INSTALLATION INSTRUCTIONS
Contents
1. RS176138 Loosely attach bracket to crossmember by threading the bolt into the nut bracket Repeat for other side 8 J Attach the aft braces to the installed brackets with the hardware from kit RS860474 See Illustration 14 9 J Tighten the aft brace mounting bolts to 80 FT LBS then the bracket to crossmember and bracket to subframe bolts to 65 FT LBS 10 LJ If applicable cut the corner of the skid plate to avoid contact with the aft brace bracket Reinstall the transfer case skid plate LOWER CONTROL ARM AND SHOCK ABSORBER INSTALLATION 1 LJ Loosely attach the lower control arms to the subframe with the hardware from kit RS860546 ALL BOLTS MUST GO IN FROM FRONT OF VEHICLE Refer back to Illustration 8 2 LJ Using OE nuts loosely install shock spacer RS176714 onto shock absorber with the angled plate of spacer on top and the notches in the spacer and upper shock mount lined up See Illustration 15a and Illustration 15b NOTE Notch will face toward the frame when installed on vehicle Top Angled 29 RS176714 Bottom Square 903 Illustration 13a Top Angled Plate OE Shock Absorber Illustration 15b 3 LJ Loosely attach shock spacer and shock assembly to upper shock mount using hardware supplied in kit RS860740 4 L Attach the shock absorber lower mount to the lower control arm with original hardware 5 L Snug all hardware and then tighten upper shock and shock spacer hardware to 33 ft Ibs and low2. application All block imprinting faces downward 20 LJ Raise the axle assembly until the riser block contacts the helper spring Be sure to align the hole in the block with the head of the center bolt NOTE If necessary CAREFULLY loosen the passenger side u bolt nuts another 1 2 turns Do not allow axle to twist or sway 21 LI Reinstall the U bolt spacer on top of the leaf spring Attach the spring to the axle with the NEW U bolts RS740014 original anchor plate and hardware from kit RS8102 Snug the nuts down but do not tighten 22 L Repeat steps 3 through 16 for the other side 23 LI Cross tighten the U bolt nuts evenly to 89 ft Ibs Recheck the torque on the center bolt 24 Install new Rancho shock absorbers or relocator kit RS6202 Tighten hardware to 85 ft Ibs BUMP STOP SPACER INSTALLATION 1 LJ Remove the bolt holding the bump stop to the frame bracket Remove the bump stop 2 LJ Place bump stop spacer RS176477 against frame bracket Attach original bump stop to spacer with the 10mm hardware from kit RS860582 See Illustration 28 Illustration 28 3 LJ Repeat steps 1 and 2 for the other side BRAKE LINE BRACKET INSTALLATION 1 LJ Remove the lower half of the brake hose bracket from top of differential housing Attach the new brake line bracket RS170014 to the rear differential with the OE hardware See Illustration 29 2 LJ Carefully reshape the OE hard brake lines and twist the plastic brake li
3. a high level of mechanical training and experience and have available to them all necessary tools and safety equipment This manual is not and should not be construed as an exhaustive list of all required safety measures Personnel should rely primarily on their training and experience as well as on their own common sense This Manual is to be read as a supplement to and must not be construed as a substitute for the owner s manual and or shop manual that originally accompanied the vehicle Refer to such use operation maintenance and safety manuals as necessary and especially after installation is complete to insure proper vehicle operation The following terminology has been used in this Manual l ACCIDENT Any event which could cause personal injury or death to anyone installing or using the suspension system as well as to passengers and bystanders or otherwise may result in property damage PRE INSTALLATION WARNINGS and INSTRUCTIONS N WARNING Only the following rim tire sizes may be used with this suspension system LT325 60R20 tire 20 x 9 in 10 offset wheel Use of any other rim tire combination increases the risk of a roll over and or accident resulting in severe personal injury or death 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 safel
