Installation Instructions
Contents
1. 5 CJ Tighten the Track bar nut and bolt to 120 ft Ibs 6 J Tighten the upper suspension arm bolts to 75 ft Ibs he dl Er gF ape i pins ae indians Rear Suspension REAR SUSPENSION 6 J Carefully lower the rear axle until the coil springs are free from the upper mount seat Remove the coll springs SHOCK ABSORBER amp COIL SPRING REMOVAL CAUTION Do not allow the axle to hang by any hoses or 1 C Chock front wheels Disconnect the track bar from cables the frame bracket Disconnect the sway bar end links from the axle brackets SUSPENSION ARM REPLACEMENT 2 J Raise the rear of the vehicle and support the frame with jack stands Remove the rear wheels 1 C Remove the driver side lower suspension arm nut and bolt from the axle bracket 3 LJ Remove bolts and separate the brake hoses from the frame rails If necessary disconnect any vent hoses and 2 CI Remove the flagnut at the frame rail bracket electrical wiring from the axle 4 C Remove the bolts from the brake cable hanger above the rear axle Remove the hanger from the cables 5 CI Support the rear axle with a floor jack Remove the Shock absorber upper mounting bolts Remove the lower nut and bolt from the axle bracket Remove the shock absorbers Remove the lower suspension arm 3 C Remove the driver side upper suspension arm flagnut and bolt from the axle bracket 4 J Remove the flagnut and bolt at the frame rail bracket Remove the upp2. Pitman Arm Puller C 4150 A Steering Linkage Puller C 3894 A Torque Wrench 250 FT LB capacity hammer 1 2 Drive Ratchet and Sockets Combination Wrenches 3 8 16 Tap File Hydraulic Floor J ack Heavy Duty ack stands Wheel Chocks Wooden Blocks Anti seize compound Safety Glasses Wear safety glasses at all times EEE SEE Ee ENE ES J 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 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 This suspension system was developed using a BF Goodrich Mud Terrain T A KM 35 x 12 50 x 18 D tire on a 18 x 9 wheel with 4 5 of backspacing Total backspacing is 5 9 Before installing any other combination consult your local tire and wheel specialist Actual tire size varies by manufacturer Se eS P 1 Total Backspacing Backspacing Mounting Face Diameter WHEEL TERMINOLOGY l Width e M The required installation time for this system is approximately 4 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
3. Short M12 1 75 x 80 HHCS M12 1 75 Stover Nut M12 Washer e ka NU 6 lt 0 z PARTS LIST QTY P N 860625 1 602627 1 770196 2 94180 2 780281 2 88517 2 94119 1 94177 1 1 176440B 4 176442 2 176444 176445 4 176523 1 176524 12 860575 1 420067 1 2 1 1 2 1 1 2 1 1 2 2 1 8 4 4 694 1 817 1 2 a DESCRIPTION Rod End Kit 7 8 14 Male Rod End 15 M12 High misalignment Sleeve Information Pack Rancho Decal Instructions Consumer Warranty Information Warning Sticker Box 2 of 3 Rear Track Bar Bracket Rear Brake Line Bracket Rear Bump Stop Spacer Rear Sway Bar Bracket Lower Suspension Arm Rear Upper Suspension Arm Rear Rear Hardware Kit Sleeve M14 2 00 x 80 HHCS M14 2 00 Stover Nut M14 Washer M12 1 75 x 30 HHCS M12 1 75 Stover Nut M12 Washer M10 1 50 x 50 HHCS M10 Washer M8 1 25 x 20 HHCS M8 1 25 Nylock Nut M8 Washer 1 4 20 x 75 HHCS 1 4 20 x Stover Nut 1 4 SAE Washer Box 3 of 3 Front Coil Spring Rear Coil Spring O mi lt ll ll ee el RAN mm cok BOB B B BN PRN PR RF RDN NN NF N WY Drag Link Track Bar K i i a Ml Pei ir ee r a aa ai e per is t X ai O i i Pi i F LE i T End Link Front Suspension FRONT SUSPENSION SHOCK ABSORBER amp COIL SPRING REMOVAL 1 C Park vehicle on a level surface Set the parking brake and chock rear wheels Disconnect the negative ground cable f
