Installation Instructions
Contents
1. 2 Ll Install with hardware from kit R8860757 Use 8mm hardware in top hole and 12mm hardware in middle hole Torque 8mm hardware to 20 ft Ibs and 12mm hardware to 55 ft Ibs 3 Ll Attach sway bar end link to drop bracket RS176733 with OE hardware Torque to 75 ft Ibs BUMP STOP DROP BRACKET INSTALLATION Box RS66453B 4 Box 4 of 5 Rear Bump Stop Spacers RS176732 Hardware from Sub Assy RS860756 1 Ll Remove bump stops from frame 2 Ll Attach bump stop spacer RS176732 to frame using OE hardware See Torque hardware to 40 ft Ibs NOTE On passenger side spacer install and snug rear bolt first with spacer rotated to allow easier access to bolt 3 Ll Attach bump stop to spacers RS176732 using 10mm hardware supplied in kit RS860756 Torque hardware to 40 ft los Illustration 26 E BRAKE DROP BRACKET INSTALLATION SF Box RS66453B 4 Box 4 of 5 E Brake Drop Bracket RS176600 Hardware from Sub Assy RS860781 1 Ll Attach e brake drop bracket RS176600 to OE e brake hanger using 8mm hardware from kit RS860781 2 Ll Attach e brake drop bracket and hanger to frame using OE hardware See Illustration 27 Illustration 27 17 LOWER VEHICLE 1 Ll Install rear wheels and lower vehicle to ground Tighten lug nuts to 140 ft Ibs Note If installing aftermarket wheels remove rotor retainer clips from wheel studs to allow wheels to sit flush against rotor See Illustration 1 2 J Attach track bar to2. wheel specialist Backspacing Negative Offset Mounting Face Diameter WHEEL TERMINOLOGY Grade5 Grade 8 NM G Grade Marking bolt strength L Length inches D Nominal Diameter inches T Thread Pitch threads per inch STANDARD BOLT TORQUE amp IDENTIFICATION P Property Class bolt strength X 7 Description hex head cap screw N 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 0 The lifespan of Rancho products depends on many factors Improper use abuse or harsh use in general may compromise the integrity of the suspension system and significantly reduce its lifespan The suspension system is also subject to wear over time Have the suspension system regularly inspected and maintained by qualified mechanics If the inspection reveals any damage or excessive wear no matter how slight immediately replace or repair the component The suspension system must be regularly maintained in order to optimize its safe and efficient use The more severe the conditions under which the suspension system is operated the more often it must be inspected and maintained 5 Vehicles equipped with two piece rear driveshaft may require and additional drive shaft carrier bearing spacer kit If you
3. from kit RS860758 at original track bar mounting location Do not tighten hardware at this time 2 Ll Loosely attach track bar bracket RS176731 at coil mount and bottom of bracket with 10mm hardware and flag nut RS176735 Use extra supplied M10 washers to fill gap between OE bracket and RS176731 if needed See Illustration 24 e cw Illustration E 3 LJ Tighten lower 10MM track bar bracket hardware to 35 ft Ibs Tighten remaining 10mm track bar hardware to 45 ft Ibs 4 L1 Using hole in track bar bracket RS176731 as a guide drill a 13 32 hole through the OE track bar mount Attach using remaining 10mm hardware from kit RS860758 Tighten to 45 ft lbs See Illustration 25 16 Drill 13 32 M10x35MM Illustration 25 COIL SPRING INSTALLATION 3F Box RS66453B 5 Box 5 of 5 Rear Progressive Coil Springs RS832B New Rancho rear shock absorbers 1 J Align lower coil spring isolator with mark 2 Ll Place original insulator on top of coil spring 832B then raise the axle guiding the coils into the frame pockets 3 Ll Attach new Rancho shock absorbers to the upper and lower mounts Torque to 120 ft Ibs SWAY BAR ENDLINK DROP BRACKET INSTALLATION Box RS66453B 4 Box 4 of 5 Rear oway Bar End Link Drop Bracket RS176733 Hardware from Sub Assy RS860756 1 Ll Place sway bar end link drop bracket RS176733 over OE end link mounting bracket See Illustration 26 Illustration 26
