INSTALLATION INSTRUCTION
Contents
1. Ibs 3 O Remove mudguards and trim wheel wells if necessary Refer to Important Note N 4 Turn the front wheels completely left then right Verify adequate tire wheel and brake hose clearance Inspect steering and suspension for tightness and proper operation 10 5 LJ With the suspension at maximum extension full droop inspect and rotate all axles and drive shafts Check for binding and proper slip yoke insertion The slip yoke should be inserted a minimum of one inch into the transfer case and or transmission 6 LI Ensure that the vehicle brake system operates correctly If new brake hoses were installed verify that each hose allows for full suspension movement 7 LJ Readjust headlamps Have vehicle Aligned at a certified alignment facility Recommended Alignment Specifications Caster degrees 2 17 to 3 07 Camber degrees 5 to 5 Sum Toe In inches 12 to 20 Please retain this publication for future reference See Important Note O2. 108 ft lbs See illustration 8 If applicable install a new cotter pin Illustration 8 6 LJ Install new Rancho shock absorber Do not reuse original shock absorber OE Bump Stop 7 O Align droop stop with control arm pad Tighten nut securely See illustration 9 Illustration 10 Lote 3 LJ Enlarge the mounting hole in the lower control 7 Eg arm to 1 2 See illustration 11 File the front rn ee Droop Stop outside corner of the OE bump stop to provide T ee e N clearance for the sway bar Illustration 9 OE Bump oh ae File Here 8 LJ If applicable slide the protective sheaths on Qo the ABS cable to the locations shown in a illustration 9 Install the loop strap from hardware kit 860423 1 2 Hole 9 LJ Place a washer between the loop strap and control arm Attach the ABS cable to the front of the control arm with the 1 4 hardware from kit 860423 illustration 9 Tighten nut and bolt securely 10 LJ Tighten the adjusting nut on the torsion bar Illustration 11 anchor bolt to the corresponding measurement from illustration 3 4 L Place bump stop on spacer 180004 as shown in illustration 11 NOTE Adjustment of anchor bolt nut is in a tightening direction only Do not adjust by loosening 5 LI Attach spacer and bump stop to lower control the nut Final height adjustment is done with kit arm with the standoff nut from hardware kit installed and vehicle on the ground 860423 Ti
3. Refer to Important Note A Tighten the bolts supplied with ball joint to 12 15 ft Ibs 7852 4 520053 4 4 Illustration 1 2 LI Apply a film of grease to the inside of the tubes on upper control arm 180001 3 LJ Insert two bushings 520053 4 into each tube as shown in illustration 1 4 LI Apply a film of grease to the inside of the installed bushings Insert sleeve 420053 into each bushing assembly 5 LI Repeat steps 1 through 4 to assemble Rancho upper control arm 180002 VEHICLE _ PREPARATION amp TORSION _ BAR UNLOADING 1 LJ Park the vehicle on a level surface Set the parking brake and chock rear wheels Measure and record the distance from the center of each wheel to the top of the fender opening See illustration 2 2 LJ Raise the front of the vehicle and support the frame with jackstands Remove the front wheels and set them aside Illustration 2 3 LJ Measure and record the length of each torsion bar anchor bolt See illustration 3 As a precaution label the torsion bars left and right Paint matching marks on the torsion bar and the corresponding lower control arm ji LLIN Illustration 3 4 LJ Remove the tension on both of the torsion bars by loosening the lock nuts and the adjusting nuts Ensure that the twisting force is eliminated from the torsion bars NOTE It is not necessary to remove the torsion bars or the anchor bolts SHOCK ABSORBER UPPER CON