4. a fastener of lesser strength or mix one hardware kit with another D Apply THREAD LOCKING COMPOUND to all bolts during installation One drop on the exposed threads of each bolt before installing the nut is sufficient to provide an adequate bond CAUTION Thread locking compound may irritate sensitive skin Read warning label on container before use E 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 F Unless otherwise specified tighten all bolts to the standard torque specifications listed at the end of the note s section USE A TORQUE WRENCH for accurate measurements G Rancho parts come with a protective coating Do not powdercoat chrome cadmium or zinc plate any of the components in this system If you wish to change the appearance of components enamel paint can be applied over the original coating H Do not weld anything to these components and do not weld any of these components to the vehicle unless specifically stated in the instructions If any component breaks or bends contact your local Rancho dealer or Rancho for replacement parts 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 kit 1 J eep Service Manual
5. easier to find where you need to continue from N Welding on a vehicle creates an electrical charge throughout the body and frame Disconnect the vehicle s battery prior to any welding Place welding ground clamps as near as possible to the weld Never use a vehicle suspension component as a welding ground point O 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 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 IS NOT RESPONSIBLE FOR DAMAGE OR FAILURE RESULTING FROM AN IMPROPER INSTALLATION Development Tire Size actual Optional Tire Size actual Wheel Size backspacing Compatible With OE Wheels 35x12 5xR18 34 8 x12 5 37x12 5xR18 36 3 x12 8 18x9 4 5 2 Fitment of the optional tire size may require trimming to provide proper clearance STANDARD BOLT TORQUE SPECIFICATIONS INCH SYSTEM Bolt Size METRIC SYSTEM Class 9 8 Class 10 9 Class 12 9 5 16 15 FT LB 20 FT LB 5 FT LB 9 FT LB 12 FT LB 3 8 30 FT LB 35 FT LB 18 FT LB 23 FT LB 27 FT LB 1 2 65 FT LB 90 FT LB 55 FT LB 75 FT LB 90 F
6. is at normal ride height 13 LI Repeat steps 1 through 12 for the passenger side j vvasker Illus 11 COIL SPRING amp SHOCK ABSORBER INSTALLATION 1 J Place the new coil springs 817 onto the axle pads Align upper pigtails towards the front of the vehicle Raise the axle until the coil springs seat on the upper isolators See illustration 12 Illus 12 NOTE When installing coil springs make sure that the rubber isolator is positioned in the upper mount and the Small egg shaped coil end is at the bottom 2 C Attach new Rancho rear shocks to the upper mounting brackets with the original bolts Tighten bolts to 37 ft Ibs 3 LJ Loosely attach shocks to the axle brackets with the Original hardware TRACK BAR BRACKET INSTALLATION 1 C Loosely attach track bar bracket 176440B to the track bar with the original hardware Insert bolt from front to rear See illustration 13 3 illus 13 2 I Place track bar bracket 176440B over the original frame bracket The front edge of the new bracket should fit inside the original bracket 3 J Insert the sleeve from kit 860575 and attach track bar bracket 176440B to the frame bracket with the 14mm hardware from kit 860575 See illustration 13 4 J Using an existing hole attach the top of bracket 176440B to the frame bracket with the 12mm hardware from kit 860575 Tighten the 12mm and OE bracket hardware to specifications NOTE Do not tighten
7. the original track bar bolt until the vehicle is at normal ride height SWAY BAR amp BRAKE LINE BRACKET INSTALLATION 1 J Disconnect the sway bar from the frame rail 2 C Insert sway bar bracket 176445 between the sway bar and the frame rail See illustration 14 11 Illus 14 3 C Attach sway bar to frame rail with the 10mm hardware from kit 860575 Tighten bolts to 35 ftlbs 4 Attach brake line bracket 176442 to the frame rail with the original brake line bolt See illustration 14 5 CI Attach brake line to the inside of bracket 176442 with the 1 4 hardware from kit 860575 Tighten nuts and bolts to 12 ft lbs 6 C To provide clearance for the end link grind the axle bracket at the locations shown in illustration 15 7 Temporarily disconnect lower shock mount Drill a 12mm hole 1 above and 1 4 toward the rear of the original end link mounting hole See illustration 15 Reinstall shock fi Heie i Illus 15 8 CI Using the new hole attach end link to axle bracket with the original hardware Tighten nut and bolt to 40 ft Ibs 9 I Repeat steps 1 through 8 for the other side BUMP STOP BRACKET INSTALLATION 1 C Using the original holes on the axle pad attach bump stop bracket 176444 to the axle with the 8mm hardware from kit 860575 See illustration 16 Illus 16 2 J Repeat for other side 3 1 Install rear wheels and lower vehicle to the ground Tighten lug nuts to 80 11