4. the space provided below Illustration 3 2 Ll Disconnect the track bar from the frame bracket See Illustration 1 3 Ll Raise the front of the vehicle and support the frame with jack stands Remove the front wheels and set them aside ATTENTION Leave 4 inches between radius arm frame mount and jack stand to allow clearance for radius arm drop brackets See Illustration 4 Illustration 4 PITMAN ARM amp 5 BAR REMOVAL 1 LJ Mark and measure the position of the drag link adjusting barrel jam nuts then loosen the jam nuts See Illustration 1 2 LJ Remove the drag link ball stud nut at the pitman arm 3 Ll Using a pitman arm puller separate the drag link from the pitman arm See Illustration 1 NOTE Make sure puller jaws seat on pitman arm not the boot retainer of the ball stud 4 LI Mark the pitman arm and steering gear box shaft for installation reference Remove the nut and washer from the pitman arm 5 Ll Using a pitman arm puller remove the pitman arm 6 LJ Remove the sway bar mounts at the frame See Illustration 1 COIL SPRING amp SHOCK REMOVAL 1 Ll Support the front axle with two floor jacks one under each coil spring 2 Ll Mark position of alignment cam bolts on radius arms See Illustration 2 3 LJ Remove the mounting bolts holding the front brake hoses brackets to axle There are 2 brackets on each side See Illustration 5 Illustration 5 4 L Remove clip at
5. to 220 ft Ibs Note If track bar does not line up with bracket have an assistant slowly turn steering wheel until holes align 3 Ll Tighten radius arm bolts at drop bracket to 220 ft Ibs 14 REAR SUSPENSION Track Bar 7 Sway Bar Vent Hose Clip Illustration 22 SHOCK ABSORBER amp COIL SPRING REMOVAL 1 LJ Chock front wheels 2 LJ Remove axle vent line clip from the rear track bar axle mounting bracket See Illustration 22 3 LI Remove the bolt and nut holding the track bar to the rear axle See Illustration 22 4 L1 Raise the rear of the vehicle and support the frame with jack stands Remove rear wheels 5 LJ Support the rear axle assembly with a floor jack Illustration 23 6 L Remove Sway bar end links from frame brackets See 8 C Remove the upper and lower shock mounting bolts Illustration 22 Remove shock absorber 7 LJ Mark location of lower coil spring isolators spring stop 9 J Carefully lower the rear axle Do not allow the axle to on lower coil mount and remove isolator from coil mount See hang by any hoses or ABS cables Illustration 23 N 15 10 LJ Remove both coil springs and upper insulators from vehicle TRACK BAR BRACKET INSTALLATION 3F Box RS66453B 4 Box 4 of 5 Rear Track Bar Bracket 8 Hardware from Sub Assy RS860758 1 Ll Place track bar bracket RS176731 over OE track bar axle bracket Install OE track bar bolt OE flag nut and spacer RS420109
6. turns and other abrupt maneuvers 1 Service and repair tasks require specialized knowledge training tools and experience General mechanical aptitude may not be sufficient to properly install this suspension system If you have any doubt whatsoever regarding your ability to properly install the suspension system please consult a qualified mechanic 2 Your brake lines and fuel lines should remain undisturbed during and after installation If you think you need to modify these components in any way you are mistaken You are installing the lift improperly and will be creating a significant risk of an accident In case of any doubt consult a qualified mechanic 3 If any component does not fit properly something is wrong You are installing the lift kit improperly and will be creating a significant risk of an accident Never modify any component of the vehicle or suspension system except as instructed herein Do not continue with installation until you have identified the problem 4 Several of the procedures described herein require at least two 2 persons to safely complete the task If you have any doubt about your ability to complete any operation by yourself always ask for help from a qualified assistant 5 Before starting any operation confirm that all personal safety devices and safety equipment are in proper condition and position 6 Give your work undivided attention Looking around carrying on a conversation and h