4. an accident 6 LI Remove the nut from the outer tie rod stud Using Kent Moore Puller J 24319 B separate tie rod stud from knuckle 7 J Loosen the nuts at the upper ball joint Using Kent Moore J 42188 B Ball Joint Separator separate ball joints from knuckle 8 J Loosen the nuts at the upper and lower ball joints Using Kent Moore Ball Joint Separator Tool J 43631 and J 45851 Adapter separate ball joints from knuckle 9 1 Remove the upper and lower ball joint nuts Carefully remove the steering knuckle 10 LJ Index mark the half shaft and front differential flange for installation reference Illustration 3 Illustration 3 11 LI Remove the half shaft flange bolts Remove the half shaft 12 LJ Index mark the shock absorber upper mount coil spring and lower mount on the outward facing side Disconnect Electronic Suspension Control connector if applicable 13 LI Remove the shock absorber lower bolts Remove the three shock absorber upper mount to frame nuts Remove the shock absorber and spring assembly 14 L Remove the lower control arm pivot bolts Remove the lower control arm 15 LI Repeat steps 1 through 14 for the other side FRONT DIFFERENTIAL REMOVAL 4WD ONLY 1 LJ Remove the four bolts that attach the crossmember to the lower control arm rear pockets Remove the crossmember 2 LJ Using a reciprocating saw or cutoff wheel cut off the driver side crossmember bracket 3 5 from the inside
5. edge See Illustration 4 File or grind sharp edges and paint exposed metal Repeat for passenger side crossmember bracket NOTE frame coating can be removed with a putty knife and solvent such as mineral spirits l 3 50 Illustration 4 3 LJ Reference mark the front driveshaft U joint to the differential yoke Remove the four bolts and two retainers from the yoke and slide the shaft rearward to disengage Tape the bearing cap assemblies and secure the shaft out of the way See Illustration 5 4 LJ Disconnect the electrical connector from the passenger side wiring harness from the top and the vent hose from the driver side of the differential assembly See Illustration 6a and Illustration 6b Differential Electrical Connector x ay A TA i Ye i 7 n Differential Vent Hose tags 43 N By Sara E Nena n i a E 8h 5e la E c a a N 1 AOS Tati gt i Q TORINA S at COOR er y F EA q Bits y A WV 4 l 4 Watts 7 ey ah that fhe g 5 LI Support the front differential assembly with adjustable jack stands or floor jack 6 LJ Remove the four mounting bolts Carefully lower and remove the front differential NOTE The rear of the differential will have to be tilted down to clear the steering rack being visible to you resulting in sudden and unexpected steering failure and an accident 7 LJ Using a reciprocating saw or cutoff wheel cut off t
6. prescription or over the counter medication you must consult a medical professional regarding any side effects of the medication that could hinder your ability to work safely WARNINGS AND INSTRUCTIONS AFTER INSTALLATION 13 After installation is complete drive the vehicle slowly in an area free from heavy traffic for at least three 3 miles Likewise before traveling on any highways or at a high rate of speed drive the vehicle for ten ten miles on side roads at moderate speed If you hear any strange noise or feel unusual vibration if a component of the suspension system is not operating properly or if any warning lights illuminate or buzzers sound stop the vehicle immediately Identify the Cause and take any necessary remedial action 14 Confirm that all components of the vehicle including all lights headlights turn signals brake lights etc linkages accelerator etc electrical switches and controls windshield wipers and defoggers etc and other warning devices low tire pressure monitoring systems are fully operational 15 Your headlights will need to be readjusted before the vehicle is used on the roads Consult the vehicle owners manual 16 The speedometer and odometer will need to be recalibrated after installation See your dealer 17 Confirm proper rear view and side view while seated in the driver seat Install supplemental mirrors as necessary 18 Your original low tire pressure monitoring sy
7. the user expressly voluntarily and knowingly accepts and assumes these risks and agrees to hold Tenneco Inc and its related companies harmless to the fullest extent permitted by law against any resulting damages ITEM 1 2 ITEM PART RS176709B RS176132B PART RS740014 RS8051 RS10490 RS8102 RS7737 RS7738 RS176719 RS331 RS860185 RS770076 RS770025 RS860410 RS770091 RS770025 RS860569 RS770127 RS770128 RS7698 RS7712 RS7642 RS170014 RS15080 RS176477 RS860582 RS770157 RS770081 RS603508 RS603525 Box 1 of 5 DESCRIPTION Subframe Aft Brace Box 3 of 5 DESCRIPTION U Bolt 9 16 18 X 13 0 Hardware Kit 5 8 Pin Pin 625 X 875 Hardware Kit 9 16 Nut 9 16 18 Nylock Washer 9 16 SAE Leaf Shim Add A Leaf Hardware Kit Add A Leaf Install HHCS 3 8 24 X 7 5 Nut 3 8 24 Hi Nut Hardware Kit Center Bolt Bolt C Bolt 3 8 24 Nut 3 8 24 Hi Nut Hardware Kit Rear Brake HHCS M8 1 25x20mm Washer M8 HHCS 5 16 18 X 1 25 Nut 5 16 18 Toplock Washer 5 16 SAE Brake Line Bracket Block 4 x 625 Hole Rear Bumpstop Spacer Hardware Kit Rear Bump Stp SHCS M10 1 5x110mm HHCS M8 1 25X10mm Washer 3 8 SAE Lockwasher M10 MM M MM AMHAHAHAAHMHMHAHA NHMNAMHM AA ITEM PART RS860546 RS770040 RS7861 RS770030 RS770140 RS176138 RS176160 RS860474 RS420072 RS520041 RS603616 RS603605 RS78361 RS7723 RS176137 RS42702 RS176579 RS860743 RS770106 RS7911 RS7915 RS860547 RS770080 RS7700