8. 0 FT LBS 4 CI Tighten the track bar bolts to 120 ft Ibs Tighten the shock absorber lower mounting bolts to 56 ft Ibs Tighten the suspension arm bolts to 125 ft Ibs 5 CI Reconnect the battery ground cable 12 FINAL CHECKS amp ADJUSTMENTS 1 C Turn the front wheels completely left then right Verify adequate tire wheel brake hose and ABS wire Clearance Inspect steering and suspension for tightness and proper operation 2 CI 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 3 J Ensure that the vehicle brake system operates correctly If new brake hoses were installed verify that each hose allows for full suspension movement 4 Readjust headlamps manufacturer s specifications Have vehicle Aligned to Alignment Specifications Adjustment Preferred Range Caster 5 0 1 0 Camber fixed angle 0 25 0 63 Toe In each wheel 0 15 015 Thrust Angle 0 0 15 NOTE The length of the upper suspension arms may be adjusted to fit an aftermarket driveshaft Consult a driveline specialist Please retain this publication for future reference See Important Note O
9. 88517 RevA INSTALLATION INSTRUCTION Jeep Wrangler JK 88517 RevA READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION 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 Extreme care must be used to prevent loss of control or vehicle rollover during abrupt maneuvers 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 Before installing this system have the vehicle s alignment and frame checked at a state approved facility The alignment must be within factory Specifications and the frame must be sound no cracks damage or corrosion B Do not install a body lift kit with Rancho s Suspension system or interchange parts from this system with components from another manufacturer Use the following Rancho shock absorbers with this system RS5000 RS9000X Front Rear RS5331 RS5332 R599331 RS 99332 C Compare the contents of this system with the parts list In these instructions If any parts are missing including fasteners contact the Rancho Technical Department at 1 734 384 7804 Each hardware kit in this system contains fasteners of high strength and specific size Do not substitute
10. T LB 7 16 45 FT LB 60 FT LB 32 FT LB 45 FT LB 50 FT LB 9 16 95 FT LB 130 FT LB 85 FT LB 120 FT LB 145 FT LB 5 8 135 FT LB 175 FT LB 130 FT LB 165FT LB 210 FT LB 3 4 185 FT LB 280 FT LB 170 FT LB 240FT LB 290 FT LB BOLT IDENTIFICATION 1 2 13x1 75 HHCS JO Gimme DT L X Grade5 Grade 8 TOUT Catia P Property Class bolt strength L Length millimeters D Nominal Diameter millimeters X Description hex head cap screw T Thread Pitch thread width mm G Grade Marking bolt strength L Length inches D Nominal Diameter inches X Description hex head cap screw T Thread Pitch threads per inch P N 176439 176441 176443 176520 176522 176525 176572B 7189 860275 420080 420090 520080 520090 860613 860574 420067 860586 770154 710173 770195 a DESCRIPTION Box lof 3 Left Front Brake Line Bracket Right Front Brake Line Bracket Front Bump Stop Spacer Lower Suspension Arm Front Upper Suspension Arm Front Composite Bearing Rod End Front Track Bar Bracket Pitman Arm Articulation Bushing Kit Sleeve 2 25 Crush Sleeve Bushing Bushing Shim Kit Washer Front Track Bar Hardware Kit Sleeve 3 8 16 x 1 5 HHTS M12 1 75 x 30 HHCS M12 1 75 Stover Nut M12 Washer M14 2 00 x 70 HHCS M14 2 00 Stover Nut M14 Washer M10 1 5 x 25 HHCS M10 1 5 Nylock Nut M10 Washer Thread Lock Bearing Kit High misalignment Sleeve 7 8 14 J am Nut High misalignment Sleeve