7. ESCRIPTION Box 4 of 5 Rear Bump Stop Spacer 3 00 Sub Assy Rear Bump Stop Spacer HHCS M10 1 50 X 30mm Nut 10mm 1 50 NyLock Washer M10 Rear Sway Bar Link Drop Bracket Sub Assy Sway Bar Endlink Brkt Hdwr HHCS M8 1 25 X 20mm Nut 8mm 1 25 NyLock Washer M8 HHCS M12 X 1 75 X 25mm Nut 12mm 1 75 NyLock Washer M12 Rear Track Bar Bracket Sub Assy Rear Track Bar Hdwr Spacer 1 00 X 56 X 1 HHCS M10 1 25 X 35mm Nut M10mm 1 25 TopLock Washer M10 Flag Nut M10 1 25 HHCS M14 2 00 X 100mm Nut M14 2 00 TOPLOCK Washer M14 E Brake Drop Bracket Sub Assy E Brake Brkt Hdwr HHCS M8mm 1 25 X 20mm Nut M8 1 25 NyLock Washer M8 Carrier Bearing Spacer Sub Assy Carrier Bearing Spacer Hdwr HHCS M8 1 25 X 55mm Washer M8 NWNHPRFPRPANNANNRFPN WA m O NON HP QU M P pP H H HB HB Box 5 of 5 ITEM PART DESCRIPTION QTY RS66453B 5 BOX 5 OF 5 1 RS832B Rear Coil Spring 2 5 Progressive 2 FRONT SUSPENSION qe Pw Ball Stud Pitman Arm 2 Isolator Vent Hose Clip Shock Absorber Radius Arm z Alignment Cam Retainer Clips Illustration 2 VEHICLE PREPARATION amp SwAY BAR REMOVAL 1 Ll Park the vehicle on a level surface Set the parking brake and chock the rear wheels Measure and record the distance from the center of each wheel to the top of the fender opening See Illustration 3 Record these measurements in
8. INSTALLATION INSTRUCTIONS 89453 Rev C For Rancho Suspension Systems RS66453B 4 5 Radius Arm Kit DIESEL MODEL ONLY 2014 Dodge Ram 2500 4WD FMVSS 126 Certified per 7 d eT 5 SS m Shown amp Tested with Fits OE 17 and up rims and spare BFG KM2 37X12 5R20 Tires ONLY WITH OE TIRES Vision Fury Rims 20 x 9 x 5 5 Backspacing A WARNING Carefully read understand and follow the instructions provided in this manual and keep it in a safe place for future reference If you have any doubt whatsoever regarding the installation or maintenance of your Rancho suspension system please see your retailer for assistance or advice Failure to follow the warnings and instructions provided herein can result in the failure of the suspension system or can cause you to lose control of your vehicle resulting in an accident severe personal injury or death These instructions should remain in the vehicle glove box for future reference Rancho Suspension 1 89453 Rev C N WARNING READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION Failure to follow the warnings and instructions provided herein can result in an accident severe personal injury or death PRELIMINARY This manual presumes that all persons installing this suspension system have a high level of mechanical training and experience and have available to them all necessary tools and safety equipment This ma
9. Rancho track bar bracket RS176731 using 14mm hardware supplied in kit RS860758 Torque both upper and lower 14mm track bar and bracket bolts to 120 ft Ibs CHECKS amp ADJUSTMENTS 3 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 4 L 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 5 LJ Ensure that the vehicle brake system operates correctly If new brake hoses were installed verify that each hose allows for full suspension movement 6 Ll Readjust headlamps 7 LJ Center steering wheel Have vehicle Aligned at a certified alignment facility 8 Ll Measure and record the distance from the center of each wheel to the top of the fender opening See Illustration 28Record these measurements in the space provided below Illustration 28 NOTE Vehicles equipped with two piece rear driveshaft may require and additional drive shaft carrier bearing spacer kit If you experience drive line vibration after installing this kit on a vehicle with a two piece rear driveshaft please contact Rancho Technical Support at1 734 384 7804 and ask for RS6609 RS176738 Carrier Bearing Spacer RS860780 Sub Assy Car
10. d Proper tire pressure is critical to safe operation of the vehicle OPERATION 19 Because it has been modified the vehicle will not handle turn accelerate or stop in the same manner as an unmodified vehicle In addition the crash protection systems designed in the vehicle may operate differently from an unmodified vehicle For example turning and evasive maneuvers must be executed at a slower rate of speed Further there is a greater risk that the vehicle could roll over These differences could result in an increased possibility of an accident personal injury or death Learn the vehicle s operations and handling characterizes and drive IMPORTANT NOTES 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 The components of Rancho s suspension system are designed as a single integrated system To avoid compromises in terms of safety performance durability or function do not substitute Rancho components with components manufactured by other companies Use of other components will result in the forfeiture of any type of warranty on the vehicle suspension system New Rancho shock absorbers are required and must be purchased separately RS999048 RS999048 RS7048 RS7048 RS5048 RS5048 C Do not powder coat or plate any of the components
