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INSTALLATION INSTRUCTIONS
FOR RANCHO SPORT KIT
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.
Before installing this system, have the vehicle's alignment
A.
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 performance, use the
following Rancho shock absorbers with this kit: RS5255, RS9255,
RS99255, or RS999255 for the front & RS5256, RS9256,
RS99256, or RS999256 for the rear.
replacement RS5407 can also be used.
C. Compare the contents of this system with the parts list in these
instructions.
SUSPENSION SYSTEMS
IMPORTANT NOTES!
OE steering stabilizer
RS6501: JEEP
strength and specific size. Do not substitute a fastener of lesser
strength or mix one hardware kit with another.
Apply THREAD LOCKING COMPOUND to all bolts during
D.
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!!
Rancho parts come with a protective coating.
G.
powder coat, 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.
Do not weld anything to these components, and do not weld
H.
any of these components to the vehicle. If any component breaks
Do not
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Summary of Contents for RANCHO RS6501
- Page 1 (no cracks, damage, or corrosion). Unless otherwise specified, tighten all bolts to the standard Do not install a body lift kit with Rancho’s suspension system torque specifications listed at the end of the note's section. Do not or interchange parts from this system with components from use an impact wrench to tighten any of these bolts.
-
Page 2: Metric System
Rancho dealer or Rancho for The required installation time for this system is replacement parts. approximately 5 to 6 hours. Check off the box ( ) at the Some of the service procedures require the use of special beginning of each step when you finish it. -
Page 3: Parts List
Press the lubricated bushings into one end of a new 1335 Rancho suspension link 1335 as shown in Figure 1. Lubricate the outside diameter of sleeve 420025 Figure 1 and the inside diameter of the installed urethane bushings with synthetic grease. -
Page 4: Front Suspension
Slowly apply grease to each end of the links NOTE: To reinstall the automatic transmission skid plate, (through the grease fitting) with a grease gun. Stop when adapter kit RS904 must be purchased separately. the grease begins to appear around the edges of the bushings. - Page 5 ¾” Figure 5 Figure 7 Install new Rancho suspension link 1335 to the frame and axle brackets as shown in figure 6. Use original Do not reattach the track bar to the axle yet. hardware but do not tighten. Tightening the bolts at this Leaving the track bar disconnected will make coil spring point could create ride height issues.
- Page 6 Compress the new front coil spring to 16 inches in SSEMBLY AND NSTALLATION length. Use a quality spring compressor like the one shown in Figure 8. Apply silicone lubricant and press bushings 545 from kit 860684 into both loops of front end link 176609. Apply silicone lubricant and press sleeves 420084 from kit 860684 into the installed bushings.
-
Page 7: Rear Suspension
Raise the rear of the vehicle and support the frame with jack stands. Remove the rear wheels. M10 Hardware ½”-13 Hardware Separate the track bar from the axle bracket. Remove the track Bar. See Figure 12. 176300 176609 Figure 12 Support the rear axle with a floor jack and remove ½”-20 Hardware the shock absorbers. - Page 8 Install new Rancho rear shocks to the upper frame rail. Tighten mounting bolts to 23 FT-LBS. Loosely attach shocks to the axle brackets.
- Page 9 Repeat steps 1 and 2 to install the rest of the bushings and sleeves. Attach the new end link assemblies to the frame brackets and rear sway bar with the hardware from kit 860155. See Figure 16. Tighten the end link mounting bolts to 40 ft.
- Page 10 Attach the shift relocating bracket 176090 to the torque shaft bracket with the hardware from kit 860160. See figure 21. Figure 19 & A INKAGE ELOCATION DJUSTMENT Pull back carpet/mat to gain access to torque shaft Figure 21 bracket mounting screws. If necessary, loosen the screws attaching the console to the floor panel.
- Page 11 FINAL CHECKS & ADJUSTMENTS Install the wheels and lower the vehicle to the ground. Tighten lug nuts to 80-110 ft-lbs. Torque the axle mounts for both the front and rear lower links to 85 ft-lbs. Torque the frame mounts for the both the front and rear lower links to 130 ft-lbs.