11. er suspension arm 5 C Lubricate two bushings 520080 and a longer Sleeve 420080 from kit 860275 with synthetic lithium grease Insert bushings and sleeve into lower suspension arm 176523 Refer back to illustration 2 6 J Insert two of the longer high misalignment sleeves from kit 860586 into the composite bearing of suspension arm 176523 7 CI Attach the bearing end of suspension arm 176523 to the frame bracket with the original hardware Insert two greased washers from kit 860613 and attach the bushing end to the axle bracket with the original hardware See illustration 10 Illus 10 8 J Install jam nut on rod end 176525 until 5 6 threads 2dr or 2 3 threads 4dr are left Apply anti seize compound and thread rod end into upper suspension arm 176524 9 J Lubricate two bushings 520090 and a shorter Sleeve 420090 from kit 860275 with synthetic lithium grease Insert bushings and sleeve into upper suspension arm 176524 Refer back to illustration 5 10 C Insert two of the shorter high misalignment sleeves from kit 860586 into the composite bearing of rod end 176525 11 C Attach the bearing end of the suspension arm assembly to the frame bracket with the original hardware Insert two greased washers from kit 860613 and attach the bushing end to the axle bracket with the original hardware See illustration 11 12 LI Center rod end 176525 and tighten jam nut Do not tighten suspension arm bolts until vehicle
12. itman arm Remove the nut and washer from the steering gear shaft 2 Remove the pitman arm from the steering gear with pitman arm puller C 4150 A 3 Insert track bar bracket 176572B into the original track bar frame bracket See illustration 6 4 LJ Using an existing hole loosely attach the inside edge of bracket 176572B with the 12mm hardware from kit 860574 5 C Using an existing hole loosely attach the outside edge of bracket 176572B with the 10mm hardware from kit 860574 6 J Insert sleeve 420067 into the bracket at the original track bar location Install the original hardware Tighten OE bolt to 125 ft Ibs Tighten the 12mm bolt to 75 ft lbs and the 10mm bolt to 45 ft Ibs NOTE Welding track bar bracket 176572B to the frame bracket is recommended for extreme off road use Refer to Important Note N on page 3 Welding should be performed by a trained professional Clean area of all paint coating R epaint cleaned area after welding 7 Attach track bar to bracket 176572B with the 14mm hardware from kit 860574 Insert bolt from rear and do not tighten until vehicle is at normal ride height 8 C Align and install new pitman arm 7789 on the Steering gear shaft Install the washer and nut Tighten the nut to 185 ft Ibs 9 C Install the drag link ball stud to the pitman arm Install the nut and tighten to 60 ft Ibs 10 CI To reposition the front wheels turn the drag link adjustment sleeve s
13. ix to eight turns in Shorten Adjustment Sleeve bolts must face forward See illustration 7 SWAY BAR END LINK INSTALLATION NOTE Requires quick disconnect kit RS6756B or solid end link kitRS6753B for a complete installation 1 CO Apply silicone lubricant and press the supplied bushings into the upper and lower end links 176461B and 176462B or end link 1760888 2 LJ Apply silicone lubricant and press a supplied sleeve into each bushing 3 For RS6 56B install a rubber washer from kit 860580 on the lower end link Connect upper and lower end links with the lynch pin from kit 860580 4 C Attach end link assembly to sway bar and axle bracket with the supplied hardware See illustration 8 Tighten nuts and bolts to 70 ft Ibs 5 CI Repeat steps 1 through 4 for the other side i T Sway Bar if BRAKE HOSE BRACKET INSTALLATION 1 C Attach left brake line bracket 176439 to the brake hose with the 1 4 hardware from kit 860575 Attach bracket to frame with the original bolt See illustration 9 Tighten nuts and bolts securely Carefully bend brake line tube away from frame rail Illus 9 2 C Repeat step 1 to install right brake line bracket 176441 on the passenger side 3 Slide grommets on ABS wire to provide slack for full Suspension turning movement Reattach ABS wires to brake lines 4 1 Install front wheels and lower vehicle to the ground Tighten lug nuts to 80 110 ft Ibs
