background image

 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 
manual 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 

 WARNING: Only the following rim/tire sizes may be used with this 

suspension system: 295/60R20 tire, 20x9-in 0 offset wheel. 

Use of any other rim/tire combination increases the risk of a roll-over 
and/or accident, resulting in severe personal injury or death.  

  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 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 "horse-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)

 

If  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  could  hinder  your 
ability to work safely. 

AFTER INSTALLATION WARNINGS AND INSTRUCTIONS  

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 (10) 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 calibrated. 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 accordantly. 

 

 

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...

Reviews: