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INSTALLATION INSTRUCTIONS
FOR RANCHO ROCK CRAWLER SUSPENSION SYSTEMS RS6505 & RS6506:
JEEP WRANGLER (TJ)
READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION
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 at a state approved facility. The alignment
must be within factory specifications and the frame must be sound
(no cracks, damage, or corrosion).
Do not install a body lift kit with Rancho's suspension system
B.
or interchange parts from this system with components from
another manufacturer.
To obtain maximum rock crawling
performance/articulation, use the following Rancho shock
absorbers with this kit: RS5255, RS9255, or RS99255 for the front
& RS5256, RS9256, or RS99256 for the rear.
Compare the contents of this system with the parts list in
C.
these instructions. If any parts are missing, including fasteners,
contact the Rancho Technical Department at 1-734-384-7804.
Each hardware kit in this system contains fasteners of high
strength and specific size. Do not substitute a fastener of lesser
strength or mix one hardware kit with another.
IMPORTANT NOTES!
D.
Apply THREAD LOCKING COMPOUND to all bolts during
installation. One drop on the exposed threads of each bolt before
installing the nut is sufficient to provide an adequate bond.
CAUTION: Thread locking compound may irritate sensitive skin.
Read warning label on container before use.
Install all nuts and bolts with a flat washer. When both SAE
E.
(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.
Unless otherwise specified, tighten all bolts to the standard
F.
torque specifications listed at the end of the note's section. Do not
use an impact wrench to tighten any of these bolts. They tend to
over tighten smaller bolts and under tighten larger bolts. USE A
TORQUE WRENCH!!
G.
Rancho parts come with a protective coating.
powdercoat, chrome, cadmium, or zinc plate any of the
components in this system. If you wish to change the appearance
of components enamel paint can be applied over the original
coating.
H.
Do not weld anything to these components, and do not weld
any of these components to the vehicle. If any component breaks
or bends, contact your local Rancho dealer or Rancho for
replacement parts.
88056
Rev I
Do not
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Summary of Contents for RANCHO RS6505
- Page 1 Do not use an impact wrench to tighten any of these bolts. They tend to Do not install a body lift kit with Rancho’s suspension system over tighten smaller bolts and under tighten larger bolts. USE A...
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Page 2: Bolt Identification
If you do not have the tools or are unsure of your abilities, have maintain ride comfort. this system installed by a certified technician. RANCHO IS NOT RESPONSIBLE FOR DAMAGE OR FAILURE RESULTING FROM The required installation time for this system is AN IMPROPER INSTALLATION. -
Page 3: Parts List
Press the lubricated bushings into one end of a new Rancho cast link (176180) as shown in figure 1. Lubricate the outside diameter of sleeve 420080 and the inside diameter of the installed urethane bushings with Figure 1 synthetic grease. -
Page 4: Front Suspension
Slowly apply grease to each end of the cast links (through the grease fitting) with a grease gun. Stop when NOTE: To reinstall the automatic transmission skid plate, an the grease begins to appear around the edges of the adapter kit must be purchased separately. bushings. - Page 5 NSTALLATION Figure 5 Lower the front axle and remove the hydraulic floor Install new Rancho cast link 176180, along with four jack. shims from kit 860070, to the frame and axle brackets as shown in figure 6. Use original hardware but do not tighten.
- Page 6 Attach the new brake hose to the frame and brake tube. Tighten securely. Repeat steps 1 through 4 to install right front brake hose RS170081. • Refill the master cylinder reservoir with approved brake fluid and bleed the front brakes as follows: •...
- Page 7 Repeat steps 1 through 5 to assemble the other end link. & S HOCK NSTALLATION Support the front axle with a floor jack. Loosely attach end link bracket 176085 to the axle bracket with hardware from kit 860561. See figure 10. Figure 11 Tighten the sway bar lower link bolts to 70 FT-LBS.
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Page 8: Rear Suspension
DO NOT REUSE ORIGINAL SHOCK bolts. Remove the lower suspension arm. ABSORBERS. Install new Rancho cast link 176180, along with four Mark the orientation of the coil springs on the axle shims from kit 860070, to the frame and axle brackets. See pads. - Page 9 DO NOT small egg-shaped coil end is at the top. OVER GREASE! Install new Rancho rear shocks to the upper frame rail. Tighten mounting bolts to 23 FT-LBS. TRANSMISSION & TRANSFER CASE Loosely attach shocks to the axle brackets.
- Page 10 Figure 18 Figure 16 Remove 3 bolts on one side and carefully lower the & A INKAGE ELOCATION DJUSTMENT crossmember/skid plate. Pull back carpet/mat to gain access to torque shaft Place 3 spacers from kit 860161 between the bracket mounting screws. If necessary, loosen the screws crossmember and the frame with the conical end of the attaching the console to the floor panel.
- Page 11 Figure 21 Remove the 4 screws attaching the cover boot to Figure 20 the cover. Slide the boot upward to expose the opening in the cover and floor pan. Insert the torque shaft into the bearing plate and reinstall the torque shaft bracket to the floor pan. Verify that Shift the transmission into 2nd and reverse.
- Page 12 FINAL CHECKS & ADJUSTMENTS 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. With the suspension at maximum extension (full droop), inspect and rotate all axles and drive shafts. Check for binding and proper slip yoke insertion.