Installation Instruction
Contents
1. Driver Side lt FRT Illus 8 6 LI Attach drop brackets 176348 and 176406 to the passenger side frame and front differential assembly as shown in illustration 9 Use the original bolts and 14mm hardware from kit 860556 Passenger Side FRT B Illus 9 7 U Tighten the differential mounting bolts to 114 ft Ibs Reconnect electrical connector and secure the vent hose 8 LI Align reference marks and reattach the front diveshaft Tighten the yoke retainer bolts to 19 ft Ibs 9 L Using a large screwdriver CAREFULLY slide the CV boot on the front driveshaft 1 4 back toward the transfer case See illustration 10 Rotate the driveshaft to slide the boot evenly CAUTION An improperly adjusted boot will reduce the service life of the boot Do not damage the CV boot _ Illus 10 SWAY BAR DROP BRACKET INSTALLATION 1 LJ Remove the front skid plate 2 LI Remove the insulator clamp bolts Remove the sway bar 3 LJ Using the original bolts attach drop bracket 176403 to the driver side frame rail and drop bracket 176404 to the passenger side frame rail See illustration 11 Tighten bolts to 37 ft Ibs Illus 11 4 LI Flip the sway bar over and rotate the clamps 180 degrees Attach the sway bar to drop brackets 176403 and 176404 with the 10mm hardware from kit 860554 See illustration 11 Tighten nuts and bolts to 37 ft Ibs NOTE DO NOT flip end links ONLY sway bar is flipped left to2. Thread Pitch thread width mm P N 170107 176346B 176348 176352 176353 176357 176399 176403 176404 176405B 176406 176407 176408 176409 176410B 176413 176414 860521 920041 420042 DESGRIPTION Box 1 of 2 Front Brake Hose Assembly Front Cross Member Differential Drop Bracket Torsion Bar Relocator Right Torsion Bar Relocator Left Aft Brace Bracket Rear Leaf Spring Bracket Sway Bar Bracket Left Sway Bar Bracket Right Rear Cross Member Differential Drop Bracket Rear Bump Stop Bracket Left Bump Stop Bracket Right Rear Bump Stop Bracket Aft Brace Rear Shackle Differential Skid Plate Aft Brace Bushing Kit Bushing Sleeve PARTS LIST QTY RO NNN JN NN Pw P P N 860522 860528 420061 860554 DESCRIPTION Aft Brace Hardware Kit 1 2 13 x 4 0 HHCS 1 2 13 Stover Nut 1 2 SAE Washer Aft Brace Hardware Kit Sleeve M12 1 75 x 80 HHCS M12 1 75 Stover Nut M12 Washer USS Washer Thread Lock Tie Wrap Sway Bar amp Bump Stop Hardware Kit M12 1 75 x 30 HHCS M12 1 75 Stover Nut M12 Washer 7 16 USS Washer M10 1 25 x 30 HHCS M10 1 25 x 50 HHCS M10 1 25 Nut M10 Washer i P N DESGRIPTION Loop Strap 9 16 USS Washer 860555 Rear Hardware Kit 170014 Rear Brake Line Bracket 420062 Sleeve M8 1 25 x 20 HHCS M8 Washer 5 16 18 x 1 25 HHCS 5 16 18 Nut M10 1 50 x 75 HHCS M10 Washer M12 1 75 x 40 HHCS M12 1 75 Stover Nut M14 2 0 x 120 HHCS M14 2 0 Nut M14 Washer 1 2 USS
3. Washer 860556 Cross Member Hardware Kit M16 2 00 x 120 HHCS M16 2 00 Nut M16 Washer O lt Rn NR ERNNNND BR RaaOoOo lt N a Ml ND FRONT SUSPENSION VEHICLE PREPARATION amp TORSION 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 Illus 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 push pins from the inner wheelhouse liners Remove the liners P N DESCRIPTION M10 1 25 x 30 HHCS 7 16 USS Washer M10 1 25 x 35 HHCS M10 Lock Washer M10 Washer M14 2 00 x 40 HHCS M14 Washer M14 2 00 Stover Nut M10 1 50 x 60 HHCS M10 1 50 Nyloc Nut M10 1 25 Top Lock Nut 1 2 Rubber Washer 94180 Information Pack 780281 Rancho Decal 88569 Instruction 94119 Consumer Warranty Information 94177 Warning Sticker Box 2 of 2 176411 Knuckle Left 1 176412 Knuckle Right 1 O lt a A Os O BD KR BR CO B PO B CO ND Pol 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 Measure and record the length of adjuster bolt threads above the adjuster nut 6 LI Remove the adjuster bolt spacer and adjuster nut See illustration 2 Adjuster Nut Torsion Bar Adjust
4. 88569 Rev C INSTALLATION INSTRUCTION Chevrolet Colorado GMC Canyon 88569 Rev C 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 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 t
