hammer

T30 Torx head bit

5mm Allen Wrench

8mm Socket / Wrench

10mm Socket / Wrench

13mm Socket / Wrench

14mm Socket / Wrench

15mm Socket / Wrench

Tools Needed:

16mm Socket / Wrench

18mm Socket / Wrench

19mm Socket / Wrench

21mm Socket / Wrench

22mm Socket / Wrench

24mm Socket / Wrench

35mm Socket

1 1/16” Socket

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

6MM 5 ft/lbs 9 ft/lbs

8MM 18ft/lbs 23 ft/lbs

10MM 32ft/lbs 45ft/lbs

12MM 55ft/lbs 75ft/lbs

14MM 85ft/lbs 120ft/lbs

16MM 130ft/lbs 165ft/lbs

18MM 170ft/lbs 240ft/lbs

Torque Specs:

Summary of content (20 pages)

PAGE 1
92132300 2012 DODGE 1500 4” LIFT KIT Thank you for choosing Rough Country for all your suspension needs. Rough Country recommends a certified technician install 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.
PAGE 2
KIT CONTENTS 1326Box1 Containing: 1-Fr Cross-member (A) 1-Rr Cross-member (B) 1324Box2 Containing: 1-Dr Fr Diff Brkt (C) 1-Dr Rr Diff Brkt (D) 1-Pass Diff Brkt (E) 1-Skid Plate (F) 1-Fr Driveshaft Spacer (G) 2-Fr Sway Bar Brkt (H) 2-Fr Sway Bar Link (I) 1-Dr Fr Brake Brkt (J) 1-Pass Fr Brake Brkt (K) 1328Box3 Containing: 2-Fr Strut Spacers (L) 2-Rr Brake Brkt (M) 2-Rr Bumpstop Brkt (N) 2-Rr Shock Flagnut (O) 2-Rr Coil Spacers (P) 2-Rr Coil Retainers (Q) 1380Box1 Containing: 1-Dr Knuckle (R) 1380Box2 Contain
PAGE 3
KIT CONTENTS R P Q P M O Q O M B E C F V V N N D G A I H J K L S L Thank You for choosing Rough Country for your off road needs!!! R
PAGE 4
INSTALLATION INSTRUCTIONS 1. 2. 3. 4. 5. Chock rear wheels of the vehicle and raise the front of the vehicle using a floor jack. Support the vehicle with jack stands. Remove wheel using 22mm socket. Remove tie-rod end nut using 21mm as shown in Photo 1. Strike with hammer to dislodge the tie rod from the knuckle. See Photo 2. PHOTO 1 REMOVE THE TIE ROD PHOTO 2 STRIKE WITH HAMMER TO DISLODGE 6. Remove brake caliper using 21mm wrench. See Photo 3. Secure out of way and remove rotor. 7.
PAGE 5
11. Remove lower strut mount using 21mm and 24 mm wrench. See Photo 7. 12. Remove sway-bar link from sway-bar using 16mm wrench. See Photo 8. PHOTO 8 PHOTO 7 REMOVE LOWER STRUT FROM ARM REMOVE UPPER SWAY BAR HARDWARE 13. Remove upper strut mount using 15mm wrench and remove strut. See Photo 9. 14. Using a dead blow hammer remove axle from diff. See Photo 10. PHOTO 9 PHOTO REMOVE UPPER STRUT MOUNT HARDWARE STRIKE AS SHOWN TO REMOVE SHAFT 15. Using 24mm wrenches remove lower control arm.
PAGE 6
17. Remove the two upper diff bolt from the motor mount / diff mount using 18mm socket. Retain the stock hardware . See Photo 13. 18. Remove rear cross-member using 18mm wrench. See Photo 14. PHOTO 14 PHOTO 13 REMOVE THE REAR CROSSMEMBER REMOVE THE UPPER MOUNT HARDWARE 19. Remove driveshaft from diff using 15mm wrench. See Photo 15. PHOTO 15 REMOVE THE DRIVESHAFT BOLTS PHOTO 16 REMOVE PASSENGER SIDE HARDWARE 20.
PAGE 7
23. Align the supplied template with the lower holes. Tape cut out to driver side lower control arm rear pocket. 24. Cut at the line on the cut out. this is done to make room for rear cross member. Grind sharp edges and paint. See Photo 19 & 20. PHOTO 19 CUT USING A RECIPROCATING SAW PHOTO 20 CUT USING A RECIPROCATING SAW 25. Install rear diff drop bracket on the differential using the stock hardware. See Photo 21. Tighten using a 18mm wrench. 26.
PAGE 8
29. Secure the driver side differential to the frame using the supplied 12mm x 45mm bolts, flat washers, and flange lock nuts. See Photo 25. 30. Secure the differential in the passenger side bracket using the supplied 12mm x 45mm bolts & flange lock nuts and bend the stock diff wiring harness bracket up for clearance. See Photo 26. PHOTO 25 REINSTALL DIFF/ BRACKET ON FRAME PHOTO 26 REINSTALL DIFF ON BRACKET 31. Tighten all diff bolts at this time using a 18mm / 19mm wrench. 32.
PAGE 9