8. 64 RS7657 RS7658 RS770095 136763624 RS42702 RS176712 RS176713 RS860550 RS770120 RS7915 RS7911 RS7719 RS176715 RS176716 RS860738 RS7906 RS77841 RS7710 RS602617 RS176235 RS860176 RS7634 RS7658 RS176717 RS860739 RS770080 RS770064 RS7657 RS176718 RS860751 RS176737 RS860748 RS96325 RS96326 RS89301 RS94180 Box 2 of 5 DESCRIPTION Hardware Kit Subframe HHCS M16 2 0x140mm Washer M16 Nut M16 2 0 Stover HHCS M16 2 0x120mm Rear Aft Brace Bracket Front Aft Brace Bracket Hardware Kit Aft Brace Sleeve 750 X 2 74 Bushing HHCS 1 2 13 X 4 0 HHCS 1 2 13 X 1 0 Nut 1 2 13 Stover Washer 1 2 SAE Nut Bracket 5 CC Thread Lok Swaybar Drop Brkt Hardware Kit Aft Brace Bracket HHCS M12 1 75 X 30MM Nut M12 1 75 Stover Washer M12 Hardware Kit Front Sway Bar HHCS M10 1 50x30mm Washer M10 Nut M10 1 50 Nylock HHCS M10 1 50x60mm 1 2 Loop Strap Tie Strap 5 CC Thread Lock Left Diff Drop Right Diff Drop Hardware Kit Front Diff HHCS M12 1 75x50mm Washer M12 Nut M12 1 75 Stover Washer 1 2 USS Brake Line Drop Lft Fnt Brake Line Drop Rt Fnt Hardware Kit Brake Line Drop HHCS 1 4 20 x 1 0 Washer 1 4 SAE Nut 1 4 20 Nylock Tie Rod End Axle Spacer Hardware Kit Axle Spacer Washer 3 8 HHCS M10 1 50x60mm Skid Plate Hardware Kit Skid Plate HHCS M10 1 50x30mm Washer M10 Nut M10 1 50 Nylock Rectangular Washer Wheel spacers for front OE wheels Spacer Front OE wheels Vent Hose Exten
9. INSTALLATION INSTRUCTIONS 89301 Rev D For Rancho Suspension Systems RS66301B Fits vehicles equipped with factory steel control arms RS66302B Fits vehicles equipped with factory aluminum control arms 2014 GMC Sierra Chevy Silverado 1500 4WD FMVSS 126 Certified Front Driveshaft Replacement Recommended Use Powertrain Industries P N 3194 9827 See Important Note P page 4 Fits OE 17 and up rims and spe BFG KM2 LT325 60R20 Tires ONLY WITH OE TIRES and 1 wheel spacer 20 x 9 in 10 offset wheels A WARNING Carefully read understand and follow the instructions provided in this manual and keep it in a safe place for future reference If you have any doubt whatsoever regarding the installation or maintenance of your Rancho suspension system please see your retailer for assistance or advice Failure to follow the warnings and instructions provided herein can result in the failure of the suspension system or can cause you to lose control of your vehicle resulting in an accident severe personal injury or death These instructions should remain in the vehicle glove box for future reference 1 89301 Rev D ZN warnine READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION Failure to follow the warnings and instructions provided herein can result in an accident severe personal injury or death PRELIMINARY This manual presumes that all persons installing this Suspension system have
10. Readjust headlamps certified alignment facility Recommended Alignment Specifications Caster degrees 4 5 1 0 Camber degrees 0 neg 3 Have vehicle Aligned at a Sum Toe In degrees 1 2 Please retain this publication for future reference See Important Note Q
11. contact the frame bracket of the lower control arm FAILURE TO PROVIDE CLEARANCE COULD CAUSE DAMAGE TO THE FRONT DIFFERENTIAL ASSEMBLY 4 J Reattach the differential electrical connector and install vent hose extension Use wire ties to reattach wiring harness to differential See Illustration 9 and Illustration 6 DRIVESHAFT INSTALLATION If front driveline vibration is present replace front driveshaft with Powertrain Industries double cardan front driveshaft P N 3194 9827 See Important Note P page 4 OE Driveshaft Installation 1 LJ Align reference marks and reattach the front driveshaft U joint to the differential yoke using OE retainers and bolts Tighten bolts to 22 ft lbs Blue Locktite is recommended on retainer bolts Double Cardan Driveshaft Installation 1 LJ Loosen the clamp attaching the slip yoke boot to the transfer case output shaft and slide boot forward off of output shaft 2 LJ Slide drive shaft slip yoke forward out of transfer case 3 L If not yet installed install and clamp boot on new driveshaft slip yoke Install but do not tighten boot output shaft clamp 4 LJ Align one of the flat sides of the new driveshafts center yoke with the transmission linkage cable and slide slip yoke into transfer case output shaft See Illustration 10 Illustration 10 5 LJ Attach the front driveshaft U joint to the differential yoke using OE retainers and bolts Tighten bolts to 22 ft los Blue Locktite is recom
