INSTALLATION INSTRUCTION
Contents
1. mmm 25 Nut Bracket 178137 2 Transmission Crossmember Illustration 26 REAR SUSPENSION END LINK SHOCK ABSORBER amp SPRING REMOVAL 1 HO Chock front wheels Raise the rear of the vehicle and support the frame with jack stands Remove the rear wheels 2 L For vehicles equipped with air springs disconnect the battery 3 LJ Support the rear axle assembly with a floor jack 4 Remove the end link nut and bolt from the frame bracket Remove the end link nut from the ball stud See illustration 27 Illustration 27 5 J Remove the end link 6 LJ Repeat steps 4 and 5 for the other side 7 J Remove the upper shock absorber nut and bolt Remove the lower shock absorber nut and bolt See illustration 28 Remove the shock absorber 8 LJ Repeat step 7 for the other side 9 L Remove the nut and bolt holding the track bar to the rear axle 10 LI Remove the bracket holding the brake line junction block to the rear differential Remove the bracket that attaches the brake line to the differential Carefully lower the rear axle CAUTION Do not allow the axle to hang by any hoses or cables Illustration 28 11 LJ For kit 6556 remove the coil springs and insulators See illustration 29 GA A pet 4 4 ZAI hie XS Illustration 29 12 LJ For kit 6557 disconnect the airline from the top of each airbag by simultaneously pushing down on the fitting and pulling up on the ho2. Sleeve Air Spring Spacer Hardware Kit 6557 only M10 1 50 x 40 HHCS M10 Washer Sensor Link Kit 6557 only Rear Height Sensor Link Short Rear Height Sensor Link Long Flexible End Information Pack Rancho Decal Installation Instruction Consumer Information Warning Sticker O 7 lt e re 5 ZP nmnnN EN IN 5 F MN WW WrR NDIF R R NIFFRPPHPNNPNMNMNPFRFN OFAN P CO P P 5 MN MN MN MN CO BNN NF Ff CO fH Ahel I FRONT SUSPENSION VEHICLE PREPARATION amp TORSION BAR REMOVAL 1 L 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 Illustration 1 2 LJ Raise the front of the vehicle and support the frame with jackstands Remove the front wheels and set them aside 3 LJ Remove the front skid plate and transmission cage 4 LI Mark the torsion bars left and right Make alignment marks on the torsion bars the lower control arms and the adjustment arms 5 LJ Install the GM torsion bar unloading tool J 36202 and increase the tension on the torsion bar Remove the adjusting bolt and nut Relieve the tension on the torsion bar and remove the tool 6 LJ Slide the torsion bar forward and remove the adjustment arm See illustration 2 Illustration 2 6 LJ Repeat steps 4 and 5 for the other side 7 LJ Remove the 2 bolt
3. 16 2 LI For kit 6557 remove the plastic air spring adapter from the axle pad Apply thread lock to bolt and place spacer assembly on the axle pad Rotate spacer to angle forward 3 LJ Using a swivel and socket extension attach spacer 176279 to the axle See illustration 37 Tighten the bolt to 45 ft Ibs Repeat for other side H N GA Socket Extension I KA y aa i pn PRE ad BATT S Ta oo ee ot og lt VLA PD ae aoe wg C4 3 s i Teinin Sy a e a PEs ll OX 478279 st dd Ni V Ee in et S ene z lih iii REKA pose kij N REG i we gt as ME 4 l AR Ry a Alyy ON G S R f i i On S N Sek my 7 i ea Ci x 3 ste i ate a A ee ae Illustration 37 4 L For kit 6557 compress the airbag by rolling it over the bottom canister evenly Place air spring assembly on spacer 176279 Align tabs and rotate spring until top snaps in place 5 LI For kit 6557 reinstall airlines on airbag fittings Push down until the line bottoms 6 LI For kit 6556 place new coil springs 692 with original insulators on the rear axle Raise the axle and guide the springs into the frame pockets i SW a s pam oet 4 if ji v A Illustration 38 7 L Attach new Rancho shock absorbers to the upper and lower mounts 8 LJ Insert brake cables through drop bracket 176276 as shown in illustration 39 Reattach the cables to th