5. able on page 2 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 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 v Colorado Canyon Service Manual Universal Steering Linkage Puller J24319 Ball Joint Separator J43631 Torque Angle Meter J36660 A 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 Jack Stands Wheel Chocks wooden blocks Hydraulic Floor Jack Center punch File Hammer Wire Brush to clean bracket mounting surfaces Black Enamel Paint Brake Fluid Tape Measu
6. e washer and axle hub nut Tighten the nut to 191 ft Ibs 9 LJ Rotate tie rod end 180 degrees and attach to steering knuckle Tighten nut to 33 ft Ibs on the first pass Tighten an additional 95 degrees using torque angle meter J 36660 A 10 LJ Loosen the jam nut on the tie rod end Rotate the inner tie rod into the tie rod end three turns Tighten the jam nut ATTENTION Tie Rod may need to be trimmed to allow for proper Toe In adjustment See Note after Recommended Alignment Specifications at end of instructions 11 LJ Set the spindle to fender height at 24 5 inches Tighten the lower control arm rear bolt to 133 ft Ibs Tighten the lower control arm front bolt to 122 ft Ibs 12 LI Repeat steps 1 through 11 to install left steering knuckle 176411 on the driver side BRAKE HOSE REPLACEMENT 1 LJ Reattach the brake 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 2 LJ Disconnect brake line from brake hose at the frame bracket Plug brake line to prevent fluid loss Remove the retaining clip 10 3 LJ Remove bolt and gaskets from brake caliper Remove brake hose Do not reuse gaskets 4 L Attach new brake hose 170107 to the caliper with the supplied washers and original bolt See illustration 18 Tighten bolt to 32 ft Ibs 5 LI Insert brake hose through frame bracket Install 9 16 USS washer from kit 860554 ov
7. er WHEEL TERMINOLOGY g JI Width NA 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 SPECIFICATIONS INCH SYSTEM METRIC SYSTEM Class 12 9 l 65 FT LB 90 FT LB 55 FT LB 75 FT LB 90 FT LB 9 16 95 FT LB 130 FT LB 85 FT LB 120 FT LB 5 FT LB 9 FT LB 12 FT LB OM O M8 8 FT LB 23 FT LB 27 FT LB MO M10 32 FT LB 45 FT LB 50 FT LB 145 FT LB 135 FT LB 175 FT LB 130 FT LB 165 FT LB 210 FT LB 185 FT LB 280 FT LB 170 FT LB 240 FT LB 290 FT LB T G 1 2 13x1 75 HHCS ToT e DT L X Grade 5 rade 8 TA G Grade Marking bolt strength L Length inches D Nominal Diameter inches T Thread Pitch threads per inch X Description hex head cap screw M12 1 25x50 HHCS ee D T L X i P Property Class bolt strength L Length millimeters D Nominal Diameter millimeters X Description hex head cap screw T
8. er fitting on top of bracket 6 LJ Remove plug and attach brake line to brake hose While keeping the hose from turning tighten the brake line fitting to 14 ft Ibs Secure hose to bracket with the new E type retaining clip 7 LJ Reconnect ABS electrical connector Attach wire to upper control arm Reinstall wheelhouse liner Illus 18 8 LJ Repeat steps 1 through 7 for the other side 9 Bleed front brakes manufacturer s recommendations per SHOCK ABSORBER amp END LINK INSTALLATION CAUTION Do not use original shock absorbers 1 LI Support the driver side lower control arm 2 J Install washer and bushing on shock absorber stud Insert shock stud through upper mounting hole Install bushing washer and nut See illustration 19 Tighten the upper nut to 22 ft Ibs Illus 19 3 LJ Attach lower mount to the lower control arm bracket with the original hardware Tighten the lower nut and bolt to 59 ft Ibs 4 L Reattach left sway bar end link to flipped sway bar See illustration 20 Tighten nuts to 32 ft Ibs NOTE DO NOT flip end links ONLY sway bar is flipped left to right DRIVER SIDE LEFT Control Arm amp End Link Illus 20 5 LJ Repeat steps through 4 to install the Rancho shock absorber and right end link on the passenger side SKID PLATE INSTALLATION NOTE Install the rubber washers from kit 860556 between the skid plate and cross members Install two washers for each
