Installation Instructions
Contents
1. both links As with any grease fitting WATCH CLOSELY and stop greasing when grease first appears at the ends or if the bushings begin to move 36 LJ Have a front end alignment performed at a certified alignment facility Rancho recommends the following specs Caster 7 5 0 5 Toe In 0 to 1 32 REAR SUSPENSION IMPORTANT NOTES e To contain the potential energy stored in a leaf spring assembly secure the leaves with two large C clamps See illustration 7 e Some springs will have a factory helper spring consisting of one or more flat or nearly flat leaves installed at the bottom of the leaf pack Do not install your Add A Leaf spring in or below the helper spring assembly e These instructions use general procedures for installing an Add A Leaf Obtain and review your vehicle s service manual for specific procedures and specifications Center Bolt Add A Leaf lus 7 1 LJ Park the vehicle on a level surface Set parking brake and chock front wheels Raise the rear of the vehicle and support the frame with jack stands 2 LI Remove the rear wheels 3 LJ Support the rear axle with a floor jack to relieve the tension on the leaf spring 4 LI Remove the rear shock absorbers Disconnect the axle vent hose from the axle housing Note Removing and installing one leaf spring assembly at a time will prevent the rear axle from tipping 5 LJ Loosen all the rear axle U bolt nuts but do not remove 62. the axle from tipping work on one side of the vehicle at a time hs Link at Now Pitman Arm Track Bar At Sill Bracket Illus 2 4 J Disconnect the stabilizer bar links and the shock absorber at the axle See Illus 1 amp 2 5 LJ Remove bolts and separate the brake hoses from the frame rails If necessary disconnect any vent hoses and electrical wiring from the axle 6 LJ Disconnect the drag link at the pitman arm by removing the retaining nut 7 LJ Remove the shock absorber upper nut retainer and bushing Remove the front shock absorber DO NOT REUSE ORIGINAL SHOCK ABSORBERS 8 J Disconnect the Track Bar at the Sill Bracket 9 Remove the passenger side lower control Arm from the axle and frame bracket See Illus 1 Retain bolts and nuts as they will be used later for installing the new Lower Control Arms 10 LJ Carefully lower the axle assembly using the jack Loosen the spring retainer and remove the coil spring CAUTION Do not allow the front axle to hang by any hoses or cables FRONT LOWER CONTROL ARM INSTALLATION 11 LI Push the 8 bushings item no 4 into the ends of the two Lower Links item no 2 They generally press in by hand or you can use a vice 12 LI Lubricate the inside of the bushings with chassis grease 13 LJ Press 4 sleeves item no 3 into the ends of the Links Use a vice or a large C clamp if necessary TOE yeuts Frame End PA Axle End
3. 0 thru 20 on the other side of the vehicle SHOCK ABSORBER COIL SPRING amp STEERING STABILIZER INSTALLATION 23 L Install retaining washer and bushing on NEW shock absorber insert shock into upper mounting hole Install bushing washer and nut Tighten nut to 17 ft lbs Repeat for other side Illus 6 24 LJ Install new coil spring item 1 and tighten the spring retainer see illus 5 amp 6 25 LJ Raise front axle and attach shock lower mounts to axle brackets with the original hardware Tighten nuts and bolts to 14 ft lbs 26 LI While raising the axle into position locating the top of the spring as shown in Illus 5 27 L Reconnect the track bar to the sill bracket and torque to 62 ft lbs Ref Illus 2 28 Reconnect the stabilizer bar link and torque to 55 ft los Ref Illus 2 29 LI Reconnect brake hose bolts and hoses to the frame rails Ref Illus 2 30 LJ Reconnect the drag link to the pitman using the retaining nut Torque to 60 ft lbs Ref Illus 2 31 LJ Remove steering stabilizer and replace with Rancho Steering stabilizer and hardware provided in the kit item no 7 Torque stabilizer to axle to 55 ft lbs and stabilizer to drag link to 35 ft lbs 32 L Install the wheel tire assemblies 33 LI Remove the jackstands and lower the vehicle back to the ground 34 LJ Tighten axle and frame lower control arm nuts to 135 Ft Lbs on both side of the vehicle 35 LI Grease each end of