4. INSTALLATION INSTRUCTION FOR RANCHO SUSPENSION SYSTEM RS 6592 FRONTIER 88092 Rev C NISSAN XTERRA amp 2WD READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION RANCHO IMPORTANT NOTES WARNING This suspension system will enhance the off road performance of your vehicle It will handle differently both on and off road from a factory equipped passenger car or truck Failure to drive this vehicle safely may result in serious injury or death to the driver and passengers ALWAYS WEAR your seat belts REDUCE your speed and AVOID sharp turns and other abrupt maneuvers A New upper ball joints are required and must be purchased separately to complete this installation The following ball joint part numbers will fit the Rancho Upper Control Arm Moog K9022 Elgin 1K9022 McQuay Norris FA1227 TRW Federal Mogul 10424 amp Nissan 4011001G25 B Before installing this system have the vehicle s alignment and frame checked by a certified technician The alignment must be within factory specifications and the frame of the vehicle must be sound no cracks damage or corrosion C Do not install a body lift kit with this suspension system or interchange Rancho components with parts from another manufacturer Use the appropriate Rancho shock absorbers Contact your local representative for the correct applications D Do not chrome cadmium or zinc plate any of the components in this s
5. TROL ARM amp DROOP STOP REMOVAL 1 LJ Support the lower control arm with a jack 2 LJ Remove the nuts and bolts attaching the shock to the frame bracket and lower control arm See illustration 4 Illustration 4 LI Remove the shock absorber LI If applicable separate the ABS cable from the upper control arm L Loosen upper ball joint nut Separate knuckle from upper ball joint with removing tool HT72520000 See illustration 5 Illustration 5 LI Remove the upper control arm adjusting bolts See illustration 6 Remove the upper control arm Illustration 6 Remove the droop stop from the frame bracket LI Repeat steps 1 through 7 for the other side DROOP STOP UPPER CONTROL ARM amp SHOCK ABSORBER INSTALLATION l LI Loosely attach Rancho droop stop 1412 to the frame bracket with the hardware from kit 860419 LI Place Rancho upper control arm 180001 for driver side or 180002 for passenger side under the ABS cable and into the frame brackets LI Insert a washer from kit 860422 into the frame bracket on each side of the bushing See illustration 7 Attach the bushing assembly to the bracket with the original adjustment bolt Illustration 7 o LI Repeat step 3 for the other frame bracket and bushing Center adjustment cams but do not tighten the adjustment bolts until the vehicle is at normal ride height LI Attach upper ball joint to knuckle Tighten the ball joint nut to 58
6. ackle Use the original hardware for the front bracket and the 12mm hardware from kit 860426 for the rear shackle 16 LJ Enlarge the U bolt holes in the original spring pad to 17 32 17 LJ Align the head of the center bolt with the hole in the axle pad Reinstall the original spring pad See illustration 17 Attach the axle to the leaf spring with the new U bolts and the hardware from kit 8011 Tighten the U bolt nuts diagonally to 72 80 ft lbs NOTE The amount of U bolt threads exposed should be equal after tightening the nuts Trim the U bolts if they extend more than 1 2 below the spring pad 18 LJ Install new Rancho shock absorber Tighten mounting nuts to 30 37 ft Ibs 19 LI Remove the clamp passenger side only attaching the sway bar to the rear axle 20 LI Remove the upper and lower mounting hardware from the right rear shock absorber passenger side 21 LI Move the sway bar aside and remove the right rear shock 22 LJ Repeat steps 5 through 17 to install the add a leaf and shackle on the passenger side NOTE Before the leaf spring front eyebolt can be removed it may be necessary to remove the fuel tank guard Sleeve 420054 Ne U Bolt 7414 cC Rear NSS Leaf Spring ia Frame Bracket Shackle 180003 o i wp M12 x 130mm O epg M12 x 110mm B Add A Leaf 334 Spring Pad 17 32 Hole 4 Illustration 17 23 LJ Install new Rancho shock absorber Tighten mount
7. ained in the consumer installer information pack If you are installing this system for someone else place the information pack on the driver s seat Please include the installation instructions when you finish P Thank you for purchasing the best suspension system available For the best installed system follow these instructions If you do not have the tools or are unsure of your abilities have this system installed by a certified technician RANCHO SUSPENSION IS NOT RESPONSIBLE FOR DAMAGE OR FAILURE RESULTING FROM AN IMPROPER OR MODIFIED INSTALLATION STANDARD BOLT TORQUE amp IDENTIFICATION INCH SYSTEM METRIC SYSTEM Class 9 8_ Class 10 9 Class 12 9 5 16 15 FT LB 20 FT LB 30 FT LB 35 FT LB 7 16 45 FT LB 60 FT LB M10 M6 M8 5 FT LB 9 FT LB 12 FT LB M8 18FTLB 23 FT LB 27 FT LB 32 FT LB 45 FT LB 50 FT LB 65 FT LB 90 FT LB 55 FT LB 75 FT LB 90 FT LB 9 16 95 FT LB 130 FT LB 85 FT LB 120 FT LB 145 FT LB 135 FT LB 175 FT LB 130 FT LB 165FT LB 210 FT LB 185 FT LB 280 FT LB 170 FT LB 240FT LB 290 FT LB 1 2 13x1 75 HHCS z Gai moe oe cP oe U D T L X Grade 5 Grade 8 L G Grade Marking bolt strength L Length inches D Nominal Diameter inches X Description hex head cap screw T Thread Pitch threads per inch M12 1 25x50 HHCS ae ek r D T L X P Property Class bolt strength D Nominal Diameter millimeters T Thread Pitch thread width mm W L Length mill