4. 88556 Rev E INSTALLATION INSTRUCTION Hummer H2 88556 Rev E 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 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 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 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 C Do not powdercoat 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 2 E Compare
5. I Repeat step 1 to install the rest of the bushings and sleeves 3 LJ Using the hardware from kit 860474 loosely attach the angled end of each aft brace to the rear of the subframe 176218 NOTE The angled end of the aft brace should direct the aft brace slightly outward 4 Attach aft brace brackets 176138 to aft braces See figure 25 5 LJ Rotate aft brace assemblies up and secure the brackets to the transmission crossmember with c clamps Remove the aft braces and mark the mounting hole locations on the bottom of the crossmember 6 Remove the brackets and drill a 1 2 hole through the bottom of the crossmember at each location 7 LJ Repeat the previous two steps for the other side Subframe 176270 O Aft Brace 176222 2 Bushing 520041 8 N a Sleeve 420042 4 8 Attach the aft brace brackets to the transmission crossmember with the hardware from kit 860474 See illustration 26 9 LI Tighten the aft brace and bracket mounting bolts to 65 ft Ibs 10 Install front wheels and lower vehicle to ground Tighten the lug nuts to 140 ft Ibs 11 LJ Tighten the lower control arm pivot bolts to 107 ft Ibs HI MG f i i l i i my he te j ty Li UGA moi 1 pr PER D Ni 3 DIET ARC it Ji ee z oe a pi Ni ic i i ah er h mene ee ni o 4 j I j i f i d m i prov i na j X j ve F j 7 y d my 1765222 Mg Ni F z F se i m ji J
6. L Length inches D Nominal Diameter inches X Description hex head cap screw T Thread Pitch threads per inch i RS6556 RS6557 P N 176138 176193 176195 176214 176215 176219 176220 176222 176226 176270 176271 176272 176274 176275 176276 176277 176279 176280 692 860179 860497 420044 860412 860413 170014 860414 860415 420052 DESCRIPTION Aft Brace Bracket Rear Bump Stop Spacer Rear Sway Bar End Link Knuckle Left Knuckle Right Box Plate Differential Support Bracket Subframe Aft Brace Axle Spacer Subframe Torsion Bar Drop Bracket R Axle Tube Drop Bracket Skid Plate Drop Bracket Track Bar Relocation Bracket Link Drop Bracket Left Rear Link Drop Bracket Right Rear Air Spring Spacer 6557 only Spacer Retainer 6557 only Coil Spring 6556 only Frt Differential Hardware Kit M10 1 50x60 HHCS 7 16 14 x 3 0 HHCS 7 16 14 Stover Nut Washer 7 16 SAE Washer End Link Hardware Kit 15x 156x9 5 Sleeve 3 8 16 x 14 0 HHCS 3 8 16 Nyloc Nut Retainer Cushion 3 8 16 Nut not used End Link Hardware Kit Rear Sleeve Bushing M12 1 75 x 70 HHCS M12 1 75 Nyloc Nut SAE Washer USS Washer Brake Line Bracket Kit Brake Line Bracket 5 16 18x1 25 HHCS 5 16 18 Top lock Nut 5 16 SAE Washer Rear Drop Link Hardware M14 2 00 x 90 HHCS M14 2 00 x 100 HHCS M14 2 00 Top Lock Nut SAE Washer 1 2 13x1 25 HHCS 1 2 13 Stover Nut 1 2 SAE Washer Rear Track Bar H
7. ar of the vehicle by the frame before the compressor will start 7 J Tighten the end link bolts to 24 ft lbs Tighten the track bar bolt to 77 ft lbs Tighten the upper link arm bolts to 77 ft Ibs and the lower link arm bolts to 89 ft lbs FINAL CHECKS amp ADJUSTMENTS 1 LJ Jounce suspension and move the vehicle to normalize ride height Verify that the front spindle to fender height is 28 5 and that both sides are equal If necessary reinstall GM tool J 36202 and adjust the tension on the torsion bars to correct the height 2 L 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 3 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 4 L Ensure that the vehicle brake system operates correctly If new brake hoses were installed verify that each hose allows for full suspension movement 5 LJ Readjust headlamps Have vehicle Aligned at a certified alignment facility Recommended Alignment Specifications Caster degrees 3 5 1 0 Camber degrees 0 3 Sum Toe In degrees 1 2 Please retain this publication for future reference See Important Note O 19