11. d hinder your ability to work safely WARNINGS AND INSTRUCTIONS AFTER INSTALLATION 13 After installation is complete drive the vehicle slowly in an area free from heavy traffic for at least three 3 miles Likewise before traveling on any highways or at a high rate of speed drive the vehicle for ten ten miles on side roads at moderate speed If you hear any strange noise or feel unusual vibration if a component of the suspension system is not operating properly or if any warning lights illuminate or buzzers sound stop the vehicle immediately Identify the cause and take any necessary remedial action 14 Confirm that all components of the vehicle including all lights headlights turn signals brake lights etc linkages accelerator etc electrical switches and controls windshield wipers and defoggers etc and other warning devices low tire pressure monitoring systems are fully operational 15 Your headlights will need to be readjusted before the vehicle is used on the roads Consult the vehicle owners manual 16 The speedometer and odometer will need to be recalibrated after installation See your dealer 17 Confirm proper rear view and side view while seated in the driver seat Install supplemental mirrors as necessary 18 Your original low tire pressure monitoring system may be re installed in your new wheels However if you choose to purchase a new system see your dealer to have them properly calibrate
12. e Drill motor Assorted Drills 1 8 through 1 2 Torque Wrench 300 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 Silicone Spray Lubricant Tape Measure Safety Glasses wear safety glasses at all times ESL ES EE ES E ES E es ES ES ees E 1 C E ES E ESI J It is extremely important to replace coil springs 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 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 The required installation time for this system is approximately 5 to 6 hours Check off the box LJ 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 M This suspension system was developed using the following tire amp wheel combination 37X12 5R20 BFGoodrich KM2 tire 20 x 9 x 5 5 backspacing wheel Maximum total backspacing is 6 8 Before installing any other combination consult your local tire and
13. experience drive line vibration after installing this kit on a vehicle with a two piece rear driveshaft please contact Rancho Technical Support at1 734 384 7804 and ask for RS176738 RS860780 Carrier Bearing Spacer Sub Assy Carrier Bearing Spacer Hdwr INCH SYSTEM METRIC SYSTEM T L X pepee 7T L Length millimeters D Nominal Diameter millimeters X Description hex head cap screw T Thread Pitch thread width mm The driver of this suspension system recognizes and agrees that there are risks inherent in driving a vehicle with a lifted suspension system including but not limited to the risk that you could be involved in an accident that would not occur in an unmodified vehicle By his her purchase and use of this suspension system the user expressly voluntarily and knowingly accepts and assumes these risks and agrees to hold Tenneco Inc and its related companies harmless to the fullest extent permitted by law against any resulting damages ITEM ITEM PART RS66453B 1 RS831B PART R566453B 2 RS77982 RS176729B RS176730B RS860753 RS770080 RS770259 RS770064 RS176725B RS860752 RS770261 RS770118 RS770123 RS420110 RS770142 RS770141 RS770064 RS176735 RS176373 RS860534 RS1417 RS7628 RS7642 RS770022 RS603508 RS7632 RS860754 RS176728 RS7906 RS7710 RS7784 RS176741 RS860782 RS77032 RS7710 RS77841 Box 1 of 5 DESCRIPTION Box 1 of 5 Front Coil Spring 4 50 D