8. ghten the nut to 12 16 ft Ibs 11 LJ Repeat steps 1 through 10 for the other side 6 LJ Repeat for other side 7 LI Apply grease to the upper control arm BUMP STOP SPACER INSTALLATION bushings through the grease fittings 1 LJ Remove the nut attaching the bump stop to the 8 LJ Install front wheels and lower vehicle to the lower control arm See illustration 10 ground Tighten lug nuts to 87 108 ft Ibs 2 LJ Remove the bump stop 9 LJ Tighten the upper control arm adjustment bolts to 72 87 ft lbs REAR SUSPENSION ADD A LEAF amp SHACKLE INSTALLATION l LC Chock front wheels Raise the rear of the vehicle and support the frame with jack stands Remove rear wheels and set them aside Support the rear axle with a floor jack Disconnect the end links from the sway bar Remove the upper and lower mounting hardware from the left rear shock absorber driver side See illustration 12 L Remove the left rear shock Remove the U bolt nuts spring pad and U bolts Disconnect the leaf spring shackle and remove the front eyebolt See illustration 13 Shackle AB Ba et iar Baz Rear Axle S p y Front Bolt 6 OR is f er D VAn Spring Pad PA 6 a a ie es aE eo amp gt eS amp Illustration 13 emove the leaf spring ie F wv Gi f Illustration 12 Frame Bracket A t amp 7 LJ Hold the spring assembly securely togethe
9. imeters X Description hex head cap screw C Cii P N 180001 180002 334 860253 130014 860419 1412 180004 420053 920053 4 860422 7852 860423 770095 770093 860424 DESCRIPTION CONTROL ARM LEFT CONTROL ARM RIGHT ADD A LEAF BOXED SUB ASSEMBLY Bump Stop Spacer Rear Front Droop Stop Hardware Kit Droop Stop 5 16 24 Nyloc Nut 5 16 SAE Flat Washer Bump Stop Spacer Front Sleeve Bushing Bushing Washer Kit Washer Front Hardware Kit 1 2 Loop Strap Standoff Nut 1 4 20 x 75 HHCS 1 4 20 Nyloc Nut 1 4 SAE Flat Washer Rear Bump Stop Hardware Kit M10 1 25 x 50 HHCS 10mm Flat Washer 10mm Lock Washer PARTS LIST QTY N AARAA NDNDNNN NN CORA WOBNNNM NDP N P N 860254 180003 420054 860410 770091 770025 860426 94180 780281 88092 94119 94177 DESCRIPTION BOXED SUB ASSEMBLY Shackle Sleeve Thread Lock U bolt U bolt Hardware Kit 1 2 20 Nyloc Nut 1 2 SAE Flat Washer Center Bolt Hardware Kit 3 8 24 x 4 5 Center Bolt 3 8 24 Hi Nut Shackle Hardware Kit M12 1 75 x 130 HHCS M12 1 75 x 110 HHCS M12 1 75 Nyloc Nut 12mm Flat Washer Information Pack Rancho Decal Instructions Consumer Warranty Information Warning Sticker QTY a SS em OO BN ND mM MH DS CO CO BN KM PLH gt 3 FRONT SUSPENSION UPPER CONTROL ARM ASSEMBLY 1 LJ Attach new ball joint purchased separately to Rancho upper control arm 180001 as shown in illustration 1
10. ing nuts to 30 37 ft lbs 24 LI Reinstall the sway bar clamp and end links Tighten the sway bar bolts to 32 41 ft lbs and the end link nuts to 30 35 ft Ibs BUMP STOP SPACER INSTALLATION 1 LJ Remove the bump stop attached to the frame rail above the rear axle See illustration 18 Frame Rail Rear Axle Bump stop Illustration 18 2 Place spacer 130014 against frame rail at the bump stop location See illustration 19 Attach the original bump stop to the spacer and frame with the 10mm hardware from kit 860424 Tighten the bolts to 12 16 ft Ibs Frame Rail Spacer 130014 Rear Axle Bump stop Illustration 19 LI Repeat spacer installation for the other side L Install rear wheels and lower vehicle to the ground Tighten the lug nuts to 87 108 ft Ibs 5 LJ Tighten the leaf spring front pivot bolts to 86 108 ft Ibs and the rear shackle bolts to 58 72 ft Ibs FINAL CHECKS amp ADJUSTMENTS 1 J Jounce suspension and move the vehicle to normalize ride height If you prefer optimum clearance adjust the tension on the torsion bars until the left front and right front measurements are both 22 inches Refer back to illustration 2 If you prefer optimum ride control set the front measurements to 21 5 inches NOTE Adjust the nut on the anchor bolt in a tightening direction only Do not adjust the height by loosing the nut 2 Tighten the lock nuts on the anchor bolts to 22 30 ft