9. ide height Verify that the front spindle to fender height is 24 5 to 24 7 and that both sides are equal If necessary adjust the tension on the torsion bars to correct the height 2 LJ 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 Readjust headlamps Have vehicle aligned at a certified alignment facility Recommended Alignment Specifications Caster degrees 4 6 1 0 Camber degrees 0 3 Sum Toe In degrees 0 2 NOTE Tie Rod may need to be trimmed to allow proper Sum Toe In adjustment If Required 1 Mark the location of the tie rod end on the tie rod Remove tie rod end Back the jam nut 1 4 inboard 2 LJ Trim 3 16 1 4 from the end of the tie rod See illustration 36 for details 3 LI Reinstall tie rod end Secure jam nut against tie rod end 3 16 1 4 From End K JU popra LJU 1 ny Ilus 36 Please retain this publication for future reference See Important Note O
10. le location on the frame bracket Drill a 31 64 hole at the marked location 5 LI Install the 12 mm hardware from kit 860554 Use the larger USS washer against the new bracket Tighten nuts and bolts securely 6 LJ Insert original bump stop into bracket 176408 7 LJ Repeat steps 1 through 6 to install the driver side lower control arm and left bump stop bracket 176407 See illustration 16 176407 d ONS STEERING KNUCKLE INSTALLATION 1 LJ Remove the ABS bracket bolt and the four hub bolts from the passenger side steering knuckle assembly Remove the steering knuckle 2 LI Clean bolt threads and apply thread lock Carefully attach right steering knuckle 176412 to the hub and bearing assembly with the original bolts See illustration 17 Tighten hub bolts to 92 ft Ibs 3 LJ Remove the ABS bracket Attach the ABS wire to the knuckle with the loop strap from hardware kit 860554 and original bolt 4 LI Support the passenger side lower control arm with a jack stand 5 LJ Carefully install the knuckle assembly on the axle shaft and lower ball joint Install the lower ball joint nut 176412 ABS Mounting Boss Do not use impact wrench Illus 17 6 LJ Insert the upper ball joint into the steering knuckle Install the upper ball joint nut 7 lI Tighten the lower ball joint nut to 107 ft Ibs Tighten the upper ball joint nut and bolt to 55 ft Ibs 8 LI Apply thread lock and install th
11. lines and attach the rear brake hose to bracket 170014 with the 5 16 hardware from kit 860555 See illustration 27 BUMP STOP BRACKET INSTALLATION 1 LJ Remove the bolts attaching the rear bump stop to the frame rail Remove the bump stop 13 Bump Stop Illus 28 2 LI Place bump stop bracket 176409 on bump stop Attach the bump stop assembly to the frame rail with the 10mm hardware from kit 860555 See illustration 29 Apply thread lock and tighten bolts to 27 ft lbs Do not over tighten 3 LJ Repeat steps 1 and 2 for the other side Illus 29 LEAF SPRING BRACKET amp SHACKLE INSTALLATION 1 LJ Loosen the leaf spring front and rear mounting bolts on both sides 2 LJ Disconnect the parking brake cable from the leaf spring See illustration 30 Parking Brake Cable Illus 30 3 LJ Remove the leaf spring front mounting bolt See illustration 31 Illus 31 4 L Lower the axle and place leaf spring bracket 176399 over the original frame bracket Using sleeve 420062 attach the bracket to the frame with the original hardware See illustration 32 Illus 32 14 CAUTION Do not allow the axle to hang by any hoses or cables Do not rest the driveshaft on the cross member 5 LJ Attach the front of bracket 176399 to the frame with the 12mm hardware and larger USS washers from kit 860555 Tighten the 12mm bolt to 55 ft Ibs then the 14mm bolt to 85 ft Ibs 6 LI Loosely attach the leaf s
12. ment Arm Adjuster Spacer a gt Ce PP adjuster Bolt Illus 2 7 LJ Disengage the torsion bar from the lower control arm Remove the adjustment arm and torsion bar 8 LJ Repeat steps 5 through 7 for the other side BUMP STOP amp SHOCK ABSORBER REMOVAL 1 LJ Remove the bump stop from the frame bracket as shown in illustration 3 Save for reuse Illus 3 2 LJ Support the lower control arm with a jack 3 LJ Remove the shock absorber upper mounting nut and insulator See illustration 4 Shock Absorber SS ae pi s Illus 4 4 L Remove shock absorber lower mounting bolt Remove shock absorber 5 L Repeat steps through 4 for the other side STEERING KNUCKLE amp LOWER CONTROL ARM REMOVAL 1 LJ Support the lower control arm 2 LI