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INSTALLATION INSTRUCTION
RS89901-1
Rev B
Rancho Upper Control Arm Upgrade Kit ‒ RS64901
Fits 2016-2005 Toyota Tacoma 4WD/2WD 6-Lug
Excludes TRD PRO and 5-Lug Models
READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION
Parts List
P/N
DESCRIPTION
RS176678B
RS176679B
RS602640
RS860725
RS520053-4
RS420102
RS603513
RS860805
RS770279
RS176808
RS89901-1
RS94180
Left Upper Control Arm
Right Upper Control Arm
Upper Ball Joints (pre-installed in control arms)
Sub-Assy C-Arm Bushings
Bushing
Sleeve 1.00X.562X2.0
Shim
Sub Assy Ball Join
Ball Joint Mount Plug
Shock Spacer 1/4"
Instruction - RS64901
Information Pack
QTY.
1
1
2
1
8
4
8
1
2
2
1
1
P/N
DESCRIPTION
RS860819
RS770164
RS770109
RS770095
RS603615
RS7710
RS77841
RS7877
RS770146
RS176689
RS7755
RS7649
RS7733
RS603545
Sub Assy, Hardware
Nut M14-1.5 Toplock
Washer, M14
1/2" Loop Strap
HHCS, 1/4-20 X .75
Nut, 1/4-20 Nylock
Washer 1/4 SAE
Nut, M12-2.00 Toplock
HHCS, M14-2.0 X 150MM
Diff Drop Spacer
Washer, 3/8 USS
HHCS, M8-1.25 X 40MM
Washer, 5/16 USS
Spacer 5/8 X 3/8 X 1/2
QTY.
1
2
4
2
2
2
4
2
2
2
2
4
4
4
WARNING
Carefully read, understand and follow the instructions provided in this manual, and keep it in a safe place for future reference. If you have
any 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 the vehicle glove box for future reference.
Required Modifications (MUST BE PURCHASED SEPARATELY)
Rancho Upper Control Arms RS176678B and RS176679B are designed to be used with Rancho Quick Lift front struts. These control arms
will correct the caster and camber of a vehicle with 1.75-2.5” of lift, allowing for a range of adjustment to achieve desired handling.
Use on an OE height vehicle makes it difficult or impossible to achieve proper wheel alignment.
The following components must be installed with this kit and MUST BE PURCHASED SEPARATELY:
• Rancho QuickLift front struts RS999915 or RS66903R7.
Wheels and Tires
Compatible With
OE Wheels
Yes
1
1
Recommended Tire Sizes
(Actual)
265/70R17 or 255/75R17
(31.6”x10.4”) (32.1”x10.0)
Wheel Size
(Backspacing)
17x8
(4.5-5.0”)
May require trimming and provide proper clearance.
Before installing any other combination, consult your local tire and wheel specialist.
Optional Modifications MUST BE PURCHASED SEPARATELY)
If you would like to keep the original stance of the vehicle (higher in the rear), Rancho Rear Upgrade Kit RS70901 can be installed to gain
1.5” lift in the rear of the vehicle.
Tools and Supplies (BECAUSE OF VEHICLE VARIATIONS, THIS MAY NOT BE A COMPLETE LIST)
Safety Glasses
(wear safety glasses at all times)
Ball Joint Puller
Heavy Duty Jack Stands
Hammer
Wheel Chocks
Rubber Mallet
Hydraulic Floor Jack
Wire Brush (to clean mounting surfaces)
Torque Wrench (200 LB-FT capacity)
Red LocTite
1/2” Breaker Bar
Penetrating Lube
(to aid removal of corroded and frozen hardware)
1/2” Drive Ratchet, Sockets, and Extensions
Grease Gun with NLGI 2 GC-LB Lithium Complex Grease*
Assorted Combination Wrenches
Degrease/Cleaner or Solvent
Assorted Metric Allen Wrenches
Cotter Pins
*NOTE: Rancho components come lubed with lithium or lithium complex grease. Use of a different type (base) of grease can cause grease separation and
breakdown of the grease and cause the component to fail.
IMPORTANT NOTES
I. Some of the service procedures require the use of special 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 qualified mechanic. See tool
list
J. It is extremely important to replace coil springs, axle flanges, and drive
shaft/pinion relationships as original. Be sure to mark left/right, front/rear, and
indexing of mating parts before disassembly. A paint marker or light colored nail
polish is handy for this.
K. Suspension components that use rubber 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.
L. The required installation time for this system is approximately 2 to 3 hours
for two people. Check off the box ( ) at the beginning of each step when you
finish it. Then when you stop during the installation, it will be easier to find
where you need to continue from.
