Installation Instructions for RS6547B
Contents
1. 176126 1429 Illustration 10 6 5 Attach the front differential assembly to the subframe 176126 with the original hardware Tighten the nuts and bolts to 75 ft Ibs 6 Attach the low profile bump stops 1429 to the subframe with the 3 8 hardware from kit 860174 7 y Using a piece of 1 2 plywood support the subframe and differential assembly with a floor jack 8 y 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 9 Attach the right axle tube bracket 176131 to the frame bracket with the original hardware Tighten all bracket mounting nuts and bolts to 75 ft Ib NOTE Verify that the left side of the front differential does not contact the rear frame bracket of the lower control arm If necessary cut off more of the fins from the differential case illustration 9 FAILURE TO PROVIDE CLEARANCE COULD CAUSE DAMAGE TO THE DIFFERENTIAL AND AXLE ASSEMBLY 10 y Reconnect the vent hose and electrical connector Align marks and reconnect the front drive shaft to the differential STEERING KNUCKLE amp HALFSHAFT INSTALLATION 1 Loosely attach the left lower control arm to the subframe with the 5 8 hardware from kit 860174 2 J Connect left steering knuckle 176128 to the lower and upper control arm ball joints Tighten the nut on the lower ball joint stud to 74 ft Ibs2. Tape the bearing cap assemblies and secure the shaft out of the way 3 y Disconnect the electrical connector and the vent hose from the differential assembly 4 y Cut off the front differential lower frame mount as shown in illustration 7 File all sharp edges and paint exposed metal Illustration 7 5 Remove the right axle tube nuts and the differential lower mounting bolt See illustration 8 tut Off Fins as marked gel From Case Illustration 8 Illustration 9 6 Support the front differential assembly with a 2 y Install bushings 520041 into differential floor jack Remove the upper mounting nut and bolt support bracket 176130 Apply silicon lubricant and press sleeve 420041 through the installed bushings 7 y Remove the differential assembly from the vehicle 3 Attach bracket assembly 176130 to the front differential as shown in illustration 10 Use the hardware from kit 860179 Tighten to specifications FRONT DIFFERENTIAL amp SUBFRAME INSTALLATION NOTE Gear oil may leak from the case when the 1 y Cut off the upper mount 1 4 from the case original bolts are removed and a section of the fins from the front differential See illustration 9 4 Loosely attach drop bracket 176131 as shown in illustration 10 to the differential axle tube with the CAUTION When modifying the front differential do 9 16 hardware from kit 860175 not cut into the case itself 176130 176137
3. 176192 to the track bar with the original hardware Insert sleeve 420052 and attach the new track bar bracket to the original as shown 1n illustration 25 Use the 9 16 hardware from kit 860415 A 25 2 Drill a 7 16 hole through the axle bracket at the location shown in illustration 26 Install the additional 7 16 hardware from kit 860415 Illustration 26 3 Tighten the 9 16 bolt to 77 ft lbs and the 7 16 bolt to 45 ft lbs Do not tighten the original track bar bolt until the vehicle is at normal ride height BUMP STOP SPACER INSTALLATION 1 y Place bump stop spacer 176193 on top of the lower link axle bracket See illustration 29 Align the rear hole in the new bracket with the existing hole Mark the additional mounting hole location T r 7 t J T y F 446 Grilled Hole Illustration 29 _ 2 Remove the spacer and drill a 3 8 hole at the marked location 3 y Attach bump stop spacer 176193 to the axle bracket with the 3 8 hardware from kit 860416 4 y Repeat steps 1 through 3 for the other side SWAY BAR END LINK ASSEMBLY amp INSTALLATION 1 Apply silicone lubricant and press bushing 545 into sway bar end link 176195 See illustration 27 Apply silicone lubricant and press sleeve 448 into the installed bushing End Link 1 6195 feo 545 Cc Sleeve A Illustration 27 2 Repeat step 1 to install the rest of the bushings and sleeves 3 Attach the
