Rough Country Rear CV Drive Shaft (Model 5097.1) Instruction Manual

1. Introduction

This manual provides detailed instructions for the installation, maintenance, and general information regarding your Rough Country Rear CV Drive Shaft, Model 5097.1. This double cardan style CV drive shaft is engineered to address vibration issues and provide a durable drivetrain solution for lifted Jeep Wrangler JK 2-Door models. Proper installation and maintenance are crucial for optimal performance and longevity of the product.

2. Compatibility

This Rough Country Rear CV Drive Shaft (Model 5097.1) is specifically designed for the following vehicle configurations:

• Vehicle: 2007-2011 Jeep Wrangler JK 2-Door models.
• Lift Requirements: Equipped with 3.5" - 6" short arm suspension lifts or 2.5" - 6" long arm suspension lifts.
• Important Note: This product is NOT compatible with 4-door (Unlimited) Jeep Wrangler JK models.

3. What's in the Box

Please verify that all components listed below are present before beginning installation:

• (1) Extended CV Drive Shaft
• Flanges
• Yokes
• Hardware

4. Specifications

5. Installation (Setup)

Installation of this CV drive shaft requires mechanical knowledge and specialized tools. It is highly recommended that a certified technician performs the installation to ensure proper function and safety.

5.1. Pre-Installation Notes

• Review all instructions thoroughly before beginning.
• Ensure the vehicle is on a level surface and properly supported with jack stands.
• Disconnect the battery's negative terminal.
• Gather all necessary tools.
• Verify that the drive shaft length is appropriate for your specific lift height and vehicle model (2-Door JK only).

5.2. Installation Procedure

1. Prepare Vehicle: Safely lift the front and rear of the vehicle and support it securely on jack stands. Ensure the parking brake is engaged and the transmission is in neutral.
2. Remove Existing Drive Shaft: Carefully unbolt and remove the factory rear drive shaft from both the transfer case and the differential. Be prepared for some fluid leakage from the transfer case.
3. Install New Pinion Flanges: This kit includes replacement flanges for the differential pinions. Install these new flanges onto the differential, ensuring they are properly seated and torqued to the manufacturer's specifications. These flanges are machined from solid billet steel and designed to accept standard mating flanges.
4. Install CV Drive Shaft: Position the new Rough Country CV drive shaft. Attach the transfer case end first, followed by the differential end. Ensure all bolts are started by hand to prevent cross-threading.
5. Torque Fasteners: Using a torque wrench, tighten all bolts connecting the drive shaft to the transfer case and differential to the vehicle manufacturer's specified torque values. Refer to your Jeep's service manual for exact specifications.
6. Lower Vehicle: Carefully lower the vehicle to the ground.
7. Post-Installation Checks:
• Check for proper clearance around the drive shaft, ensuring it does not contact any other components during suspension articulation.
• Verify that all fasteners are tight.
• Test drive the vehicle at low speeds initially, listening for any unusual noises or vibrations.

6. Maintenance

Regular maintenance is essential to ensure the longevity and safe operation of your Rough Country CV Drive Shaft and associated components.

• Fastener Checks: It is the buyer's responsibility to have all bolts and nuts checked for tightness after the first 500 miles of operation, and then again every 1,000 miles thereafter. Loose fasteners can lead to component failure and unsafe driving conditions.
• System Inspections: Wheel alignment, steering system, suspension, and driveline systems must be inspected by a qualified, professional mechanic at least every 3,000 miles. This ensures proper vehicle geometry and identifies any wear or damage early.
• Greasing: The CV joints are equipped with grease fittings. Periodically grease these fittings using an appropriate grease gun. The fittings are strategically placed out of the way of the transmission oil pan for easier access and to prevent grease from spreading unnecessarily.

7. Troubleshooting

This section addresses common issues that may arise after installation.

7.1. Persistent Vibrations

• Check Installation: Ensure all components are installed correctly and all fasteners are torqued to specification. An improperly installed drive shaft can cause vibrations.
• Pinion Angle: For lifted vehicles, proper pinion angle is critical for CV drive shaft operation. If vibrations persist, consult a professional to verify and adjust your vehicle's pinion angle.
• Balance: Although new drive shafts are balanced, damage during shipping or installation can affect balance. If all other checks fail, consider having the drive shaft professionally balanced.

7.2. Fitment Issues (Drive Shaft Length)

• Verify Lift Height: Confirm that your vehicle's actual lift height falls within the specified range (3.5" - 6" short arm or 2.5" - 6" long arm). Variances in lift kits or vehicle setup can affect required drive shaft length.
• Measure Before Installation: It is always recommended to measure the required drive shaft length for your specific vehicle configuration before final installation. Compare this to the collapsed (23.875") and extended (27.375") measurements of this product.
• Contact Support: If you encounter significant length discrepancies, contact Rough Country customer service for assistance.

8. Warranty & Support

8.1. Warranty Information

This Rough Country Rear CV Drive Shaft is backed by Rough Country's Limited Lifetime Replacement Warranty. For specific terms, conditions, and claim procedures, please refer to the official Rough Country warranty documentation or visit their website.

8.2. Customer Support

Should you have any questions, require technical assistance, or need to address warranty claims, please contact Rough Country customer support directly. Their contact information can typically be found on their official website or included with your product packaging.