8. ardware Kit Sleeve 9 16 12x4 00 HHCS 9 16 12 Stover Nut 9 16 SAE Washer 7 16 14x1 25 HHCS 7 16 14 Stover Nut 7 16 SAE Washer PARTS LIST QTY P N 860416 860433 420041 520041 860436 860438 860474 420042 520041 860475 420043 552 860476 860477 860478 860479 520039 1 520039 2 520039 3 860480 860577 176273 176278 94180 780281 88556 94119 94177 NOR E NE PRR BRN N CO BRNN FP NFP RRR NNN DN BBE BO CONN NEF DN UR FURR NN PPR RP RPNPNNRP RP RPE NN DN DESCRIPTION Bump Stop Hardware Kit Rear 3 8 16x1 50 HHCS 3 8 16 Stover Nut 3 8 SAE Washer Subframe Hardware Kit 15x 095x2 19 Sleeve Bushing 5 8 18 x 4 5 HHCS 5 8 18 x 5 5 HHCS 5 8 18 Stover Nut 5 8 SAE Washer Thread Lock Axle Spacer Hardware Kit M10 1 50 x 60 HHCS Lock Washer Brake Hose Bracket Hardware Kit M6 1 0 x 10 HHTS Aft Brace Hardware Kit Sleeve Bushing 1 2 13 x 4 00 HHCS 1 2 13 x 1 00 HHCS 1 2 13 Stover Nut 1 2 SAE Washer Nut Bracket Thread Lock Torsion Bar Crossmember Hardware Kit Sleeve Bushing 9 16 12 x 3 00 HHCS 9 16 12 Stover Nut 9 16 SAE Washer 3 8 16 x 1 50 HHTS Right Axle Tube Hardware Kit M12 1 75 x 90 HHCS M12 1 75 Stover Nut M12 Washer Front Differential Hardware Kit M14 2 00 x 90 HHCS M14 2 00 Stover Nut 9 16 SAE Washer Skid Plate Hardware Kit M10 1 50 x 30 HHCS M10 Washer 3 8 16 x 1 00 HHTS Front Differential Bushing Kit Upper Bushing Front Differential Lower Bushing Front Differential
9. case To avoid excessive oil seepage do not stop installation at this point 5 Attach bracket assembly 176220 to the front differential with the hardware from kit 860179 Refer to illustration 12 Tighten the bolts to 35 ft Ibs 6 Loosely attach bracket assembly 176220 to subframe 176270 with the hardware from kit 860477 See illustration 13 7 Insert top bushing 520039 1 and OE washer between differential and subframe Place lower bushing 520039 2 under subframe See illustration 13 8 Insert sleeve 520039 3 into bushings Loosely attach the rear of the differential assembly to the subframe with the original hardware 520039 1 MO2387 520039 2 MO2388 Qor 10mm 5 ha Illustration 12 176270 Illustration 13 9 LI With the help of an assistant carefully raise the subframe up into the lower control arm frame brackets Attach the subframe to the brackets with the original hardware Tighten the subframe to bracket bolts to 107 ft Ibs 10 LI Attach the right axle tube bracket 176272 to the frame bracket with the original hardware and to the axle tube with the hardware from kit 860476 See illustration 14 Tighten all differential mounting bolts securely ze go 176272 Z Tilustration 14 CAUTION Verify that the grease fitting on the relay rod does not contact the left side of the differential See illustration 16 If necessary remove additional material from the differen
10. d and carefully remove the o ring Caliper Assembly Hub amp Bearing Assembly ee wie 7 i bu k po O k ay 5 R 1 si Uj Mi mi M nae ma gt S av Steering Knuckle ef Se v Illustration 4 8 LJ Mark the differential output flange and the axle flange for installation reference 9 LI Remove the six bolts from the inboard flange See illustration 5 Illustration 5 10 LJ Remove the lower control arm pivot bolts See illustration 6 Remove the lower control arm Illustration 6 11 LJ Repeat steps 1 through 10 for the other side FRONT DIFFERENTIAL REMOVAL 1 LJ Remove the five bolts that attach the rear crossmember to the differential and frame See illustration 7 Remove the crossmember 4 gt Sammon os Vel gt a Crossmember Illustration 7 2 LI Reference mark the front drive shaft U joint to the differential yoke Remove the bolts and retainers from the yoke and slide the shaft rearward to disengage Tape the bearing cap assemblies and secure the shaft out of the way 3 LJ Disconnect the vent hose from the differential assembly 4 LI Support the front differential assembly with a floor jack Remove the right axle tube bolt and the differential upper mounting bolt 5 LJ Remove the differential assembly from the vehicle 6 LJ Cut off the driver side crossmember control arm bracket at the location shown in illustration 8 The cut off location sh