4. FT LB M12 1 25x50 HHCS gt aS a a oo a Aarne D T L ki o L Length millimeter Bescriplion hex head cap screw P Property Class Bolt strengih DO Nominal Craricter rillimotors T Thread Pitch thread width rim P N 176126 176128 176129 176130 176131 176132 176135 176138 176190 176191 176192 176193 176194 176195 672 860174 1429 420041 520041 860175 860176 860177 176137 420042 420045 520041 860179 DESCRIPTION Subframe Knuckle Left Knuckle Right Differential Support Bracket Right Axle Tube Drop Bracket Subframe Aft Brace Axle Spacer Aft Brace Bracket Link Drop Bracket Left Rear Link Drop Bracket Right Rear Track Bar Relocation Bracket Bump Stop Spacer Torsion Bar Drop Bracket Sway Bar End Link Rear Coil Spring Subframe Hardware Kit Bump Stop low profile Sleeve Bushing 5 8 18x4 5 HHCS 5 8 18x5 5 HHCS 5 8 18 Stover Nut 5 8 SAE Washer 3 8 16 Nyloc Nut 3 8 SAE Washer Thread Lock Front differential Hardware Kit 9 16 12x1 75 HHCS 9 16 12 Stover Nut 9 16 SAE Washer 9 16 USS Washer Axle Spacer Hardware Kit M10 1 50x60 HHCS SAE Washer Support Tube Hardware Kit Nut Bracket 75x 095x2 73 Sleeve 1 00x 219x1 00 Sleeve Bushing 1 2 13x1 25 HHCS 1 2 13x2 5 HHCS 1 2 13x4 00 HHCS 1 2 13 Stover Nut 1 2 SAE Washer Differential Hardware Kit M10 1 50x60 HHCS 7 16 14x3 0 HHCS 7 16 14 Stover Nut SAE Washer 7 16 SAE Washer PARTS LIST QTY pk peek
5. torsion bar drop bracket 7 y Attach the drop brackets to the crossmember with the original bolts 8 Attach the crossmember assembly to the frame brackets with the 9 16 and 3 8 hardware from kit 860411 Tighten the 3 8 bolts to 35 ft Ibs then the 9 16 amp original bolts to 70 ft Ibs 9 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 10 Install the torsion bar unloading tool and increase the tension on the torsion bar 11 y Reinstall the retaining plate and adjusting bolt Thread the adjusting bolt in until 1 6 inches of threads are exposed below the retaining plate Remove the unloading tool 12 Repeat steps 9 through 11 for other side 13 Install front wheels and lower vehicle to ground Tighten the lug nuts to 140 ft Ibs 14 y Tighten the lower control arm pivot bolts to 107 ft Ibs REAR SUSPENSION END LINK SHOCK ABSORBER amp C OIL SPRING REMOVAL 1 Chock front wheels Raise the rear of the vehicle and support the frame with jack stands Remove the rear wheels 2 Support the rear axle assembly with a floor jack 3 J Remove the end link nut and bolt from the frame bracket Remove the end link nut from the ball stud See illustration 17 Illustration 17 4 J Remove the end link 5 y Repeat steps 3 and 4
6. 190 to the frame with the original hardware Install the 1 2 hardware from kit 860414 Tighten the 1 2 nut and bolt to 65 ft Ibs and the original bolts to 80 ft Ibs 7 y Insert the brake cable through the hole in the new drop bracket and into the frame mount until the Illustration 21 locking tabs snap into place See illustration 23 Attach the cable end to the equalizer g Illustration 22 8 Attach the upper and lower links to drop bracket 9 Repeat steps through 8 excluding the brake 176190 with the 9 16 hardware from kit 860414 Do cable to install drop bracket 176191 on the passenger not tighten the bolts until the vehicle is at normal ride side height 11 COIL SPRING amp SHOCK ABSORBER INSTALLATION 1 y Place new coil springs 672 with original insulators on the rear axle Raise the axle and guide the springs into the frame pockets 2 Attach new Rancho shock absorbers to the upper and lower mounts 672 Illustration 23 BRAKE LINE BRACKET INSTALLATION 1 Attach the new brake line bracket 170014 to the rear differential with the original bracket bolt See illustration 24 arena 94 2 y Carefully reshape the brake line and attach the junction block to the top of bracket 170014 Use the 5 16 hardware from kit 860143 12 3 y Reattach the brake line to the rear axle with the two original bolts TRACK BAR BRACKET INSTALLATION 1 Attach track bar bracket
7. INSTALLATION INSTRUCTION 88146 RevA FOR RANCHO SUSPENSION SYSTEM RS6546 CHEVROLET SUBURBAN 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 DO NOT install suspension system RS6546 on vehicles equipped with the Autoride Suspension Option B 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 C Do not install a body lift kit with this suspension system or interchange Rancho components with parts from another manufacturer Use the following Rancho shock absorbers Front shocks RS9268 or RS17337 Rear shocks RS9274 or RS17346 D Do not chrome cadmium or zinc plate any of the components in this system To change the appearance of components enamel paint can be applied over the original coating E Each hard