N. Important information for the end user is contained in the
consumer/installer information pack. If you are installing this system for
someone else, place the information pack on the driver’s seat. Please include
the installation instructions when you finish.
O. The lifespan of Rancho products depends on many factors. Improper use,
abuse or harsh use in general may compromise the integrity of the suspension
system and significantly reduce its lifespan. The suspension system is also
subject to wear over time. Have the suspension system regularly inspected and
maintained by qualified mechanics. If the inspection reveals any damage or
excessive wear, no matter how slight, immediately replace or repair the
component. The suspension system must be regularly maintained in order to
optimize its safe and efficient use. The more severe the conditions under which
the suspension system is operated, the more often it must be inspected and
maintained.
A. Before installing this system, have the vehicle’s alignment and frame
checked by a certified technician. The alignment must be within factory
specifications and the frame of the vehicle must be sound (no cracks, damage
or corrosion).
B. The components of Rancho’s suspension system are designed as a single
integrated system. To avoid compromises in terms of safety, performance,
durability or function, do not substitute Rancho components with components
manufactured by other companies. Use of other components will result in the
forfeiture of any type of warranty on the vehicle/suspension system. Some
components required for the installation of this kit may need to be purchased
separately.
C. Do not powder-coat or plate any of the components in this system. To
change the appearance of components, automotive paint can be applied over
the original coating.
D. Each hardware kit in this system contains fasteners of high strength and
specific size. Do not mix hardware kits or substitute a fastener of lesser
strength. See bolt identification table at end of instruction.
E. Compare the contents of this system with the parts list in these instructions.
If any parts are missing, contact the Rancho Technical Department at 1-734384-7804.
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.
G. Apply a drop of thread locking compound to all bolts during installation.
CAUTION: Thread locking compound may irritate sensitive skin. Read
warning label on container before use.
H. Unless otherwise specified, tighten all nuts and bolts to the standard torque
specifications shown in the table at end of instruction. USE A TORQUE WRENCH
for accurate measurements.
2
PREPARATION
6)
Remove brake line mounts from steering knuckles
and frame rails. Remove ABS wire mounts from upper
control arms. See
1)
Park vehicle on a level surface. Set the parking brake
and chock rear wheels.
2)
Measure and record the distance from the center of
each wheel to the top of the fender opening. Record these
measurements in the space provided.
Upper Strut Mount
ABS Wire
Sway Bar
End Link
3)
Raise the front of the vehicle and support the frame
with jack stands. Remove the front wheels and set them
aside.
4)
Brake Hose
Remove front skid plate if equipped. See Illustration 1
Steering Knuckle
FRONT
Illustration 3
7)
Remove sway bar end links from steering knuckles.
See Illustration 3 and Illustration 4.
Upper Control Arm
Illustration 1
Strut
Upper
Ball Joint
5)
Remove clips holding rubber fender well liners to
body. See Illustration 2.
Steering
Knuckle
Sway Bar
Liner
Liner
Sway Bar Mount
FRONT
Tie Rod
Illustration 4
Illustration 2
3
8)
Mark drivers side of sway bar. Remove sway bar
mounts from frame. See Illustration 2.
2)
Press bushings into upper control arm. See
Illustration 6.
3)
Press sleeves into control arm bushings using a
rubber mallet, bench vise, or C-clamp. Ensure bushings are
seated completely into control arm to ease instillation of
control arm.
STRUT SPACER INSTALLATION
Spacer will provide an additional 1/2-3/4” of lift
1)
Remove cotter pin and loosen outer tie rod stud nut.
Using appropriate puller, separate then remove tie rod
stud from steering knuckle. See Illustration 4.
2)
Remove cotter pin and loosen upper ball joint stud
nut. Using appropriate puller, separate then remove upper
ball joint stud from steering knuckle. See Illustration 4
WARNING: CONTROL ARM WILL SPRING UP WITH
GREAT FORCE WHEN BALL JOINT SEPARATES FROM
KNUCKLE. USE PRY BAR TO HOLD DOWN AND
SLOWLY LIFT BALL JOINT STUD OUT OF KNUCKLE
WHEN REMOVING BALL JOINT STUD NUT.
3)
Remove the three upper strut mounting nuts. See
Illustration 4.
Illustration 6
CAUTION: DO NOT TURN STRUT’S CENTER ROD NUT!
UPPER CONTROL ARM REMOVAL
4)
Remove lower strut mounting bolt.
1)
5)
Remove strut from vehicle
2)
Push upper control arm bolt forward until it contacts
body. Mark where bolt contacts body. Push bolt back into
control arm.