11. e axle frame and connector KIT 6557 1 LJ Measure and record the length of the original sensor link from center of hole to center of hole See illustration 40 Flexible End Flexible End Illustration 40 2 LJ If the length of the original sensor link is 4 6 inches install the flexible ends from kit 860577 on the shorter rods NOTE The flexible ends may be installed on the longer rods Remove if necessary 3 LJ If the length of the original sensor link is 5 3 inches install the flexible ends on the longer rods 4 LI Apply silicone lubricant and carefully attach the new sensor links to the upper control arm brackets and sensor arms Refer back to illustration 31 BRAKE LINE BRACKET INSTALLATION 5 LJ Attach the new brake line bracket 170014 to the rear differential with the original bracket bolt See illustration 41 Illustration 41 6 LJ Carefully reshape the brake line and attach the junction block to the top of bracket 170014 Use the 5 16 hardware from kit 860413 7 L Reattach the other brake line bracket to the differential TRACK BAR BRACKET INSTALLATION 1 L Attach track bar bracket 176275 to the track bar with the original hardware Insert sleeve 420052 and attach the new track bar bracket to the original bracket as shown in illustration 42 Use the 9 16 hardware from kit 860415 a pid T ge ag Ae Titictanon 42 2 LJ Drill a 7 16 hole thro
12. e shaft splines or the knuckle hub with grease 7 UO Place axle spacer 176226 against the differential flange Place the axle flange against the spacer and align the flange marks Attach the axle to the differential with the hardware from kit 860436 See illustration 16 Tighten the flange bolts to 58 ft lbs Sre H a s RE v ne k y ida 2 a 4 dij i r 7 d 7 Illustration 16 Reattach the front caliper with the original mounting bolts Be sure to clean the bolt threads and apply thread lock Tighten the caliper mounting bolts to 129 ft Ibs 8 LJ Install the brake rotor 9 HO Place a drift or large screwdriver through the caliper to prevent the drive axle from turning See illustration 17 Illustration 17 10 LI Tighten the axle hub nut to 155 ft Ibs Remove the drift from the rotor 11 LJ Adjust the brake hose clamp and place it over the two mounting holes on the back of the steering knuckle See illustration 18 Insert the tab into one hole and install the new self tapping screw from hardware kit 860438 into the other ABS Cable Illustration 18 12 LI If applicable reconnect the ABS cable Attach the ABS cable to the knuckle and upper control arm as shown in illustrations 18 and 19 13 LJ Repeat steps 1 through 12 for the other side 14 L Attach the sway bar to the lower control arm with the new end link assemblies from kit 860497 See illustration 19 Insert t
13. he 3 8 x 14 bolt from the top and use the supplied nyloc nut only 15 L Install new Rancho shock absorbers 11 Brake Hose lt x er i 1 S x gt v Illustration 19 TORSION BAR amp DROP BRACKET INSTALLATION 1 LJ Insert two bushings and a sleeve from kit 860475 into each torsion bar drop bracket 176271 2 LJ Loosely attach the drop brackets to the torsion bar crossmember with the 9 16 hardware from kit 860475 frame brackets with the original hardware illustration 20 Attach the crossmember assembly to the See Self tapping Screw 2 Illustration 420 3 LJ Mark and center punch the 2 holes on the bottom of each frame rail Drill a 11 32 hole at each of the marked locations Insert the 3 8 self tapping screws from kit 860475 Tighten the screws to 20 ft Ibs 4 U Align marks and insert the left and right torsion bars into their respective lower control arms Carefully slide the bars forward Do not allow the torsion bars to contact the front axle boots 5 LJ Slide a torsion bar rearward through the crossmember while holding the adjustment arm in proper position Verify that the reference mark on the adjustment arm matches the mark on the end of the torsion bar 6 LJ Install the torsion bar unloading tool and increase the tension on the torsion bar 7 J Reinstall the retaining plate and adjusting bolt Thread the adjusting bolt in until 1 5 inches of threads are exp