12. d A Leaf under the spring pack and reinstall the helper spring Install a leaf shim RS176719 on each side of helper spring Temporarily secure the assembly together with a 3 8 x 7 5 bolt and nut from kit RS860185 Install a C clamp on each side of the bolt See Illustration 25 NOTE The 3 8 bolt will keep the center holes aligned as the spring pack is compressed 3 8X9 0 Bolt Add A Leaft RS176719 Illustration 25 15 LJ Alternating between C clamps compress the spring pack to within 4 inches Install nylon safety straps as shown in Illustration 26 16 LJ Carefully without disturbing the C clamps remove the 3 8 bolt Install the center bolt and nut from kit 860410 See Illustration 26 Do not compress the spring with the center bolt Center Bolt from kit 860184 Illustration 26 17 LJ Tighten the C clamps to fully compress the spring assembly Once compressed tighten the center bolt to 25 ft los If necessary hold the head of the center bolt with locking pliers 18 LI Remove the C clamps and straps 19 LJ Insert a block pin from kit RS8051 into the hole in the axle pad Place the new riser block RS15080 on the axle pad with the taller end of the block in the rear and the top hole offset to the front See Illustration 27 15 U bolt 7495 Spacer Riser Block ee a il P i E ae Anchor Plat le Anchor Piate Illustration 27 NOTE Ignore the up stamped on the riser block for this
13. d into differential housing Subframe RS176709B OO Aft Brace RS176132B 2 AFT BRACE INSTALLATION 1 LI Using a silicon spray lubricate two bushings RS520041 and one sleeve RS420072 from kit RS860474 Press the bushings and sleeve into aft brace RS176132B as shown in Illustration 14 2 LJ Repeat step 1 to install the rest of the bushings and sleeves 3 LJ Loosely attach the aft braces to previously installed brackets on subframe RS176709B with the hardware from kit RS860474 See Illustration 14 NOTE Both aft braces should angle slightly outward from front to rear 4 LJ If applicable remove the transfer case skid plate 5 LJ For 2WD vehicles temporarily attach aft brace bracket RS176138 to the aft brace as shown in Illustration 14 Using the slotted hole in the bracket as a template mark the mounting hole location on the transmission crossmember Drill a 1 2 hole at the marked location Remove bracket Repeat for other side 6 J Insert nut brackets RS176137 inside the crossmember as shown in Illustration 14 Align nut brackets over the drilled holes for 2WD vehicles and over the existing holes for 4WD vehicles 11 Aft Brace Bracket RS176160 2 eran Sleeve RS420072 4 Transmission Crossmember Nut Bracket RS176137 2 Aft Brace Bracket RS176138 2 Illustration 14 7 LJ Apply thread lock and insert a 1 00 bolt with washer from kit RS860474 through the slotted hole in bracket
14. d where you need to continue from M This suspension system was developed using the following tire amp wheel combination LT325 60R20 BFGoodrich KM2 tire 20 x 9 in 10 offset wheel Maximum total backspacing is 6 9 Before installing any other combination consult your local tire and wheel specialist OE wheels 17 and larger will fit this suspension system ONLY with OE tires and 4 front wheel spacer RS176737 1 2 13x1 75 HHCS tot oy oy L X Grade 5 Grade 8 L Length inches G Grade Marking bolt strength D Nominal Diameter inches T Thread Pitch threads per inch OO Gama P Property Class bolt strength D Nominal Diameter millimeters X Description hex head cap screw T Thread Pitch thread width mm X Description hex head cap screw Backspacing Negative Offset I Mounting Face Diameter WHEEL TERMINOLOGY E Width N Important information for the end user is contained 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 O The lifespan of Rancho products depends on many factors Improper use abuse or harsh use in general may compromise the integrity of the suspension system and significantly reduce its lifespan The suspension system is also subject to wear over time Have the suspension system r
15. egularly inspected and maintained by qualified mechanics If the inspection reveals any damage or excessive wear no matter how slight immediately replace or repair the component The suspension system must be regularly maintained in order to optimize its safe and efficient use The more severe the conditions under which the suspension system is operated the more often it must be inspected and maintained P If front driveline vibration is present replace front driveshaft with Powertrain Industries double kardan front driveshaft P N 3194 9827 powertrainindustries com 1 800 798 4585 STANDARD BOLT TORQUE amp IDENTIFICATION INCH SYSTEM METRIC SYSTEM 56 15FT4B 20FT4B Me 5FTIB 9FTLB 12FTLB P WFTAIB FTLB M8 18FTIB_ 23FTAB 2FTLB 76 TUB 60FTAB MiO STB 45FT AB 50FTLB 12 6FTAIB 90FTLB M2 STAB 75FT LB 90FTLB M6 FTAB 130FTAB Ml4 FTLB 120FTLB 145FTLB 5B 13FTAB 175FTAB Mi6 130FTLB 165FT LB 210 FT LB 280 FTLB Mi8 170FTIB 240 FT LB D T L X uzLasdonhes CX i L Length millimeters The driver of this suspension system recognizes and agrees that there are risks inherent in driving a vehicle with a lifted suspension system including but not limited to the risk that you could be involved in an accident that would not occur in an unmodified vehicle By his her purchase and use of this suspension system