8. and the nut on the upper ball joint stud to 37 ft Ibs 3 Apply thread lock and attach the hub and bearing assembly to the left steering knuckle with the original hardware See illustration 11 Tighten the mounting bolts to 133 ft Ibs 4 Loosen the tie rod end jam nut and thread the tie rod end inward two 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 Ibs 5 y Insert the wheel drive shaft halfshaft into the knuckle hub Install the shaft washer and nut NOTE Do not lubricate the wheel drive shaft splines and the knuckle with grease Hub amp Bearing Assembly Steering Knuckle 175128 Illustration 11 6 Place axle spacer 176135 against the differential flange Place the axle flange against the spacer Align the flange marks and attach the axle to the differential with the hardware from kit 860176 Be sure to apply thread lock to the bolts Tighten the flange bolts to 58 ft Ibs 7 Install the brake rotor 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 y Place a drift or large screwdriver through the caliper to prevent the drive axle from turning See illustration 12 Illustration 12 9 Tighten the axle hub nut to 165 ft lbs Remove the drift from the rotor 10 Slide the bra
9. cts offer no significant incremental collision protection beyond that provided by the original vehicle design as produced by the vehicle manufacturer Buyer assumes all risk and liability whatsoever resulting from the installation and use of Rancho Gear products Rancho assumes no liability for injury collision or other road hazard These products are not a substitute for safe and careful driving Vehicles equipoed with supplemental restraint systems air bags that are deployed by impact rather than a sudden velocity decrease should not be modified or altered with any aftermarket grill guard or brush bar Such modification could alter the deployment of the airbag s in the event of a frontal impact collision or other road hazard Limited 5 Year Warranty Limited 5 year warranty on Rancho Gear products Rancho Industries warrants each new Grille Guard Side Step Taillight Guard and Skid Plate against factory defects in material and workmanship except finish for 5 years after the date of purchase RIGHTS RESERVED Rancho Industries reserves the right to make changes in design material and specifications or to make product changes as deemed necessary without prior notice Obligations or liabilities will not be assumed wih respect to similar products previously advertised PRINTING ERRORS Every effort has been made to avoid printing errors in our literature However if there are any specification or application errors we must disclaim resp
10. e STEERING KNUCKLE amp LOWER CONTROL ARM REMOVAL 1 Separate the brake hose from the bracket on top of the steering knuckle Use pliers to pry the bracket open Remove the bolt and brake hose bracket from the upper control arm 2 y Remove the brake caliper and its mounting bracket as an assembly Hang the caliper assembly with wire or a tie wrap 3 Remove the brake rotor 4 J Remove the prevailing torque nut from the outer tie rod stud Discard nut Disconnect the tie rod end from the steering knuckle with a universal puller 5 y If applicable separate the ABS speed sensor cable at the frame and the upper control arm 6 Remove the hub and bearing assembly mounting bolts See illustration 5 Remove the hub and bearing assembly Caliper Assembly Pa Hub amp Bearing Assembly Steering Knuckle Illustration 5 7 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 8 Remove the lower control arm pivot bolts See illustration 6 Remove the lower control arm Illustration 6 9 J Repeat steps 1 through 8 for the other side FRONT DIFFERENTIAL REMOVAL 1 y If applicable remove the front differential skid plate 2 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
11. 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 28 Illustration 28 4 J Repeat step 3 for the other side Do not tighten the end link bolts until the vehicle is at normal ride height 5 y Install rear wheels and lower vehicle to ground Tighten lug nuts to 140 ft Ibs 6 Tighten the end link bolts to 24 ft lbs Tighten the track bar bolt to 77 ft Ibs Tighten the upper link arm bolts to 77 ft Ibs and the lower link arm bolts to 89 ft Ibs FINAL CHECKS amp ADJUSTMENTS 1 Jounce suspension and move the vehicle to normalize ride height Verify that the front spindle to fender height 1s 25 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 Notes 2 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 y Readjust headlamps Have vehicle Aligned at a certified alignment facility Recommended Alignment Specifications Caster degrees 4 5 1 0 Camber degrees 0 3 Sum Toe In degrees 1 2 RANCHO RANCHO INDUSTRIES USA LIMITED WARRANTY 14 ABOUT OUR WARRANTY Rancho Industries USA warrants the listed products for the listed time period and or mileage to the origina