14. ifferential Hammer Wire Brush to clean bracket mounting surfaces Black Enamel Paint Silicone Spray Lubricant Tape Measure Safety Glasses wear safety glasses at all times NET ELE IOOOOONOOOOOOOOOLOLOLL J Itis 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 Welding on a car 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 M The required installation time for this system is approximately 7 to 8 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 37 x 12 5 x 17LT tire 17 x 10 wheel with 5 inches of wheel backspacing Before installing any other combination consult your local tire and wheel specia
15. list Do not exceed 5 inches of wheel backspacing Backspacing Negative Offset Mounting Face Diameter WHEEL TERMINOLOGY EH Ba Width mi 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 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 12 9 12 FT LB 38 3OFTIB 35FILB M8 IS PT LB 23FT LB 27 FT LB 50 FT LB p20 OS PTB OOFT LB OT MI2 SSFIAB 75FT LB 90 FT LB NG OS PTB BOPTLB MI4 5 FT LB I20FI LB 145 FT LB 3 8 135 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 M12 1 25x50 HHCS Pi ai ue D T L X P Property Class bolt strength D Nominal Diameter millimeters T Thread Pitch thread width mm kij AG Tu L Length millimeters X Description hex head cap screw SO feat X Grade 5 Grade 8 l L G Grade Marking bolt strength
16. osed below the retaining plate Remove the unloading tool 8 LJ Repeat steps 5 through 7 for other side SKID PLATE INSTALLATION OEM 1 LJ Attach drop bracket 176274 to the front crossmember with the hardware from kit 860478 2 LI Temporarily attach the OE skid plate to drop bracket 176274 with the original skid plate bolts See illustration 21 176274 KA ie Illustration 21 3 LI Lift the skid plate up until it contacts the front pockets of the Rancho subframe Mark the two contact points on the skid plate Remove skid plate 4 LI Cut and file skid plate at the marked locations See illustration 22 Reattach the skid plate to drop bracket 176274 5 LJ Flatten the outside tubes on the front of the transmission cage See illustration 23 Illustration 22 Illustration 23 6 LJ Insert the cage between the skid plate and the subframe Attach the cage and skid plate to the subframe with the original bolts Reattach the cage to the transmission crossmember 7 LI Using the skid plate as a template drill two 5 16 holes into the front crossmember of the Rancho subframe Install the self tapping screws from hardware kit 860478 See illustration 24 Illustration 24 AFT BRACE ASSEMBLY amp INSTALLATION 1 LJ Lubricate two bushings 520041 and one Sleeve 420042 from kit 860474 with a silicone spray Press the bushings and sleeve into aft brace 176222 as shown in illustration 26 2 L
17. ould be just outside the bracket sleeves i E 5 a a Me 2 9 if 5 A o Ni S Ty 5S 1 E i ul Cut Here f Em ZARA TRE A z k i at JE woo a tih z a Pa seo 2s 1 3 u ae i GAs AS Illustration 8 7 J Disconnect the battery See important note L 8 LI Weld box plate 176219 to inside of lower control arm frame bracket as shown in illustration 9 176219 78 i 2 x 3 E e gt EN Illustration 9 NOTE Box plate 176219 does not have a protective coating and may develop surface rust Remove rust before welding plate to lower control arm frame bracket After installation coat the plate and bracket with enamel paint or undercoating FRONT DIFFERENTIAL amp SUBFRAME INSTALLATION 1 L To keep chips from falling into the differential install a plugged hose on the vent fitting See illustration 10 Carefully cut off the upper mount from the front differential as shown usrano 10 2 J Cut and file additional material until the top of the differential looks like illustration 11 Illustration 11 3 LJ Install two bushings 520041 into differential support bracket 176220 Apply silicon lubricant and press sleeve 420041 through the installed bushings See illustration 12 4 LJ Remove the 5 case bolts from the front of the differential NOTE After removing the bolts oil may seep from the