14. iesel Box 2 of 5 DESCRIPTION Box 2 of 5 Pitman Arm Swaybar Drop Brkt Left Swaybar Drop Brkt Right Sub Assy Swaybar Drop Brkt HHCS M10 1 50 X 30mm Nut M10 1 50 NyLock Washer M10 Front Track Bar Bracket Sub Assy Front Track Bar Brkt HHCS M18 2 50 X 90mm Nut M18 2 50 NyLock Washer M18 Spacer 1 25 X 1 01 X 1 37 L HHCS M10 1 25 X 30mm Nut M10 1 25 TopLock Washer M10 Flag Nut M10 1 25 Bump Stop Bracket Front Sub Assy Front Bumpstop Bumpstop 2 Stud Nut 5 16 24 NyLock Washer 5 16 SAE HHCS 3 8 24 X 3 00 Washer 3 8 SAE Nut 3 8 24 NyLock Sub Assy Brake Line Bracket Brake Line Spacer Backet HHCS 1 4 20 X 1 00 Nut 1 4 20 NyLock Washer 1 4 SAE Coil Spring Locator Sub Assy Coil Spring Locator Button Head Screw 1 4 20 X 75 Nut 1 4 20 NyLock Washer 1 4 SAE NWPBNNP WOOP PP RP BB BNP PB N I NNNRPFNBNNN FP SF ITEM ITEM PART RS66453B 3 RS176723B RS176724B RS89452 RS94180 PART R566453B 4 RS176732 RS860756 RS770080 RS7657 RS770064 RS176733 RS860757 RS770127 RS603112 RS770128 RS770247 RS7807 RS7915 RS176731B RS860758 RS420109 RS770138 RS770141 RS770064 RS176735 RS770043 RS7877 RS770109 RS176600 RS860781 RS770127 RS603112 RS770128 RS176738 RS860780 RS770131 RS770128 Box 3 of 5 DESCRIPTION Box 3 of 5 Left Radius Arm Right Radius Arm Instructions RS66453B Information Pack Box 4 of 5 D
15. 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 4 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 A 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 l 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 If you do not know how to safely use any of these tools stop the project and consult a qualified mechanic Dodge Service Manual Pitman Arm Puller T64P 3590 F or equivalent Universal Gear Puller Bench Vis
16. nd out a half turn so the ball joint threads point up See Illustration 20 12 RS77982 j Et Illustration 20 4 L1 Attach the drag link to the pitman arm with the OE nut Torque nut to 65 ft Ibs 5 LJ Rotate the adjusting barrel down in the front 5 7 turns to make drag link assembly shorter Tighten jam nuts SWAY BAR DROP BRACKET INSTALLATION Box RS66453B 2 Box 2 of 5 Front oway Bar Drop Bracket RS17729B RS176730B Hardware from Sub Assy RS860753 1 Ll Attach left sway bar drop bracket RS176729B to the driver side the frame with OE hardware The Rancho logo will face out and the sway bar will be offset to the front of the vehicle See Illustration 21 Illustration 21 2 Ll Attach right sway bar drop bracket RS176730B to the passenger side the frame with OE hardware The Rancho logo Will face out and the sway bar will be offset to the front of the vehicle See Illustration 21 3 Ll Attach the sway bar to the drop brackets with 10mm hardware from kit RS860753 Torque hardware to 40 ft Ibs LOWER VEHICLE 1 Ll Install the front wheels and lower the vehicle to the ground Tighten lug nuts to 140 ft Ibs Note If installing aftermarket wheels remove rotor retainer clips from wheel studs to allow wheels to sit flush against rotor See Illustration 1 2 Attach track bar to bracket RS176725 with 18mm 13 hardware from kit RS860752 Tighten both 18mm track bar and bracket bolts
17. nual is not and should not be construed as an exhaustive list of all required safety measures Personnel should rely primarily on their training and experience as well as on their own common sense This Manual is to be read as a supplement to and must not be construed as a substitute for the owner s manual and or shop manual that originally accompanied the vehicle Refer to such use operation maintenance and safety manuals as necessary and especially after installation is complete to insure proper vehicle operation The following terminology has been used in this Manual ACCIDENT Any event which could cause personal injury or death to anyone installing or using the suspension system as well as to passengers and bystanders or otherwise may result in property damage PRE INSTALLATION WARNINGS and INSTRUCTIONS A WARNING Only the following rim tire sizes may be used with this suspension system 37X12 5R20 tire 20 x 9 x 5 5 Backspacing rim Use of any other rim tire combination increases the risk of a roll over and or accident resulting in severe personal injury or death A 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 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