12. es outside of the United States the finish any condition s caused by abnormal use or service and product specific limitations if any listed below THE LOSS OF USE OF THE PRODUCT LOSS OF TIM INCONVENIENCE COMMERCIAL LOSS OR CONSEQUENTIAL DAMAGES ARE NOT COVERED RANCHO INDUSTRIES RESERVES THE RIGHT TO CHANGE THE DESIGN OF ANY PRODUCT WITHOUT ASSUMING ANY OBLIGATION TO MODIFY ANY PRODUCT PREVIOUSLY MANUFACTURED THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE SOME STATES DONOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS WHICH EXTEND BEYOND THIS WARRANTY PERIOD THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE FACE HEREOF SELLER DISCLAIMS IMPLIED WARRANTY OF MERCHANTABILITY THIS WARRANTY SHALL NOT APPLY TO ANY RANCHO PRODUCT WHICH HAS BEEN MODIFIED CUSTOMIZED OR IMPROPERLY INSTALLED WARRANTY DOES NOT APPLY TO ANY RANCHO COMPONENTS USED FOR RACING PURPOSED OR RACE TYPE ACTIVITIES WARRANTY DOES NOT APPLY TO ANY RANCHO INDUSTRIES RACING PRODUCTS The product time periods and or mileage under this warranty are as follows RS5000 RS5600 RS9000 RSX LIMITED LIFETIME WARRANTY Limited lifetime warranty on
13. for the other side 6 Remove the upper shock absorber nut and bolt Remove the lower shock absorber nut and bolt See illustration 18 Remove the shock absorber Illustration 18 7 y Repeat step 6 for the other side 8 Remove the nut and bolt holding the track bar to the rear axle 9 Remove the bracket holding the brake line junction block to the rear differential Remove the two bolts attaching the brake line to the left and right sides of the rear axle 10 Carefully lower the rear axle Do not allow the axle to hang by any hoses or cables Remove the coil springs and insulators See illustration 19 _ Illustration 19 LINK DROP BRACKET INSTALLATION 1 Starting with the driver side remove the nuts and bolts attaching the upper and lower links to the frame See illustration 20 Do not detach the links from the passenger side a Upper Link Lower Link Illustration 20 2 J Disconnect the left side brake cable from the 3 Insert left link drop bracket 176190 into the equalizer Remove the cable from the mounting frame brackets See illustration 22 Temporarily bracket by depressing the locking tabs attach the bracket to the frame with the original bolts 4 Mark and center punch the new 1 2 hole location on the bottom of the original lower link bracket Equalizer 5 Remove the drop bracket and drill a 1 2 hole at the marked location 6 Reattach drop bracket 176
14. ion Wrenches Heavy Duty Jack Stands Wheel Chocks wooden blocks Hydraulic Floor Jack Center punch File Large C Clamps Bench Vise and Adjustable Straps Reciprocating Saw to modify frame and differential Hammer Wire Brush to clean bracket mounting surfaces Silicone Spray Lubricant Tape Measure Safety Glasses wear safety glasses at all times Sad Te Sse tg eae a eg ge de a Oy a Ce Os ee a K 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 L 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 M The required installation time for this system is approximately 12 hours Check off the box 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 285 75 R16 tire 16 x 8 wheel with 4 5 inches of wheel backspacing Before installing any other combination consult your local tire and wheel specialist A 16 inch factory wheel with more than 4 5 inches of backspacing cannot be u
15. ke hose clamp down and attach it to the top hole in the back of the steering knuckle Use a clamp bolt from the original knuckle 11 y If applicable reconnect the ABS cable Attach the ABS cable to the knuckle and upper control arm with tie wraps See illustration 13 12 Repeat steps 1 through 11 for the other side 13 y Attach the sway bar to the lower control arm with the new end link assemblies from kit 860180 and the original bushings See illustration 14 Insert the 3 8 x 14 bolt from the top 14 Install new Rancho shock absorbers Subframe 176126 Illustration 14 AFT BRACE INSTALLATION 1 Lubricate two bushings 520041 and one sleeve 420042 from kit 860177 with a silicon spray Press the bushings and sleeve into aft brace 176132 as shown in illustration 15 2 Repeat step 1 to install the rest of the bushings and sleeves a Sleeve 420042 4 Alt Brace 176132 2 Bushing 520044 8 Transmission Crossmember Nut Bracket 178137 2 Aft Brace Bracket 176136 2 Illustration 15 3 J Loosely attach each aft brace assembly to the rear of the subframe 176126 with the hardware from kit 860177 4 y If applicable remove the transfer case skid plate 5 To mount the driver side aft brace bracket drill a 1 2 hole through the bottom of the transmission crossmember See illustration 15 6 Insert nut bracket 176137 inside the crossme