18. ower link to hang downward 7 L Insert left link drop bracket 176276 into the frame brackets Attach the bracket to the frame with the original bolts See illustration 34 Illustration 34 8 LJ Drill a 1 2 hole through the bottom of the lower frame bracket Install the 1 2 hardware from kit 860414 9 LJ Tighten the 1 2 nut and bolt to 65 ft lbs and the original bolts to 80 ft Ibs 10 U Loosely attach the upper link to drop bracket 176276 with the 14mm hardware from kit 860414 NOTE Do not attach the lower link or brake cables at this time Do not tighten the link pivot bolts until the vehicle is at normal ride height 11 LJ Place bump stop spacer 176193 on top of the lower link axle bracket See illustration 35 Align the rear hole in the new bracket with the existing hole Mark the additional mounting hole location Illustration 35 12 LI Remove the spacer and drill a 3 8 hole at the marked location 13 LI Attach bump stop spacer 176193 to the axle bracket with the 3 8 hardware from kit 860416 14 L Loosely attach the lower link to drop bracket 176276 with the 14mm hardware from kit 860414 15 H Repeat applicable steps to install drop bracket 176277 and bump stop spacer 176193 on the passenger side AIR OR COIL SPRING INSTALLATION 1 LJ For kit 6557 insert retainer 176280 and the hardware from kit 860480 into spring spacer 176279 See illustration 36 Illustration 36
19. s holding the torsion bar crossmember to the frame rail brackets See illustration 2 Remove the crossmember 8 Remove the torsion bars from the lower control arms SHOCK ABSORBER END LINK REMOVAL 1 LJ Remove the front shock absorbers Remove the front bump stops 2 LJ Remove the sway bar end links See illustration 3 Illustration 3 STEERING KNUCKLE HALF SHAFT amp LOWER CONTROL ARM REMOVAL 1 LJ Loosen the brake hose bracket from the brake hose top of steering knuckle by prying the bracket open with pliers Remove the brake hose brackets from the steering knuckle and upper control arm 2 L Remove the brake caliper and its mounting bracket as an assembly Hang the caliper assembly with wire or a tie wrap 3 LJ Label the brake rotor left or right Remove the brake rotor Remove the axle hub nut and washer 4 LI Remove the prevailing torque nut from the outer tie rod stud Disconnect the tie rod end from the steering knuckle with a universal puller 5 L If applicable disconnect the ABS connector and separate the cable from the upper control arm and the steering knuckle 6 LJ Remove the nuts at the upper and lower ball joints Disconnect the ball joints from the steering knuckle using separating tool J43631 Remove the steering knuckle and hub assembly 7 LI Remove the hub and bearing assembly mounting bolts See illustration 4 Remove the hub and bearing assembly Remove the splash shiel
20. se See illustration 30 Rotate and remove the air spring assembly Push Pul Warning Contents under pressure Desiccant particles may be released after airline removal Wear safety glasses when removing airline Roll airbag over bottom canister as shown Illustration 30 13 LINK DROP BRACKET amp BUMP STOP SPACER INSTALLATION 1 LJ Remove the gas tank skid plate to gain access to the driver side lower link frame bolt 2 LI For kit 6557 spray the ends of the airbag sensor links with a silicone lubricant See illustration 31 Using a separator tool carefully remove the links he Illustration 31 CAUTION The plastic sensor arm is easily breakable Secure the arm and remove the link slowly 3 LJ Separate the parking brake cable at the cable connector on the driver side See illustration 32 mite uka pio I k 1 if a a sr k zdej ba UR nie ee rovi ki URE Le dka z L ap a hal a a p TPA z x 7 1 PET PA MAD jeve i god ah s F 4 mi i UK i W f he ed E Sree 2 ako za JA Illustration 32 4 J Disconnect the brake cable from the frame and axle 5 L Remove the nuts and bolts attaching the upper and lower links to the driver side frame See illustration 33 Do not detach the links from the passenger side 15 a Lower Link Illustration 33 6 LJ Loosen the bolt attaching the lower link to the axle bracket Allow the l