11. r with two c clamps illustration 14 or place the assembly in a bench vise i Helper Spring Illustration 14 8 LI Mark the front of the helper spring for installation reference Remove the center bolt 9 LI Carefully remove the C clamps or remove the assembly from the bench vise Set the helper spring aside 10 LJ Lightly grease the tip sliders of new add a leaf 334 Place the add a leaf on the bottom of the existing spring pack and reinstall the helper spring See illustration 15 _ Center Bolt 770091 Nut 770025 Add A Leaf 334 Helper Spring Illustration 15 11 LJ Insert a new center bolt 770091 from kit 860410 Loosely secure the assembly with the supplied nut 770025 Do not compress the spring with the center bolt 12 LJ Compress the spring assembly with two C clamps illustration 16 or a bench vise Tighten the center bolt nut to 25 ft Ibs 13 LJ Remove the C clamps or remove the assembly from the bench vise NOTE Trim the new center bolt if the threads extend more than 1 2 beyond the nut Center Bolt 770091 m i a tae eee eee ae e E j men aa g P Add A Leaf 334 2 Helper Spring Illustration 16 14 LJ Insert sleeve 420054 into the leaf spring rear frame bracket See illustration 17 Attach shackle 180003 to the frame bracket with the 12mm hardware from kit 860426 15 LJ Loosely attach the leaf spring to the front bracket and rear sh
12. rive Ratchet and Sockets Assorted Combination Wrenches Heavy Duty Jack Stands Wheel Chocks wooden blocks Hydraulic Floor Jack Center punch File Large C Clamps or Bench Vise Hammer Wire Brush to clean bracket mounting surfaces Grease Tape Measure Safety Glasses wear safety glasses at all times EE mF 9 WY E a 1 WO E E E K It is extremely important to replace torsion bars CV flanges and front drive shaft pinion relationships as original Be sure to mark left right front rear and indexing of mating parts before disassembly A paint marker or light colored nail polish is handy for this L Suspension components that use rubber or urethane bushings should be tightened with the vehicle at normal ride height This will prevent premature failure of the bushing and maintain ride comfort M The required installation time for this system is approximately 4 to 5 hours Check off the box M at the beginning of each step when you finish it Then when you stop during the installation it will be easier to find where you need to continue from N This suspension system was developed using the following tire amp wheel combination 265 75 R16 tire 16 x 8 wheel with 5 5 inches of wheel backspacing To provide clearance removing the mudguards and trimming the wheel wells is necessary Before installing any other combination consult your local tire and wheel specialist O Important information for the end user is cont
13. ystem To change the appearance of components enamel paint can be applied over the original coating E Each hardware kit in this system contains fasteners of high strength and specific size Do not mix hardware kits or substitute a fastener of lesser strength See bolt identification table on page 2 F Compare the contents of this system with the parts list in these instructions If any parts are missing contact the Rancho Technical Department at 1 800 574 6257 G Install all nuts and bolts with a flat washer When both SAE small OD and USS large OD washers are used in a fastener assembly place the USS washer against the slotted hole and the SAE washer against the round hole H Apply a drop of thread locking compound to all bolts during installation CAUTION Thread locking compound may irritate sensitive skin Read warning label on container before use Unless otherwise specified tighten all nuts and bolts to the standard torque specifications shown in the table below USE A TORQUE WRENCH for accurate measurements J Some of the service procedures require the use of special tools designed for specific procedures The following tools and supplies are recommended for proper installation of this system M Nissan Xterra Frontier Service Manual Upper Ball Joint 4011001G25 see note A Ball Joint Remover HT72520000 Drill motor Assorted Drills 1 8 through 17 32 Torque Wrench 250 FT LB capacity 1 2 D
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