16. l retail purchaser against defect and wear out when used on passenger cars and light trucks under normal operating conditions The warranty does not apply to Rancho products which have been improperly applied or installed The consumer wil be responsible for removing from the vehicle and returning any defective item s transportation costs prepaid to the dealer from which it was purchased or a Rancho Authorized Installer and for reinstallation of the part upon return A copy of the sales receipt is required for all warranty adjustments Rancho Industries will without charge repair or replace at its option defective products or component part s In the case that the customer is unable to return to the original place of purchase or an Authorized Installer the consumer may contact Rancho Industries at 1 800 574 6257 to obtain a Return Authorization Number prior to shipping The consumer will be responsible for removing from the vehicle and returning any defective item s transportation cost pre paid to the following address 1 International Drive Monroe MI 48161 A copy of the sales receipt is required for any warranty adjustments Rancho Industries will without charge repair or replace at its option defective products or component part s Such item s wil be returned with transportation costs prepaid within the United States from Rancho Industries The customer will be responsible for reinstallation Exclusions from this warranty are sal
17. mber as shown in illustration 15 Align the bracket over the existing or previously drilled hole 7 y Apply thread lock and insert a 1 25 bolt with washer from kit 860177 through the slotted hole in bracket 176138 Attach the bracket to the crossmember by threading the bolt into the nut bracket Do not tighten the bolt at this time 8 Repeat steps 6 and 7 for the other side 9 Attach each aft brace to the crossmember brackets with the hardware from kit 860177 See illustration 15 10 Tighten the aft brace mounting bolts to 80 FT LBS then the bracket to crossmember bolts to 65 FT LBS 11 y If applicable cut the corner of the skid plate to avoid contact with the aft brace bracket Reinstall the transfer case skid plate TORSION BAR amp DROP BRACKET INSTALLATION 1 y Place torsion bar drop bracket 176194 against the frame rail directly below the crossmember bracket Temporarily install the 9 16 bolt from kit 860411 See illustration 16 2 J Mark and center punch the 2 holes on the bottom of the existing bracket 3 Remove the bracket and drill a 7 16 hole at each of the marked locations 4 Repeat steps 1 through 3 for the other side 5 Align marks and insert the left and right torsion bars into their respective lower control arms Slide the arms forward Torsion Bar Crossmember Illustration 16 6 y Insert two bushings and a sleeve from kit 860411 into each new
18. onsibility This document was created with Win2PDF available at http www daneprairie com The unregistered version of Win2PDF is for evaluation or non commercial use only
19. pd NO BRP BRP NABNN CON BNR NNRFRNNNNRWNHNN DPN NNRP NFP NNN NO RRR NN WN FE e ee P N 860180 420044 860411 485 552 860412 448 545 860413 170014 860414 860415 420052 860416 88146 94140 DESCRIPTION End Link Hardware Kit Front Sleeve Retainer 3 8 16x14 0 HHCS 3 8 16 Nyloc Nut T Bar Crossmember Hardware Kit Sleeve Bushing 3 8 16x1 00 HHCS 3 8 16 Stover Nut 3 8 SAE Washer 9 16 12x3 00 HHCS 9 16 12 Stover Nut 9 16 SAE Washer End Link Hardware Kit Rear Sleeve Bushing M12 x 1 75 x 70 HHCS M12 X 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 9 16 12x3 50 HHCS 9 16 12x4 00 HHCS 9 16 12 Stover Nut 9 16 SAE Washer 1 2 13x1 25 HHCS 1 2 13 Stover Nut 1 2 SAE Washer Rear Track Bar Hardware 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 Bump Stop Hardware Kit Rear 3 8 16x1 50 HHCS 3 8 16 Stover Nut 3 8 SAE Washer Instructions Consumer Information Pack QTY me COR BRR NRK RK NRK KKK LF NNWANNRKNRK RK RR NNNN A FFKANNWAAANKNN ON FRONT SUSPENSION VEHICLE PREPARATION amp TORSION BAR REMOVAL 1 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