36. Install lower control arm using stock cam bolts. See Photo 31. 37. Install skid plate using supplied 3/8” X 1” bolts and 3/8” washers on the front cross-member. Use 14mm socket to tighten. See Photo 32. PHOTO 31 INSTALL THE CONTROL ARM PHOTO 32 TIGHTEN SKID PLATE HARDWARE 38. Install the skid plate on the rear cross-member as shown in Photo 33 with the supplied 3/8” x 1” and washers. 39. Using 1 1/16 wrench and socket tighten cross member bolts. See Photo 34.
PAGE 10
42. Install the spacer on strut using stock hardware using 15mm wrench. See Photo 37. 43. Install strut onto truck using 14mm wrench to tighten upper supplied 3/8” nuts and washers See Photo 38. PHOTO 37 INSTALL THE SPACER ON STRUT PHOTO 38 INSTALL STRUT ON FRAME 44. Attach lower control arm to lower part of strut using stock hardware. Tighten lower strut hardware using a 24mm and 21 mm wrench. See Photo 39. 45. Remove sway-bar link from control arm using 18mm and 8mm wrench. 46.
PAGE 11
49. Notch a section of the stock mount to remove the brake line as shown in Photo 43 and remove line from housing. Straighten bends in hard metal lines making sure to not kink lines. 50. Install new brake line bracket onto brake line using supplied 5/16” x 3/4” bolts, washers and nuts. See Photo 44. PHOTO 43 CUT BRAKE LINE MOUNT PHOTO 44 INSTALL LINE ON NEW BRACKET 51. Then attach bracket to frame using stock bolt in lower hole and new supplied 3/8” x 1” bolts, washers and nuts. See Photo 45.
PAGE 12
55. Slide the axle in the bearing assembly and install the knuckle on the upper ball joint using a 21mm and 10mm wrench. See Photo 49. 56. Tighten the axle nut using a 35mm socket. See Photo 50. PHOTO 50 PHOTO 49 INSTALL AXLE NUT INSTALL KNUCKLE ON UPPER BALL JOINT 57. Unclip ABS wire from upper control arm and install wire back into bearing assembly using 5mm allen wrench. See Photo 51. 58. Using WD-40 move the rubber insulator into right spot and clip back into upper control arm. See Photo 52.
PAGE 13
REAR INSTALLATION INSTRUCTIONS 1. Remove wheels using a 22mm socket. 2. Remove ABS clip from axle. See Photo 1. 3. Remove the brake line as shown in Photo 2 using 13mm. PHOTO 1 PHOTO 2 4. Remove sway-bar link using 8mm and 18mm wrench for lower end and 18mm for top end. See Photo 3 & 4. PHOTO 3 PHOTO 4 5. Support rear end. 6. Remove the shocks from the axle using 21mm wrench. See Photo 5. 7. To remove the upper shocks from the frame mount, remove the inner fender well using 8mm socket. See Photo 6.
PAGE 14
8. Remove upper track bar bolt using 21mm wrench. See Photo 7. 9. Remove the vent hose from axle. 10. Remove coil springs. See Photo 8. PHOTO 7 PHOTO 8 11. Install the flat upper spacer retainer as shown in Photo 9 on the upper coil seat. 12. Install the spring spacer and secure with the supplied 3/8” x 2 1/2” bolt through the upper flat retainer to hold the spacer in place. Tighten using a 14mm Socket & wrench. See Photo 10. PHOTO 9 PHOTO 10 13.
PAGE 15
. Install bushing a sleeves into shocks. Install shock onto truck using stock hardware with new flag nut for top bolt. See Photo 18. 2.2 Shock Absorbers will install with the body up. 16. Also install washer on bottom of shock to the outside of truck. See Photo 19. Use 21mm to tighten. PHOTO 18 PHOTO 19 17. Pull down and straighten brake line. Take care not to kink the brake line. 18. Install sway bar links & brake line brackets on the frame with the supplied 12mm x 65mm bolts, washers and nut.
PAGE 16
21. Install track bar into bracket with stock bolt. You may have to do this with truck on the ground. Tighten upper bolt using 22mm wrench and lower with 21mm wrench. 22. With WD-40 or alcohol adjust the rubber insulator on ABS wire so that it will fit back into clip on brake line. See Photo 22. 23. Cut zip tie for axle vent tube and install new zip tie and vent tube on lower part of frame. See Photo 23 & 24. 24. Reinstall fender wells using 8mm socket. 25. Check to make sure all fasteners are tight. 26.
PAGE 17
CUTTING TEMPLATE
PAGE 18
PAGE 19
CUTTING TEMPLATE
PAGE 20