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10 

14) 

 

  Using  the  remaining  hardware  from  kit  RS860707, 

loosely  attach  aft  drop  bracket  RS176653  to  the  aft  OE 
frame mount.  See Illustration 21. 

15) 

 

 Using OE hardware, loosely and the axle tube drop 

brackets RS176841  (forward half) and  RS17634  (rear half) 
to  the  passenger side  OE  frame  mount  along  with  spacer 
RS176422 

OR 

the  OE  dampener mount  (if  equipped).  See 

Illustration 22 and Illustration 23. 

The wider end of each bracket with the notch is attached 
to the top. 

16) 

 

  Using  12mm  hardware  from  kit  RS860820,  loosely 

attach  differential  passenger  side  axle  tube  mount  drop 
brackets  RS176654  and  RS176239.  See Illustration  22  and 
Illustration 23. 

DO NOT TIGHTEN! BRACKETS MUST BE LOOSE! 

TIGHTEN BRACKETS IN THE FOLLOWING ORDER: 

17) 

 

  FIRST  -  Snug  the  six  differential aft  mounting  bolts 

until  the  aft  drop  bracket  RS176653  sits  flush  with  frame 
mount and differential. See Illustration 21. 

18) 

 

  SECOND  -  Snug  the  four differential  housing  driver 

side  forward  mount  bolts  until  the  drop  brackets  sit  flush 
with  the  frame  mount  and differential.  See Illustration  20 
and Illustration 21. 

19) 

 

 THIRD - Tighten the differential housing aft mounting 

bolts to 70 ft. lbs. 

20) 

 

 FOURTH - Tighten the differential housing driver side 

forward mounting bolts to 70 ft. lbs. 

21) 

 

  FIFTH  –  Slowly  snug  the  passenger  side  axle  tube 

mounting  bolts  starting  with  the  upper  bolts,  while 
confirming  the  drop  brackets  are  installed  correctly.  See 
Illustration 22 and Illustration 23. 

The  passenger  side  brackets  must  align  properly  with 
the  mounts.
  If there  is  more  than  1/16” (.063”)  gap  in  any 
location, shimming will be required to prevent excessive side 
loads being applied to the differential axle tube. 

If  the  brackets  and  mount  are  not  parallel  to  each  other, 
loosen and re-torque the differential  housing rear mounting 
bolts. 

WARNING:  Do not tighten the passenger axle tube mounting brackets if 
step 21 cannot be successfully completed! 

22) 

 

  SIXTH  -  When  the  right/passenger  axle  tube 

mounting  and  spacer  brackets  are  installed  and  aligned 
properly, tighten mounting bolts to 70 ft. lbs. 

23) 

 

 Hang the half shaft with wire or a tie wrap. 

 

Illustration 19 

 

Illustration 20 

 

Illustration 21 

 

Illustration 22 

RS176841 

RS176834 

Spacer RS176837 

RS176651 

RS176240 

FRONT 

RS176240 

RS176651 

Differential 

OE Hardware 

Hardware from RS860820 

Frame Mount 

RS176653 

FRONT 

Aft Frame Mount 

Forward Frame Mount 

Frame Mount 

Summary of Contents for RS66402B

Page 1: ...y 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...

Page 2: ... 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 tiresize are properly matched 8 If any components of the vehicle or suspension system are damaged in any way during installation immediately replace the component 9 During installation carefully ...

Page 3: ...er or urethane bushings should be tightened with the vehicle at normal ride height unless otherwise specified This will prevent premature failure of the bushing and maintain ride comfort M Some of the service procedures require the use ofspecial tools designed for specific procedures If you do not know how to safely use any of these tools or do not have them stop the project and consult a qualifie...

Page 4: ...e Wrench 250 FT LB capacity 1 2 Drive Ratchet and Sockets Assorted Socket Extensions at least 18 combined 21 mm Open End Crowfoot Wrench Snap on SCOM21 or equivalent 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 Dot 3 Brake Fluid Black Enamel Paint Silicone Spray Lubricant ...

Page 5: ... Bracket 1 RS860707 Sub Assy Aft Diff Drop Bracket 1 RS770107 HHCS M12 1 75X35 6 RS7915 Washer M12 6 ITEM PART DESCRIPTION QTY 14 RS176835 Front Drive Shaft Spacer 1 RS860822 Sub Assy Drive Shaft Spacer 1 RS770108 HHCS M12 1 75X40 4 RS7915 Washer M12 4 15 RS176419 Front Sway Bar End Link Extension 2 16 RS170108 Brake Line Front Left 1 17 RS170109 Brake Line Front Ram 1 RS860730 Sub Assy Rear Brake...