4. 89000 RevA INSTALLATION INSTRUCTION Suspension System RS66000 amp RS66001 Jeep Cherokee XJ 1984 2001 89000 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 lt will handle differently both on and off road from a factory eguipped 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 RS7000 RS9000 Front Rear RS5239 RS5129 RS7239 RS7129 RS99239 RS99129 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 con
5. Illus 3 14 LI Determine the spacers item 5 or 6 required for the FRAME END of the link Usually these are Early model XJ 2 Thin Spacers Item 5 Later model XJ 2 Thick Spacers Item 6 Ref Illus 3 and 4 Verify the spacer selection by placing the selected washers onto the sleeve on the assembled control arm Adjust the number of washers if reguired You should not need to force the combination into the pocket Ref Illus 3 and 4 Axle End Illus 4 15 LJ Once spacer selection is determined lightly grease the spacers 16 LI Slide the rear of the Rancho link into the frame with the spacers Correct orientation of the link is determined by positioning the straight out grease fitting is located under the axle see illus 4 and the other one points down and to the rear 17 LI Insert the stock bolt through the frame bracket and sleeve If a washer was there originally reuse it see Illus 3 18 J Run the stock nut on by hand until stopped by the self locking feature 19 L Install the front of the Rancho link with a combination of spacers between the bushing and the axle bracket using the criteria used in step number 13 Be sure to lightly grease the spacers before installation 20 LJ Insert the stock bolt through the axle bracket and sleeve If a washer was there originally reuse it see Illus 3 21 Ll Run the stock nut on by hand until stopped by the self locking feature 22 LI Repeat Steps 1
6. LJ Starting with one side remove rear axle U bolts and anchor plate Remove the spring eye bolts and or shackles Carefully lower the rear axle enough to remove the leaf spring from the vehicle Do not allow the axle to hang from any brake lines or cables 7 LJ Hold the spring assembly securely together with C clamps See illustration 7 If applicable remove any leaf spring alignment clamps 8 LL Remove the center bolt using vise grips to hold the round head If the bolt is rusted it may be necessary to drive the bolt out with a hammer and drift punch 9 O Carefully remove the C Clamps 10 LJ Apply a small amount of grease to the top ends of the new Add A Leaf item no 8 and insert it into the leaf pack in a pyramid fashion Keep the progressive order of longer leaf on top 11 LJ Reinstall C clamps on leaf assembly and install a NEW center bolt and nut item no 14 amp 15 Align leaves and tighten center bolt to specifications 20 ft lbs for 5 16 center bolt Note It may be necessary to cut off the center bolt if the length is to long 12 LI Remove C clamps and reinstall the spring assembly onto the axle with U bolts anchor plate washers and nuts Do not tighten at this time 13 LJ Raise the axle and install the original eye bolts and or shackles Do not tighten at this time 14 LJ Repeat steps 5 through 13 for installing the Add A Leaf into the remaining leaf spring assembly 15 LI Tighten U bolt nuts t
7. mended for proper installation of this kit M Jeep Service Manual Torque Wrench 250 FT LB capacity Hammer 1 2 Drive Ratchet and Sockets Combination Wrenches Hydraulic Floor Jack Heavy Duty Jack stands Wheel Chocks Wooden Blocks Safety Glasses Wear safety glasses at all times S ELE EINES Les 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 M The required installation time for this system is urethane bushings should be tightened with the vehicle approximately 4 hours Check off the box M at the at normal ride height This will prevent premature beginning of each step when you finish it Then when failure of the bushing and maintain ride comfort you stop during the installation it will be easier to find where you need to continue from L This suspension system was developed using a 31 x 11 50 x 15 tire on a 15 x 8 wheel with 3 75 of N Welding on a vehicle creates an electrical charge backspacing Before installing any other combination throughout the body and frame Disconnect the consult your local tire and wheel specialist Actual tire vehicle s battery prior to any welding Place welding size varies by manufacturer ground clamps as near a