Disconnect the sway bar end from the sway bar Leave end link attached to control arm 3 LJ Remove the nut from the outer tie rod stud Disconnect the tie rod end from the steering knuckle with the recommended puller J24319 4 Disconnect the ABS wire at the frame rail harness Separate the wire from the frame and upper control arm 5 O Remove the axle hub nut Label the wheel hub and rotor assembly left or right for installation reference 6 LJ Remove the brake caliper and its mounting bracket as an assembly Hang the caliper assembly with wire or a tie wrap 7 LJ Remove the nut from the lower ball joint stud Separate the ball joint f
13. of the rear bolts and one for the front 1 LJ Using the 35mm length bolts attach skid plate 176414 to the front and rear cross members with the 1 10mm hardware from kit 860556 Tighten the front bolt then the rear to 32 ft lbs Illus 21 AFT BRACE INSTALLATION 1 LJ Lubricate two bushings and one sleeve from kit 860521 with a silicone spray Press the bushings and sleeve into aft brace 176410B See illustration 22 Cross Member 1 6405B 176410B 2 Illus 22 2 LJ Repeat step 1 to install the rest of the bushings and sleeves 3 LJ Loosely attach the aft braces to cross member 176405B with the hardware from kit 860522 Angle the aft braces slightly outward from front to rear 4 LI Loosely attach the two aft brace brackets 176357 on top of the transmission cross member See illustration 23 Insert sleeve 420061 into the existing hole and attach the brackets with the hardware from kit 860528 TE Illus 23 5 LJ Attach aft braces to brackets with the hardware from kit 860522 Tighten the bracket to cross member bolts then the aft brace bolts to 45 ft lbs TORSION BAR INSTALLATION 1 LJ Fully insert left torsion bar relocator 176353 into the driver side lower control arm Align the hex opening as close to the original bushing as possible See illustration 24 Transfer index mark to relocator Illus 24 2 LJ Align mark on left torsion bar with mark on torsion bar relocator Insert torsi
14. on bar into left relocator 3 LI Align marks and install torsion bar arm Refer back to illustration 2 4 J Install the adjuster bolt spacer and adjuster nut Tighten the adjuster bolt to its original height 5 LI Repeat steps 1 through 4 to install right torsion bar relocator 176352 on the passenger side 6 LJ Install front wheels and lower vehicle to ground Tighten the lug nuts to 103 ft Ibs REAR SUSPENSION SHOCK ABSORBER REMOVAL 1 LJ Chock front wheels Raise the rear of the vehicle and support the frame with jack stands Remove the rear wheels 2 LJ Support the rear axle assembly with a floor jack CAUTION Do not allow the axle to hang by any hoses or cables 3 LJ Disconnect the rear differential vent hose from the frame 4 L Remove the shock absorber upper and lower mounting bolts and nuts See illustration 25 Remove the shock absorber Lower Mount Illus 25 5 LJ Repeat for the other side BRAKE LINE BRACKET INSTALLATION 1 LJ Remove the mounting bolt for the brake hose at the rear differential bracket See illustration 26 Illus 26 2 LI Remove the brake hose bracket and mounting bolt 3 LJ Attach brake line bracket 170014 to the rear differential as shown in illustration 27 Use the 8mm bolt and washer from kit 860555 ma A w gt gt yad J z A N J 170014 s pet n t v 4 ha x 4 ne 7 Illus 27 4 J Carefully reshape the brake
15. pring to bracket 176399 with the 14mm hardware from kit 860555 7 LI If necessary lower the spare tire Remove the rear shackle mounting bolts See illustration 33 Remove the shackle Illus 33 8 LJ Using the original hardware loosely attach rear shackle 176413 to the leaf spring and frame bracket See illustration 34 he V ANI 2 Si Yams j omen Viva eo ETRE Illus 34 9 LJ To reattach the parking brake cable bend the leaf spring bracket slightly inward Attach cable to bracket with the original bolt 10 LJ Repeat steps 2 through 9 for the other side SHOCK ABSORBER INSTALLATION NOTE Do not install the original shock absorbers 1 LJ Attach new Rancho shock absorber to upper mount with the original bolts See illustration 35 Tighten