16. ely use any of these tools stop the project and consult a qualified mechanic Chevrolet Service Manual Kent Moore Puller J 24319 B Kent Moore J 42188 B Ball Joint Separator Kent Moore Ball Joint Separator Tool J 43631 Kent Moore Adapter J 45851 Die Grinder Drill motor Assorted Drills 1 8 through 1 2 Torque Wrench 250 FT LB capacity 1 2 Drive Ratchet and Sockets O0OHUG0OHUGOOHULHO L Assorted Combination Wrenches Heavy Duty Jack Stands Wheel Chocks wooden blocks Hydraulic Floor Jack Center punch File Reciprocating Saw to modify frame Hammer Wire Brush to clean bracket mounting surfaces Silicone Spray Lubricant Brake fluid Tape Measure Safety Glasses wear safety glasses at all times ONOOUOUOUOUOUOUOUOUOUO0 J It is extremely important to replace coil springs 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 K 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 L The required installation time for this system is approximately 5 to 6 hours Check off the box LI at the beginning of each step when you finish it Then when you stop during the installation it will be easier to fin
17. er shock mounting bolts to 44 ft Ibs HALF SHAFT amp STEERING KNUCKLE INSTALLATION 1 LJ Remove the hub splash guard and ABS wire and bracket from the driver side steering knuckle Transfer parts to left steering knuckle RS176710 as shown in Illustration 16 12 A RS176710 Illustration 16 2 LJ Apply thread lock to bolts Attach the hub splash guard and ABS wire steering knuckle RS176710 with the original hardware Tighten the hub mounting bolts to 133 ft los Attach ABS wire to knuckle with the loop strap from kit RS860547 3 LJ Loosely attach left steering knuckle RS176710 to the lower ball joint with the original hardware 4 LJ Insert the half shaft into the hub Swing knuckle up to align with upper ball joint and half shaft to align with axle flange half shaft can rest on lower control arm Pull or pry upper control arm down to insert upper ball joint stud through knuckle and loosely attach with OE hardware Tighten the nut on the lower ball joint stud to 74 ft Ibs and the nut on the upper ball joint stud to 37 ft los See Illustration 17 Illustration 17 5 LI Place axle spacer RS176235 against the driver side differential flange Align flange marks and place the half shaft flange against the spacer Apply thread lock to bolts and attach the half shaft to the differential with the hardware from kit RS860176 See Illustration 18 Tighten the flange bolts to 58 ft Ibs i yp RS176235 I
18. he front lower flange of the differential See Illustration 6b and Illustration 7 For Skid Plate Clearance Illustration 7 FRONT DIFFERENTIAL DROP BRACKET INSTALLATION 4WD ONLY NOTE When attaching differential drop brackets face the open side of the bracket out and the larger end toward the front 1 LI Attach right drop bracket RS176713 to the passenger side differential frame mount with the original hardware See Illustration 8 Tighten nuts and bolts to 65 ft Ibs N WARNING Verify that the right drop bracket RS176713 or axle tube mount does not contact the steering rack or steering rack electrical connections Failure to provide clearance could cause damage to the steering rack resulting in sudden and unexpected steering failure and an accident pe i l r 7 4 A AA _Clearanc a Illustration 8 2 L Attach left drop bracket RS176712 to the driver side differential frame mount with the original hardware See Illustration 9 Tighten bolts to 65 ft Ibs A Vent Hose Connectoy A a Extension RS176712 Illustration 9 3 LI With the help of an assistant loosely attach the front differential to the installed drop brackets with the hardware from kit RS860550 Refer to Illustration 8 and Illustration 9 Install the larger USS washers on the passenger side axle tube mount Tighten the nuts and bolts to 65 ft Ibs NOTE Verify that the front differential and axle flanges do not