21. 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 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 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 Hummer H2 Service Manual Torsion Bar Unloading Tool J 36202 Universal Steering Linkage Puller 24319 Ball J oint Separator 43631 Prevailing Torque Nuts for steering linkage amp front wheel drive shaft Welder Die Grinder Drill motor Assorted Drills 1 8 through 1 2 Torque Wrench 250 FT LB capacity 1 2 Drive Ratchet and Sockets Assorted Combination Wrenches Heavy Duty J ack Stands Wheel Chocks wooden blocks Hydraulic Floor J ack Center punch File Reciprocating Saw to modify frame and d
22. tial case 5 LJ Align marks and reconnect the front drive shaft to the differential If applicable reconnect the vent hose and electrical connector STEERING KNUCKLE amp HALFSHAFT INSTALLATION 1 LJ Loosely attach the left lower control arm to the subframe with the 5 8 hardware from kit 860433 2 LJ Connect left steering knuckle 176214 to the lower and upper control arm ball joints 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 Ibs 3 LJ Lubricate the original o ring with wheel bearing grease Install the o ring and splash shield See illustration 15 Be sure to align the ABS cable between the splash shield and steering knuckle Hub amp Bearing Assembly O ring S eee S 1 m kodi nodi Pi t we Z m k h S ay itt ce J vj Illustration 15 10 NOTE Replace o ring if worn or damaged 4 LI Apply thread lock to original bolts and attach the hub and bearing assembly to the left steering knuckle Refer to illustration 15 Tighten the mounting bolts to 133 ft Ibs 5 LJ Loosen the tie rod end jam nut and thread the tie rod end inward 2 5 complete turns Retighten the jam nut and attach the tie rod end to the new knuckle Tighten the new prevailing torque nut to 33 ft lbs 6 J Insert the wheel drive shaft halfshaft into the knuckle hub Install the shaft washer and a new hub nut NOTE Do not lubricate the wheel driv
23. ugh the axle bracket at the location shown in illustration 43 Install the additional 7 16 hardware from kit 860415 TTT LLL LLL Illustration 43 3 Tighten the 9 16 bolt to 77 ft Ibs and the 7 16 bolt to 45 ft Ibs Do not tighten the original track bar bolt until the vehicle is at normal ride height SWAY BAR END LINK ASSEMBLY amp INSTALLATION 1 LJ Apply silicone lubricant and press the bushing from kit 860412 into sway bar end link 176195 See illustration 44 Apply silicone lubricant and press the sleeve into the installed bushing BE Link 176195 VANE Sleeve Illustration 44 2 LI Attach the end link assembly to the frame bracket with the original bolt Attach the sway bar to the end link with the 12mm hardware from kit 860412 See illustration 45 mere 45 3 LJ Repeat step 3 for the other side Do not tighten the end link bolts until the vehicle is at normal ride height 4 J Install rear wheels and lower vehicle to ground Tighten lug nuts to 140 ft Ibs 5 LI For kit 6557 ensure that the air spring is fully engaged with spring spacer 176229 and the air bag has minimal distortion Refer back to illustrations 30 and 37 6 LJ To inflate the air springs for kit 6557 Reattach the battery Start the engine and run for approximately two minutes to verify that the air suspension is operating properly NOTE It may be necessary to close compartment doors and slightly raise the re
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