bolts to 26 ft Ibs 2 LJ Attach new Rancho shock absorber to lower mount with the original hardware Tighten nut and bolt to 70 ft lbs Lower Mount Ilus 35 3 LJ Repeat for other side 4 LJ Install rear wheels and lower vehicle to ground Tighten lug nuts to 103 ft lbs 5 LI Tighten the nut and bolt on the leaf spring front mount to 59 ft lbs on the first pass Tighten the leaf spring shackle bolts to 63 ft Ibs 6 LJ Tighten the nut and bolt on the leaf spring front mount an additional 80 degrees using torque angle meter J 36660 A 15 FINAL CHECKS amp ADJUSTMENTS 1 LJ Jounce suspension and move the vehicle to normalize r
16. re Safety Glasses wear safety glasses at all times Ee JE a JE a a el i Gl Gl iE ae LE EV EVE a E p 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 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 4 to 5 hours Check off the box VI 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 The recommended tire and wheel size for this suspension system is a 285 70 R17 with 4 5 inches of wheel backspacing Minor wheelhouse trimming is required Before installing any other combination consult your local tire and wheel specialist Actual tire size varies by manufacturer Backspacing Negative Offset sei Mounting Face Diamet
17. right 5 LI Reinstall the front skid plate CROSS MEMBER INSTALLATION 1 LI To provide clearance for front cross member 176346B file the corners in both lower control arm front mounts See illustration 12 Remove sharp edges and paint exposed metal Illus 12 2 LI Attach front cross member 176346B to the lower control arm front mounts with the original hardware See illustration 13 Tighten the bolts to 122 ft lbs Illus 13 3 LJ Using the 30mm length bolts loosely attach rear cross member 176405B to the frame brackets with the 10mm hardware from kit 860556 See illustration 14 Use the shorter 10mm bolts with a lock washer and USS washer installed for the two inside locations 4 L Push up the cross member assembly Tighten the 10mm bolts evenly to 40 ft Ibs Illus 14 LOWER CONTROL ARM amp BUMP STOP BRACKET INSTALLATION 1 LJ Loosely attach the passenger side lower control arm to the front and rear cross members Use the 16mm hardware from kit 860556 for the front cross member and the original hardware for the rear 2 LJ Enlarge the hole in the bottom of the original bump stop frame bracket to 13 32 3 LJ Attach right bump stop bracket 176408 to the bottom of the original frame bracket with the 10 mm hardware from kit 860554 See illustration 15 Use the larger USS washer against the new bracket Illustration 15 4 LJ Using bracket 176408 as a template mark the rear mounting ho
18. rom the lower control arm with the recommended puller J43631 8 LJ Remove the nut from the upper ball joint Separate the ball joint from the upper control arm Remove the steering knuckle and hub assembly See illustration 5 ABS Wire Steering Knuckle Illus 5 9 LJ Remove the lower control arm pivot bolts See illustration 6 Remove the lower control arm 10 LJ Repeat steps 1 through 9 for the other side FRONT DIFFERENTIAL DROP BRACKET INSTALLATION 4WD ONLY 1 LJ Disconnect the vent hose and electrical connector Support the front differential assembly with adjustable stands 2 LJ Reference mark the front driveshaft to the front differential yoke Remove the yoke retainer bolts and retainers See illustration 7 Illus 7 3 LJ Disconnect the driveshaft from the differential Wrap bearing caps with tape and support the shaft CAUTION Lowering the driveshaft to far may damage the CV boot at the transfer case 4 LI Remove the front differential assembly mounting bracket to frame bolts Carefully lower the differential about 4 inches 5 LI Attach drop brackets 176348 and 176406 to the driver side frame and front differential assembly as shown in illustration 8 Use the original bolts and 14mm hardware from kit 860556 NOTE Drop brackets 176352 and 176406 must be installed with the angled end attached to the differential bracket and the welded gusset toward the front of the vehicle N
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