19. it RS860547 Loosely attach the sway bar drop brackets RS176579 to the frame rails at the original sway bar location See Illustration 20 2 LJ Using the washers and nuts from hardware kit RS860547 and OE bolts loosely attach the sway bar to drop brackets RS176579 wg 4 A Y 4 gt j RS176579 Illustration 20 3 LJ Loosely attach the sway bar end links to the lower control arms with the original end link assemblies NOTE If unable to attach sway bar to lower control arm wait until the vehicle is on the ground at ride height 4 J Tighten all sway bar drop bracket mounting bolts to 45 ft los Do not tighten sway bar end links to lower control arm LOWER VEHICLE 1 LJ Install front wheels and lower vehicle to ground If reinstalling OE wheels use 14 wheel spacers RS176737 see important note M Tighten the lug nuts to 140 ft Ibs 2 LJ Tighten the lower control arm pivot bolts to 107 ft Ibs Tighten the sway bar end link bolts to 22 ft lbs REAR SUSPENSION ADD A LEAF amp RISER BLOCK INSTALLATION 1 LJ Chock front wheels Raise the rear of the vehicle and support the frame with jack stands Remove the rear wheels 2 LJ Separate four ABS wire clips from frame and axle Remove clips from wires 3 LJ Separate ABS sensors from axle by removing torx bolts and sliding sensor out of axle The passenger side brake hose bracket may need to me separated from the parking brake bracket to remove passenger
20. llustration 18 6 LJ Install the half shaft washer and nut Tighten nut to 165 ft Ibs 7 LJ Attach tie rod end RS602617 to steering knuckle RS176710 with the supplied nut Tighten ball stud nut to 33 ft los Tighten jam nut to 22 ft los Thread OE jam nut and tie rod end RS602617 onto OE tie rod leaving 1 3 8 of threads exposed 8 LJ Install the brake rotor and rotor attachment torx screw Apply thread lock and attach the caliper to the knuckle with the Original mounting bolts Tighten the caliper mounting bolts to 129 ft Ibs 9 J Repeat steps 1 through 8 for passenger side BRAKE LINE DROP BRACKET INSTALLATION 1 LJ Install driver side brake line drop bracket RS176915 to upper control arm pocket using OE and supplied 14 hardware from kit RS860738 See Illustration 19 2 LJ Attach brake OE brake hose bracket to brake line drop bracket with supplied 14 hardware from kit RS860738 Bolt head must face to the front of the vehicle to allow clearance with upper control arm Insert ABS wire clip in brake line drop bracket and frame See Illustration 19 PAN UEC j i ee TER Ge ay 3 ee bath hype 5 ASAS eo 1 4 Hardware 5 OE Nardware ene Bracket 1 4 Hardware TE gee Bolttiead Facing Illustration 19 13 3 LJ Repeat steps 1 and 2 on passenger side with brake line drop bracket RS176916 SWAY BAR DROP BRACKET INSTALLATION 1 LJ Using the washers and shorter M10x30mm bolts from hardware k
21. mended on retainer bolts SUBFRAME INSTALLATION 1 LJ Cut 15 3 8 off the rear of the front skid plate Attach the front of the skid plate using OE hardware Attach the cut end of the skid plate to the frame crossmember using OE hardware and RS176718 washers Do not re install metal cross braces See Illustration 11 RS176718 Illustration 11 2 LI Attach aft brace brackets RS176160 to subframe with hardware form kit RS860743 Snug but do not fully 10 tighten See Illustration 14 3 LJ With the help of an assistant raise the subframe up into the lower control arm frame brackets Attach the subframe to the brackets with the original hardware Insert the forward bolts from the front and the aft bolt the rear Install OE cone washer under nut See Illustration 8 Tighten the subframe to bracket bolts to 107 ft Ibs NOTE If subframe contacts corners of front control arm frame brackets enlarge the inside corners using a round file or die grinder See Illustration 12 Trim skid plate more if necessary Illustration 12 4 LJ Install skid plate RS176717 to subframe using 10mm hardware from kit RS860739 The slots in the skid plate should be perpendicular to the slots in the subframe See Illustration 13 Illustration 13 NOTE Skid plate and differential should have at least 14 of clearance If required grind differential flange See Illustration 7 and Illustration 8 Only grind protruding flange DO NOT grin
22. ment are in proper condition and position 6 Give your work undivided attention Looking around carrying on a conversation and horse play are careless acts that can result in an error in installation and or serious injury 7 Install only tires approved by the United States Department of Transportation DOT approved Make sure the rim and tire size are properly matched 8 If any components of the vehicle or suspension system are damaged in any way during installation immediately replace the component 9 During installation carefully inspect all parts of the vehicle and replace anything that is worn or damaged 10 Nip points present the risk of the catching lacerating crushing and or amputating fingers hands limbs and other body parts during operations Always keep clear Wear protective gloves 11 Oil and hydraulic fluids are poisonous dangerous to health and are known to the State of California to cause cancer birth defects or other reproductive harm Do not inhale vapors or swallow Do not allow contact with the eyes or skin Should any oil or fluids be swallowed or inhaled or come into contact with the eyes immediately follow the safety precautions on the label or call a poison control center immediately Should any of the oil or fluids contact your skin immediately wash thoroughly 12 Never install the suspension system if you are under the effects of alcohol medications and or drugs If you are taking