6)
Place strut spacer ring RS176808 on top of strut’s
upper mount. See Illustration 5
Remove control arm nut and washer. See Illustration 4.
3)
Using pliers, or adjustable crescent wrench, slowly
bend body out at mark to clear upper control arm bolt.
See Illustration 7.
The spacer ring may only install in one direction. If it does
not fit, flip ring over.
RS176808
QuickLift Strut
Upper Mount
Illustration 7
4)
Open engine compartment hood and note
obstructions to upper control arm bolt. See Illustration 8
and Illustration 9.
Illustration 5
7)
Loosely install strut with spacer ring in upper mount
using OE hardware.
NOTE: On some models hoses or wire harness may need
to be unclipped or unbolted from inner fender well. Take
care not to damage any hoses or wires.
8)
Pry lower strut bushing into position and attach to
lower control arm using OE hardware. Tighten upper shock
mounting nuts to 47 lb-ft. Tighten lower shock mounting
bolt and nut to 61 lb-ft.
5)
Slowly push upper control arm bolt forward and
behind bent lip of body, bending more if needed. Guide
bolt through any obstructions in engine compartment. Bolt
will have to be guided between wire harness and body to
prevent damage to wire harness. A punch or 3/8” socket
extension may be used to tap bolt out.
UPPER CONTROL ARM PREPARATION
1)
Apply a thin coating of lithium grease to upper
control arm bushings and sleeve from kit RS860725.
4
6)
Remove upper control arm and remaining washer.
Bolt does not have to be removed from engine
compartment.
3)
Slide bolt through control arm mount. When bolt
comes through mount, install another shim on bolt. Shim
may need to be tapped in place between control arm
mount and bushing.
4)
Slide bolt into aft control arm sleeve and continue
until bolt is completely through control arm mount and
both sleeves.
Control Arm Bolt
Wire Harness
5)
Install another shim on bolt, along with supplied
M14-1.5 toplock nut and M14 washer from kit RS860722.
Note: On some vehicles control arm mounting bolt can be
installed from the back to front to ease installation. Shims
must still be used against each bushing.
Driver Side Engine Compartment
6)
Grease control arm bushings at grease fittings. Stop
as soon as any grease is visible. DO NOT OVER GREASE!
Illustration 8
7)
lbs.
Control Arm Bolt
Tighten control arm mounting bolt and nut to 85 ft
8)
Insert upper ball joint into steering knuckle and
install nut. Tighten to 81 lb-ft. Install new cotter pin,
tightening ball joint nut as needed to align castle nut with
hole.
DO NOT LOOSEN BALL JOINT NUT TO INSTALL
COTTER PIN!
Wire Harness
9)
Grease upper ball joint until boot starts to swell. DO
NOT OVER GREASE! Install ball joint mount plug RS770279
in ball joint mount of upper control arm. See Illustration 12.
Passenger Side Engine Compartment
Illustration 9
UPPER CONTROL ARM INSTALLATION
10)
Install tie rod end into steering knuckle. Install nut
and tighten to 67 lb-ft. Install new cotter pin, tightening
ball joint nut as needed to align castle nut with hole.
1)
Push bolt toward upper control arm mount, and
install one shim from kit RS860725 on bolt, leaving enough
room to place upper control arm over mount.
DO NOT LOOSEN BALL JOINT NUT TO INSTALL
COTTER PIN!
2)
Hold Rancho upper control arm in position on
control arm mount and slide bolt into control arm sleeve.
When bolt comes through sleeve, install another shim on
bolt. See Illustration 10.
11)
Remove ABS wire to upper control arm bracket
from the ABS wire by bending bracket, taking care not to
damage ABS wire. See Illustration 11.
NOTE: The bent tube of the control arm goes to the front of
the mount; the straight tube goes to the rear. See
Illustration 10.
Shims
Shims
Control Arm Mount
Illustration 11
FRONT
Illustration 10
5
13)
Reinstall brake hose and ABS wire brackets to frame
and steering knuckle.
3)
Lower differential enough to insert spacers between
cross member and mounting bracket.
14)
Attach ABS wire to upper control arm using loop
strap and ¼” hardware from kit RS860722. See Illustration
12.
4)
Install Rancho front differential drop spacers
RS176689 between cross member and differential
mounting bracket using M14-2.0X150mm bolts, washers
and toplock nuts from kit RS860722. Use washer under nut
only. Tighten to 100 ft lbs. See Illustration 14.
Loop Strap
Differential Spacers
FRONT
Illustration 14
Illustration 12
5)
Install the front skid plate using the OEM bolts on
the front, and the M8-1.25X40mm bolts, 5/16” USS
washers and round spacers from kit RS860722 on the rear.