18. of the axle just enough to keep the spring from falling out 11 L Install new Rancho shocks in the upper shock mounts 12 L Carefully raise the axle enough to install the shocks on the lower mounts Attach with the OE hardware and torque to 120 ft Ibs 13 LI Re attach the OE brake line brackets to the axle spring mount using the OE hardware 14 O Install brake line brackets RS176728 to the axle radius arm mount using the OE hardware NOTE Use loctite and take care not to strip out self tapping screws used on brake line mounts 15 LJ Carefully re shape brake line and attach the OE brake line bracket to RS176 28 using hardware from kit RS860754 See Illustration 17 Illustration 17 16 LJ Re rout the axle vent hose under the frame rail and attach metal clip at OE location on shock spring mount See Illustration 18 Axle Vent Hose PITMAN ARM AND DRAG LINK INSTALLATION SF Box RS66453B 2 Box 2 of 5 9 Pitman arm RS77982 1 Ll Using the reference marks on the OE pitman arm as a guide attach new pitman arm RS77982 to the steering shaft Install the OE lock washer and nut with Locktite Tighten the nut to 225 ft Ibs See Illustration 20 2 Ll Remove tie rod end from the drag link adjusting barrel and trim off tab flush with the threads See Illustration 19 Illustration 19 3 Ll Re install the tie rod end onto the adjusting barrel and adjust to the previous marks and measurement Rotate the tie rod e
19. ole through the center of each dimple in the frame brackets See Illustration 10 Illustration 10 3 LJ Place bump stop bracket RS176373 over the frame bracket as shown in Illustration 11 Keep the chamfered corner of the bracket toward the rear RS176373 RS1417 Illustration 11 4 L Attach bump stop bracket RS176373 to the frame bracket with the 3 8 hardware from kit RS860534 Use two of the supplied 3 8 washers under each hole between the OE and new bump stop brackets Tighten nuts and bolts to 30 ft Ibs 5 LJ Attach bump stop RS1417 to bracket RS176373 with the 5 16 hardware from kit RS860534 Tighten nuts to 20 ft Ibs CoiL SPRING amp SHOCK ABSORBER INSTALLATION 3F Box 88664538 1 Box 1 of 5 Front Coil Springs RS831B Box RS66453B 2 Box 2 of 5 Spring Positioner RS176741 Hardware from Sub Assy RS860534 New Rancho front shock absorbers NOTE Both springs will have to be rotated 90 clockwise when looking from the top 1 J Remove the upper spring isolators and cut off locating tabs See Illustration 12 Illustration 12 2 Ll Mark center punch and drill a 74 hole on the outside of the upper spring mount dimple 74 from the lower edge of the dimple De bur inside of hole with a round or half round file See Illustration 13 Illustration 13 3 LJ Install spring positioner RS176741 into hole of upper spring mount While holding posi
20. orse play are careless acts that can result in an error in installation and or serious injury 7 Install only tires approved by the United States Department of Transportation DOT approved Make sure the rim and tire size are properly matched 8 lf any components of the vehicle or suspension system are damaged in any way during installation immediately replace the component 9 During installation carefully inspect all parts of the vehicle and replace anything that is worn or damaged 10 Nip points present the risk of the catching lacerating crushing and or amputating fingers hands limbs and other body parts during operations Always keep clear Wear protective gloves 11 Oil and hydraulic fluids are poisonous dangerous to health and are known to the State of California to cause cancer birth defects or other reproductive harm Do not inhale vapors or swallow Do not allow contact with the eyes or skin Should any oil or fluids be swallowed or inhaled or come into contact with the eyes immediately follow the safety precautions on the label or call a poison control center immediately Should any of the oil or fluids contact your skin immediately wash thoroughly 12 Never install the suspension system if you are under the effects of alcohol medications and or drugs If you are taking prescription or over the counter medication you must consult a medical professional regarding any side effects of the medication that coul
21. rier Bearing Spacer Hdwr Please retain this publication for future reference See Important Note Q 18