14. rom the battery 2 LJ Remove the end link to frame bracket nut and bolt Remove the ball stud nut at the sway bar Remove the end link Repeat for other side 3 LI Remove the track bar to frame bracket nut and bolt 4 C Raise the front of the vehicle and support the frame with jack stands Remove the front wheels and set them aside 5 LI If equipped remove the transmission skid plate 6 LJ Remove the nut from the drag link at the pitman arm Separate the drag link ball stud from the pitman arm with a puller tool Do not use a pickle fork 7 C Support the front axle with a jack Remove the shock absorber upper nut retainer and bushing 8 Remove the shock absorber lower nut and bolt Remove the front shock absorber 9 J Repeat steps 6 and 7 for the other side DO NOT REUSE ORIGINAL SHOCK ABSORBERS 10 CJ If necessary disconnect any vent hoses and electrical wiring from the axle Separate the brake hoses from the frame rails by removing the bracket bolts 11 C Carefully lower the front axle and remove the coil Springs Push down on axle if necessary CAUTION Do not allow the front axle to hang by any hoses or cables SUSPENSION ARM REPLACEMENT 1 C Support the front axle with a jack 2 C Remove the driver side upper suspension arm from the frame and axle brackets Remove the driver side lower Suspension arm from the frame and axle brackets See Illustration 1 Illus 1 3 1 Lubricate two bushing
15. s 520080 and a longer sleeve from kit 860275 with synthetic lithium grease Insert bushings and sleeve into the front barrel of lower suspension arm 176520 See illustration 2 Front Barrel Bushing 176520 Illus 2 4 C Apply a film of grease to the outside of the installed bushings Place a washer from kit 860587 against each bushing Attach the front barrel assembly to the driver side axle bracket with the original hardware See illustration 3 5 C Insert the longer high misalignment sleeves from kit 860586 into the rear barrel of lower suspension arm 176520 Attach the rear barrel assembly to the frame bracket with the Original hardware Tighten nuts and bolts to 125 ft Ibs 6 J Thread jam nut on rod end 602627 until 6 threads are left Apply anti seize compound and thread rod end into upper suspension arm 176522 7 Cd Insert the sleeves from kit 860625 and attach rod end to frame bracket with the original hardware Attach bracket end of upper suspension arm 176522 to the axle bracket with the original hardware See illustration 3 602627 FRI ee 176522 176520 i Washer J Illus 3 8 CJ Center rod end 602627 and tighten jam nut to 125 ft Ibs Do not tighten upper suspension arm bolts until vehicle is at normal ride height 9 I Repeat steps 2 through 8 to install suspension arms on the passenger side NOTE To disconnect the upper suspension arm from the passenger side frame bracke
16. t the mounting bolt must be cutoff or the exhaust removed Additional 12mm hardware is Supplied in kit 860586 for the cutoff procedure BUMP STOP SPACER COIL SPRING amp SHOCK ABSORBER INSTALLATION 1 CO Drill a 5 16 hole through the center of the coil Spring axle pad For ease of installation tap the hole 3 8 16 2 J Install original insulator on top of coil spring 6948 Place bump stop spacer 176443 inside the coil spring NOTE If you have a winch mounted to the front bumper add spring spacer RS70082 purchased separately to compensate for the additional weight 3 C Insert the spring assembly into the upper pocket and onto the axle pad See illustration 5 Align pig tail with groove in axle pad 4 C Attach the bump stop spacer to the axle pad with the self tapping screw from kit 860574 5 CI Repeat steps 2 through 4 for the other side 6 J Install retaining washer and bushing on NEW shock absorber insert shock into upper mounting hole Install bushing washer and nut Tighten nut until bushings compress Repeat for other side lt my i Illus 5 7 CI Raise front axle and attach shock lower mounts to axle brackets with the original hardware Tighten nuts and bolts to 56 ft Ibs 8 LI Reattach vent hose and electrical wiring if necessary PITMAN ARM amp TRACK BAR BRACKET INSTALLATION 1 C Center the steering wheel and mark the position of the original p
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