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INSTALLATION INSTRUCTIONS
FOR SUSPENSION SYSTEMS
READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING
INSTALLATION
A. The vehicle's alignment must be within factory
specifications before installing this system. Have
the alignment checked at a state approved facility.
B. Check the frame of the vehicle for any damage or
severe corrosion. If there is any structural damage,
Do Not install this system
C. Do not install a body lift kit with Rancho's
suspension system or interchange parts from this
system with components from another
manufacturer. Use the appropriate Rancho shock
absorbers. Contact your local Rancho
representative for the correct application.
D. Compare the contents of this system with the parts
list in these instructions. If any parts are missing,
including fasteners, contact the Rancho Technical
Department at 1-800-5SHOCKS. Each hardware kit
in this system contains fasteners of high strength
and specific size. Do not substitute a fastener of
RS6502
RS6503
&
IMPORTANT NOTES!
lesser strength or mix one hardware kit with
another.
E. 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.
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.
: JEEP WRANGLER (TJ)
88029
REV B
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Summary of Contents for rancho suspension RS6502
- Page 1 INSTALLATION INSTRUCTIONS 88029 REV B RS6502 RS6503 FOR SUSPENSION SYSTEMS & : JEEP WRANGLER (TJ) READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION IMPORTANT NOTES! A. The vehicle’s alignment must be within factory lesser strength or mix one hardware kit with specifications before installing this system.
- Page 2 PO BOX 5429 LONG BEACH, CA 90805 ∋ 1-800-574-6257 ∋...
- Page 3 G. Unless otherwise specified, tighten all bolts to the Molybdenum Grease or Anti Seize Compound Silicone Spray standard torque specifications listed at the end of Safety Glasses--Wear safety glasses at all times the note's section. Do not use an impact wrench to tighten any of these bolts.
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Page 4: Parts List
Track Bar Relocation Kit 1335 Lower Suspension Arm Sleeve Front Coil Spring (RS6503 only) 7/16-14x1.0 HHCS Rear Coil Spring 7/16-14 Stover Nut Front Coil Spring (RS6502 only) 7/16 SAE Washer 8567 Rear Bump Stop Spacer Kit M12-1.75x70 HHCS Spacer M12-1.75 Nut 8597... -
Page 5: Front Suspension
2. ≤ From inside the engine compartment, LOWER SUSPENSION ARM ASSEMBLY remove the upper stud nut, retainer and Bushing & Sleeve Installation grommet from both front shock absorbers. 1. ≤ Lubricate the outside diameter of two red 3. ≤ Raise the front of the vehicle and support urethane bushings, from kit 8597, with a the frame with jack stands. - Page 6 Figure 3 Figure 5 3. ≤ If equipped with ABS brakes, remove sensor Note: Position the arm so that the grease wires and clamps from the inboard side of the fittings are accessible. Also, the cam adjuster lower arms. Save clamps for reuse. bolt may have to be installed from the opposite way.
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Page 7: Rear Suspension
4. ≤ Raise the rear of the vehicle and support the pockets. Carefully remove the spring compressor. frame with jack stands. Remove the rear 4. ≤ Rotate spring so pig tail end fits back in wheels. spring pocket. Install spring retainer and bolt. 5. - Page 8 assembly. Also, position the arm so that the 2. ≤ Remove bracket and drill holes. Drill a grease fittings are accessible. 13/32" hole through the top of the axle bracket 4. ≤ Repeat steps 2 and 3 for the other side. and 15/32"...
- Page 9 10. ≤ Tighten all lower arm mounting nuts to 130 Bump Stop Spacer & Coil Spring Installation FT-LBS. 1. ≤ Remove the rubber bump stop and bump 11. ≤ Grease new lower suspension arms until stop bracket from the upper spring mount. you see a slight amount of grease coming out 2.
- Page 10 3. ≤ Install a conical washer and apply thread lock to 3 flat head bolts from kit 860073. Insert a bolt through the crossmember, each spacer, and into the frame. See figure 12. 4. ≤ Repeat steps 2 and 3 for the other side of the crossmember.
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Page 11: Final Checks And Adjustments
8. ≤ Verify that transfer case range lever is fully 2. ≤ Readjust headlamps. Have vehicle Aligned engaged in 4L position. Tighten adjusting trunnion lock bolt. to manufacturer’s specifications. 9. ≤ Reinstall carpet/mat and tighten console Alignment Specifications mounting bolts. ADJUSTMENT PREFERRED RANGE... - Page 12 RANCHO INDUSTRIES USA LIMITED WARRANTY ABOUT OUR WARRANTY Rancho Industries USA, warrants the listed products for the The product, time periods and/or mileage under this warranty listed time period and/or mileage to the original retail are as follows: purchaser against defect and wear-out when used on passenger cars and light trucks under normal operating RS1000 / RS5000 / RS5600 / RS7000 / RS9000 conditions.
- Page 13 • Exhaust system parts that rust or are blown-out by faulty engine conditions • Any component that has been modified, customized, or improperly installed • Any part that is obsolete and is no longer available or supplied by Rancho RIGHTS RESERVED Rancho Industries reserves the right to make changes in design, material and specifications or to make product changes as deemed necessary without prior notice.
- Page 14 This document was created with Win2PDF available at http://www.daneprairie.com. The unregistered version of Win2PDF is for evaluation or non-commercial use only.