23. ne retainers on the axle to allow OE brake line bracket to attach to RS170014 Attach the upper brake hose bracket to the top of bracket RS170014 using the 5 16 hardware from kit RS860569 NOTE On some models brake line bracket RS170014 may need to be bent up and back to connect OE brake bracket E 70014 aa Illustration 29 3 LJ Remove the driver side lower parking brake cable from the aft OE parking brake hanger wire 4 LJ Reinstall both fore and aft OE parking brake hanger wires See Illustration 30 16 CAE re ae 4 r ws 5 D gt Ba ae S y oe S a aa 3 E E A ws o r ra e 5 e N OM et ae Passenger Side Cable e y ui B ar Driver Side Cable Illustration 30 5 J Install rear wheels and lower vehicle to ground Tighten lug nuts to 140 ft Ibs FINAL CHECKS amp ADJUSTMENTS 6 LI 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 7 J With the suspension at maximum extension full droop inspect and rotate all axles and driveshafts 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 8 LJ Ensure that the vehicle brake system operates correctly If new brake hoses were installed verify that each hose allows for full suspension movement 9 LJ
24. r braces STEERING KNUCKLE SHOCK ABSORBER HALF SHAFT 4WD ONLY amp LOWER CONTROL ARM REMOVAL 1 L Remove ABS sensor wire clips from the upper control arm and frame Seperate the ABS sensor wire plug at the frame Remove the brake hose ABS wire bracket ABS Sensor Wire Detach Points a A P wh ay aY A Brake Hose ABS Wirg Bracket t A ce VA ve Ne e aE w zu N D N T Illustration 2 NOTE For vehicles equipped with Electronic Suspension Control Autoride separate brake hose from sensor link bracket 2 LJ Remove the brake caliper anchor bolts Remove the brake caliper and its mounting bracket as an assembly Hang the caliper assembly with wire or a tie wrap WARNING Do not allow the caliper to hang by the brake hose You could damage the hose without this damage being visible to you resulting in sudden and unexpected brake failure and an accident 3 L Label the brake rotor left or right Remove rotor attachment torx screw Remove the brake rotor 4 J Remove hub dust cap carefully using a small chisel and hammer to separate the edge of the cap from the hub Work around the outer edge of the cap where it meets the hub 5 LJ Remove the axle nut using a 36mm socket WARNING Do not hammer the ball studs to separate them from components You could damage the ball studs without this damage being visible to you resulting in sudden and unexpected failure of the ball studs and
25. rbers are required and must be purchased separately Reuse OE Strut RS999297 With RS7297 Spacer RS176714 RS5297 C Do not powder coat or plate any of the components in this system To change the appearance of components automotive paint can be applied over the original coating D 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 4 E Compare the contents of this system with the parts list in these instructions If any parts are missing contact the Rancho Technical Department at 1 734 384 7804 F 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 G Apply a drop of thread locking compound to all bolts during installation ZN CAUTION Thread locking compound may irritate sensitive skin Read warning label on container before use H Unless otherwise specified tighten all nuts and bolts to the standard torque specifications shown in the table on page 2 USE A TORQUE WRENCH for accurate measurements l 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 If you do not know how to saf