8. o 55 ft lbs 16 LI Install shock absorbers and torque upper and lower nuts to 44 ft lbs 17 LJ Reconnect axle vent hose 18 LJ Install the rear wheels and lower the vehicle to the ground Do not release parking brake or remove wheel chocks 19 LJ Jounce vehicle to settle springs Torque eye bolts and or shackles to 80 ft lbs 20 LJ Install the NEW leaf alignment clamps as shown in illustration 8 Apply light pressure to the clamps when installing them and do not bend the tabs of the clamps sharply Note The leaf alignment clamps will prevent lateral shifting or fanning of the spring leaves They are not intended to hold the leaves against one another 21 LJ Check the vehicle s alignment and adjust headlamps INCORRECT CORRECT too sharp of a bend Please retain this publication for future reference See Important Note O
9. s possible to the weld Never use a vehicle suspension component as a welding ground point Va Ea ze JA Total Backspacing ae O Important information for the end user is contained Negative Ofiset 7 Pa in the consumer installer information pack If you are x z TA installing this system for someone else place the m information pack on the driver s seat Please include VRELO the installation instructions when you finish g Face aaa P Thank you for purchasing the best suspension WHEEL system available For the best installed system follow nm dai TERMINOLOGY these instructions If you do not have the tools or are Width 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 Compatible With Development Tire Size actual Optional Tire Size actual Wheel Size backspacing OE Wheels 31x11 5xR15 33x12 5xR15 15x8 3 75 1 Fitment of the optional tire size may require trimming to provide proper clearance STANDARD BOLT TORQUE SPECIFICATIONS INCH SYSTEM METRIC SYSTEM Bolt Size Class 12 9 5 16 12 FT LB 27 FI LB 7 16 50 FT LB 1 2 90 FT LB 9 16 145 FT LB 5 8 210 FT LB 3 4 290 FT LB BOLT IDENTIFICATION G Pl g p hrar esms OAO ME 11212580 HHOS AE G Grade Marking bolt strength L Length inches P Property Class bolt strength L Length millimeters D Nominal Diameter inches X Descrip
10. tains fasteners of high strength and specific size Do not substitute 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 powder coat 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 recom
11. tion hex head cap screw D Nominal Diameter millimeters X Description hex head cap screw T Thread Pitch threads per inch T Thread Pitch thread width mm v oO P N RS608 RS176637 RS860702 RS5401 94180 780281 RS89000 94119 94177 DESCRIPTION Box 1 of 2 Front Coil Spring Lower Link Bushing Assy Hardware Kit Sleeve Lower Link Bushing Shim 040 x 2 47 x 60 Washer 120 x 2 25 x 563 Steering Stabilizer Information Pack Rancho Decal Instructions Consumer Warranty Information Warning Sticker PARTS LIST 10 11 12 13 14 15 P N RS513 RS7455 RS7405 RS8011 RS8011 RS8302 RS8366 2 DESCRIPTION Box 2 of 2 Add A Leaf U Bolt Chrysler type Rear Axle U Bolt Dana 35 Rear Axle U Bolt Nut Washer Hardware Kit 77 20 Nylock Nut Washer U Clip Hardware Kit U Clip Cap Center Bolt Nut Kit 5 16 24 Center Bolt Nut Center Bolt Kit 5 16 24 Center Bolt Z lt NARNDN gt FF B CC F BP FRONT SUSPENSION LOWER CONTROL ARM SHOCK ABSORBER 8 COIL SPRING REMOVAL 1 LJ Park vehicle on a level surface Set the parking brake and chock rear wheels Disconnect the negative ground cable from the battery 2 J Raise the front of the vehicle and support the frame with jack stands allowing the front wheels to hang Remove the front wheels and set them aside 3 LJ Support the front axle with a floor jack Note to keep
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