Page 6: ...thebrake hose at the frame rail Plug line to prevent brake fluid seepage 2 Remove the bolt holding the brake hose to the frame See Illustration 3 Illustration 3 3 Remove the brake hose banjo bolt at the caliper Remove brake hose 4 Attach right brake hose RS170109 to the caliper with new washers and the original banjo bolt See Illustration 4 Tighten the bolt to 20 ft lbs Illustration 4 5 Attach bra...

Page 7: ...e outer tie rod end from the steering knuckle with removing tool 9360 Remove the nut and outer tie rod stud from knuckle See Illustration 5 Illustration 5 5 Loosen thenutat the upper ball joint Usingremoving tool 9360 separate the ball joint from the steering knuckle Pry down upper control arm and remove nut and upper ball joint from steering knuckle See Illustration 6 Illustration 6 6 Loosen the ...

Page 8: ... to rack Tighten inner tie rod to 125 ft lbs Do not over tighten Illustration 12 6 Install boot in original location on rack and inner tie rod Secure boot to rack with a tie wrap from hardware kit RS860562 Secure boot to inner tie rod with the OE clamp 7 Attach outer tie rod end RS602614 to tie rod RS602641 As reference leave a 45 gap between jam nut and tie rod end 8 Repeat steps 1 through 7 for ...

Page 9: ...ustration 17 File sharp edges and paint exposed metal WARNING Do not use a flame cutter or torch to remove bracket You could warp weaken or damage the bracket without the damage being visible to you resulting in loss of vehicle control and an accident WARNING Failure to follow differential drop bracket installation and torque sequence can result in damage to the differential axle tube 11 Loosely i...

Page 10: ...THIRD Tighten the differentialhousing aft mounting bolts to 70 ft lbs 20 FOURTH Tighten the differential housing driver side forward mounting bolts to 70 ft lbs 21 FIFTH Slowly snug the passenger side axle tube mounting bolts starting with the upper bolts while confirming the drop brackets are installed correctly See Illustration 22 and Illustration 23 The passenger side brackets must align proper...

Page 11: ...bolts to 155 ft lbs LOWER CONTROL ARM SHOCK ABSORBER INSTALLATION 1 Insert the left lower control arm into the sub frame pockets on the driver side Loosely attach the control arm with the original hardware Align cam bolts if so equipped NOTE Do not tighten pivot bolts until vehicle is at normal ride height 2 Insert the right lower control arm into the sub frame pockets on the passenger side Loosel...

Page 12: ...ub bolts to 120 ft lbs NOTE If equipped with ABS brakes position the speed sensor opening on the hub toward the front of the vehicle 3 Install axle hub spacer RS176232 on the passenger side axle shaft See Illustration 30 Illustration 30 4 Support the lower control arm with a jack Insert axle shaft through hub and install steering knuckle RS176231 onto the lower ball joint Install lower ball joint ...

Page 13: ...er well liner screws and pull liner out to assess and remove upper shock mounting bolt Use a 21mm crowfoot wrench and extensions to hold nut from spinning 7 Remove brake line wire hanger from frame and ABS cable from holders 8 Repeat step 6 and 7 for other side 9 Carefully lower the rear axle Do not allow the axle to hang by any hoses or ABS cables WARNING Do not allow the axle to hang by any hose...

Page 14: ...bs 6 Reinsert original track bar bolt into axle bracket Tighten to 110 ft lbs See Illustration 36 Illustration 36 FINAL CHECKS ADJUSTMENTS 1 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 2 With the suspension at maximum extension full droop inspect and rotate all axles and driv...

Page 15: ...37 Illustration 37 3 Re attach outer tie rod end RS602614 to tie rod RS602641 As reference leave a 45 gap between jam nut and tie rod end Refer back to Illustration 12 4 Attach outer tie rod end to steering knuckle with the original nut Tighten ball stud nut to 50 ft lbs Tighten the jam nut to 94 ft lbs FINAL MEASURMENT 1 Park the vehicle on a level surface Measure and record the distance from the...

Page 16: ... Rear Components Bump Stop Spacer RS176589 55 ft lbs Shock Absorber Upper Mount 100 ft lbs Shock Absorber Lower Mount 100 ft lbs Brake Line Sway Bar bracket RS176698 M8 Hardware 18 ft lbs Brake Line Sway Bar bracket RS176698 M12 Hardware 55 ft lbs Sway Bar End Link Upper Mount 55 ft lbs Track Bar 110 ft lbs Wheel Lug Nuts 130 ft lbs STANDARD BOLT TORQUE IDENTIFICATION INCH SYSTEM METRIC SYSTEM Bol...

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