22. rm from the front axle 5 LJ Loosely attach the passenger side radius arm RS176724B to the front axle on the passenger side Use the original hardware 6 L Lift the radius arms into the frame brackets Install the original bolts and nuts Do not tighten until the vehicle is at normal ride height See Page 14 TRACK BAR BRACKET INSTALLATION Box RS66453B 2 Box 2 of 5 Front Track Bar Bracket RS176725B Hardware from Sub Assy RS860752 1 Ll Place track bar bracket RS176725B over the OE track bar mount Loosely install 10mm hardware from kit RS860752 in locations 1 and 2 to hold the bracket in place See Illustration 9 RS176725 Illustration 9 2 LJ Loosely install supplied 18mm hardware and spacer RS420110 at OE track bar mounting location See Illustration 9 3 LJ Using the hole in the track bar bracket as a guide location 3 enlarge the slot in the vehicle cross member to 13 32 4 J Insert flag nut RS176735 through the hole in top of the cross member and attach the track bar bracket to the cross member with 10mm hardware Torque to 30 ft Ibs 5 Torque remaining 10mm hardware to 45 ft Ibs in the order numbered in Illustration 9 Do not tighten 18mm hardware BUMP STOP BRACKET INSTALLATION 3F Box 88664538 2 Box 2 of 5 Bump Stop Brackets 3 Hardware from Sub Assy RS860534 1 Ll Remove the bump stops from the frame brackets by hitting from the side with a hammer 2 Ll Drill a 13 32 h
23. taching wire to solenoid on passenger side of axle See Illustration 6 Illustration 6 5 LJ Disconnect the front differential vent hose clip at driver side shock spring mount tower and plastic clip on inside of frame rail See Illustration 2 and Illustration 7 Illustration 7 6 LJ Remove the front shock absorbers starting at the axle 7 LJ Carefully lower the axle enough to relieve the tension on the coil springs and remove coils A WARNING Do not allow the axle to hang by any hoses or ABS cables You could damage the hoses or ABS cables without this damage being visible to you resulting in sudden and unexpected failure of a hose or ABS system and an accident RADIUS ARM REMOVAL AND INSTALLATION SF Box RS66453B 3 Box 3 of 5 Left Radius Arm RS176723 Right Radius Arm RS176724 1 Ll Support the jack point of both radius arms with jack stands Remove the radius arm mounting bolts at the frame and lower the radius arms out of the frame brackets See Illustration 8 CAUTION Always support at least one radius arm with a jack stand to keep the axle from rotating downward Check driveshaft slip joint boot to prevent tearing 000 8 2 LJ Remove the driver side radius arm from the front axle 3 Ll Loosely attach the driver side radius arm RS176723B to the front axle on the driver side Use the original hardware Support driver side radius arm with jack stand 4 J Remove the passenger side radius a
24. tioner up against spring mount drill a 74 hole through positioner using previously drilled 74 hole as a guide 4 LJ Install spring positioner RS176741 using 74 hardware supplied it kit RS8860782 Install with button head out and washer under nut See Illustration 14 f 1 j n vn 1 4 Hardware RS176741 Illustration 14 5 LJ Re install the passenger side upper spring isolator with the coil stop to the rear of the vehicle See Illustration 15 uw s Pee FRONT Coil Pigtail g j DOC Passenger side coil spring after rotating 90 from OE position Illustration 15 6 Ll Place the passenger side spring RS831B in the lower and upper mounts The top of the spring will have a small flat section on the edge Align the upper pigtail to the isolator See Illustration 15 7 J Raise the passenger side of the axle just enough to keep the spring from falling out 8 J Re install the driver side upper spring isolator with the coil stop to the outside of the vehicle See Illustration 16 11 n MN Coil Pigtail p a e z a LEHL a i 1 i Driver side coil spring after rotating 90 from OE position Illustration 16 9 L Place the driver side spring RS831B in the lower and upper mounts The top of the spring will have a small flat section on the edge Align the upper pigtail to the isolator See Illustration 16 10 LJ Raise the driver side
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