26. side ABS sensor 4 LJ Separate top and bottom halves of brake hose bracket at top of differential See Illustration 21 a Illustration 21 5 LI Remove both fore and aft parking brake hanger brackets om vee See Illustration 22 illustration 22 6 LJ Support the rear axle assembly with a floor jack Remove both rear shock absorbers Do not reuse OEM shock absorbers 7 J With the axle still being supported remove the anchor plate U bolts and spacer from driver side See Illustration 23 8 LJ Loosen passenger side U bolt nuts two turns each A WARNING Do not allow the axle to hang by any hoses or ABS cables You could damage the hoses or ABS cables without this damage being visible to you resulting in sudden and unexpected failure of a hose or ABS system and an accident 9 LI Carefully lower the rear axle and remove the original riser block Do not allow the axle to hang by any hoses or 14 cables U bolt a Spacer Illustration 23 10 LJ Clamp the spring assembly securely together with two C clamps as shown in Illustration 24 M elper Spring Illustration 24 11 L Loosen the nut and remove the center bolt If necessary hold the head of the center bolt with locking pliers Do not remove the spring clips 12 LI Carefully remove the C clamps and set the helper spring aside 13 LI Apply a small amount of grease to the top ends of Rancho Add A Leaf RS331 14 LI Place the Ad
27. sion Kit Tube Fitting Straight Barbed 3 16 Vent Hose Extension 8 0 Instructions RS66301B Information Pack ARMOFOBRH DMPNON FOND RH ANMNHANANS NO 4 4 2 4 2 1 1 1 4 8 4 2 1 1 1 4 8 4 2 2 1 12 12 1 1 4 8 4 2 1 2 1 1 1 1 1 Box 4 of 5 Box 5 of 5 ITEM PART DESCRIPTION QTY 2 RS176714 Shock Spacer L R 18 RS860740 Hardware Kit Shock Spacer ITEM PART DESCRIPTION RS770080 HHCS M10 1 50x30mm RS770064 Washer M10 RS66301B ONLY RS7657 Nut M10 1 50 Nylock RS860741 Steering Knuckle Fits Steel Control Arms RS176710 Knuckle Lft Fits Steel Control Arms RS176711 Knuckle Rt Fits Steel Control Arms RS66302B ONLY RS860742 Steering Knuckle Fits Alum Control Arms RS176720 Knuckle Lft Fits Aluminum Control Arms RS176721 Knuckle Rt Fits Aluminum Control Arms FRONT SUSPENSION VEHICLE PREPARATION amp SWAY BAR REMOVAL 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 1 Record these measurements in the space provided below illustration 1 2 LJ Disconnect the sway bar from the lower control arms Save end links for reuse 3 L Raise the front of the vehicle and support the frame with jack stands Remove the front wheels and set them aside 4 LJ If applicable remove the front skid plate and crossmembe
28. stem may be re installed in your new wheels However if you choose to purchase a new system see your dealer to have them properly calibrated Proper tire pressure is critical to safe operation of the vehicle OPERATION 19 Because it has been modified the vehicle will not handle turn accelerate or stop in the same manner as an unmodified vehicle In addition the crash protection systems designed in the vehicle may operate differently from an unmodified vehicle For example turning and evasive maneuvers must be executed at a slower rate of speed Further there is a greater risk that the vehicle could roll over These differences could result in an increased possibility of an accident personal injury or death Learn the vehicle s operations and handling characterizes and drive accordantly IMPORTANT NOTES A 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 B The components of Rancho s suspension system are designed as a single integrated system To avoid compromises in terms of safety performance durability or function do not substitute Rancho components with components manufactured by other companies Use of other components will result in the forfeiture of any type of warranty on the vehicle suspension system New Rancho shock abso
29. y 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 1 Service and repair tasks require specialized knowledge training tools and experience General mechanical aptitude may not be sufficient to properly install this suspension system If you have any doubt whatsoever regarding your ability to properly install the suspension system please consult a qualified mechanic 2 Your brake lines and fuel lines should remain undisturbed during and after installation If you think you need to modify these components in any way you are mistaken You are installing the lift improperly and will be creating a significant risk of an accident In case of any doubt consult a qualified mechanic 3 If any component does not fit properly something is wrong You are installing the lift kit improperly and will be creating a significant risk of an accident Never modify any component of the vehicle or suspension system except as instructed herein Do not continue with installation until you have identified the problem 4 Several of the procedures described herein require at least two 2 persons to safely complete the task If you have any doubt about your ability to complete any operation by yourself always ask for help from a qualified assistant 5 Before starting any operation confirm that all personal safety devices and safety equip
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