20. sed with this suspension system O Important information for the end user is contained in the consumer information pack If you are installing this system for someone else display the information pack by hanging it from the rear view mirror 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 METRIC SYSTEM STANDARD BOLT TORQUE amp IDENTIFICATION ae sid Bolt Size Class 9 8 Class 10 9 Class 12 9 M6 5 FT LB 9 FT LB 12 FT LB M8 18 FT LB 23 FT LB 27 FT LB M10 32 FT LB 45 FT LB 50 FT LB 55 FT LB 75 FT LB 90 FT LB 130 FT LB M14 85 FT LB 120 FT LB 145 FT LB 175 FT LB M16 130 FT LB 165FT LB 210 FT LB INCH SYSTEM Bolt Size Grade Grade 8 5 16 15 FT LB 20 FT LB 3 8 30 FT LB 35 FT LB 7 16 45 FT LB 60 FT LB 1 2 65 FT LB 90 FT LB 9 16 95 FT LB 5 8 135 FT LB 3 4 185 FT LB 280 FT LB 1 2 13x1 73 HHCS gt mera co a Cx b N C T L x Giada 5 Gaded L G Grade Marking ball strength C Nominal Diameter inches T Thread Pitch fhreads per inch L Length inches A Description hex head cap sorevw M18 170 FT LB 240FT LB 290
21. these Rancho shock absorbers Rancho Industries warrants each new shock against factory defects in material and workmanship except for finish including the shock boot for as long as the original retail purchaser owns the vehicle on which the units were originally installed RC9000 REMOTE CONTROL LIMITED 2 YEAR 24 000 MLE WARRANTY 15 Limited 2 year 24 000 mile warranty on these Rancho products Rancho Industries warrants each new RS4000 Air Rancho shock and RC9000 Remote Control System against factory defects in materal and workmanship except for finish including shock boot for the first to occur of 2 years or 24 000 miles after the date of purchase SUSPENSION COMPONENTS LIMITED LIFETIME WARRANTY Limited lifetime warranty on all of Rancho s suspension products Rancho Industries warrants each new Suspension Component against factory defects in material and workmanship except finish for as long as the original retail purchaser owns the vehicle on which the products were originally installed THIS LIMITED WARRANTY DOES NOT COVER THE FOLLOWING e Any component that has been modified customized or improperly installed e Any part that is obsolete and is no longer available or supplied by Rancho RANCHO GEAR Disclaimer Statement Grille Guards Side Steps Skid Plates and Taillight Guards are designed as decorative accessories to enhance the styling of the vehicle and are not intended as collision protection devices These produ
22. tration 1 2 y Raise the front of the vehicle and support the frame with jackstands Remove the front wheels and set them aside 3 J Mark the torsion bars left and right Make alignment marks on the torsion bars the lower control arms and the adjustment arms 4 y 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 5 Slide the torsion bar forward and remove the adjustment arm See illustration 2 Pad Adjustment Arm aN Illustration 2 6 Repeat steps 4 and 5 for the other side 7 y Remove the 2 bolts 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 WHEEL DRIVE SHAFT HALFSHAFT REMOVAL 1 Remove the front shock absorbers Unsnap the bump stop from the mounting cup 2 Remove the sway bar end links See illustration 3 Illustration 3 3 Mark the differential output flange and the axle flange for installation reference 4 y Remove the nut and washer from the hub Remove the six bolts from the inboard flange See illustration 4 Illustration 4 5 y Pull the halfshaft out of the hub and through the lower control arm opening Be careful not to damage the drive shaft boots 6 Repeat steps 3 through 5 for the other sid
23. ware 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 F Compare the contents of this system with the parts list in these instructions If any parts are missing contact the Rancho Technical Department at 1 800 574 6257 G 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 H 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 Unless otherwise specified tighten all nuts and bolts to the standard torque specifications shown in the table below USE A TORQUE WRENCH for accurate measurements J 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 Chevrolet Service Manual Torsion Bar Unloading Tool J36202 Universal Steering Linkage Puller J24319 Ball Joint Separator J43631 Prevailing Torque Nuts for steering linkage Die Grinder Drill motor Assorted Drills 1 8 through 1 2 Torque Wrench 250 FT LB capacity 1 2 Drive Ratchet and Sockets Assorted Combinat
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