Install spacers between the frame and skid plate.
15)
Reattach sway bar and brackets to frame, using
reference mark to ensure correct orientation. Tighten to
30 lb-ft.
16)
Reattach sway bar end links to steering knuckle.
Tighten to 52 lb-ft.
17)
6)
Install rear skid plate using the M8-1.25X40mm
bolts, 5/16” USS washers and round spacers from kit
RS860722 on the front. Install spacers between the frame
and skid plate. Re-use the OEM bolts on the rear of the
skid plate.
Reattach rubber fender well liners to body.
DIFFERENTIAL DROP SPACER INSTALLATION
1)
Support front differential with floor jack.
7)
Install front wheels and lower vehicle to the ground.
Tighten lug nuts to 95 ft lbs.
2)
Remove the two forward front differential mounting
brackets to cross member mounting bolts. See Illustration
13.
FINAL CHECKS AND ADJUSTMENTS
1)
Turn the front wheels completely left then right.
Verify adequate tire, wheel, brake hose and ABS wire
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 drive shafts. Check
for binding and proper slip yoke insertion. The slip yoke
should be inserted a minimum of one inch into the
transfer case and/or transmission.
3)
Ensure that the vehicle brake system operates
correctly. If new brake hoses were installed, verify that
each hose allows for full suspension movement.
Differential mounting bolts
Illustration 13
6
5)
Readjust headlamps. Have vehicle Aligned to
manufacturer’s specifications.
6)
Measure and record the distance from the center of
each wheel to the top of the fender opening. Record these
measurements in the space provided.
NOTE: Alignment specifications will vary with year and
model. Have vehicle aligned to specifications specific to
your vehicle
General Recommended Alignment Specifications
Adjustment
Preferred
Range
Caster
2.00°
±0.75°
Camber
0.4°
±0.75°
Toe-In (each wheel)
0.06”
±0.08”
Thrust Angle
0
±0.15°
Torque Specs
Upper Strut Mounting Nuts
Lower Strut Mounting Bolt
Tie Rod End Ball Stud Nut
Upper Ball Joint Nut
Sway Bar Mounting Bolts
Sway Bar End Link to Steering Knuckle
Sway Bar End Link to Sway Bar
Upper Control Arm
Brake Line Bracket to Steering Knuckle
ABS Wire Bracket to Upper Control Arm
Differential Mount to Cross Member
Skid Plate
Wheel Lug Nuts Aluminum Wheel
Bolt Size
5/16
3/8
7/16
1/2
9/16
5/8
3/4
INCH SYSTEM
Grade 5
15 LB-FT
30 LB-FT
45 LB-FT
65 LB-FT
95 LB-FT
135 LB-FT
185 LB-FT
47 lb-ft.
61 lb-ft.
67 lb-ft.
81 lb-ft.
30 lb-ft.
52 lb-ft.
52 lb-ft.
85 lb-ft.
21 lb-ft.
9 lb-ft.
116 lb-ft
20 lb-ft
95 lb-ft.
STANDARD BOLT TORQUE & IDENTIFICATION
METRIC SYSTEM
Grade 8
Bolt Size
Class 8.8
Class 10.9
20 LB-FT
M6
5 LB-FT
9 LB-FT
35 LB-FT
M8
18 LB-FT
23 LB-FT
60 LB-FT
M10
32 LB-FT
45 LB-FT
90 LB-FT
M12
55 LB-FT
75 LB-FT
130 LB-FT
M14
85 LB-FT
120 LB-FT
175 LB-FT
M16
130 LB-FT
165 LB-FT
280 LB-FT
M18
170 LB-FT
240 LB-FT
7
Class 12.9
12 LB-FT
27 LB-FT
50 LB-FT
90 LB-FT
145 LB-FT
210 LB-FT
290 LB-FT
Rancho Technical Department at 1-734-384-7804.
9) During installation, carefully inspect all parts of the vehicle and replace
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.
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.
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.
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.
PRE-INSTALLATION WARNINGS and INSTRUCTIONS
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 kit 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 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.
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.
The driver of this suspension system recognizes and agrees that there are
risks inherent in driving a vehicle with a modified suspension system, including
but not limited to the risk that you could be involved in an accident that would not
occur in an unmodified vehicle. By his/her purchase and use of this suspension
system, the user expressly, voluntarily and knowingly accepts and assumes these
risks, and agrees to hold Tenneco, Inc. and its related companies harmless to the
fullest extent permitted by law against any resulting damages.
8
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