Installation Instructions for Rancho

Installation Instructions for Rancho
89451 Rev B
INSTALLATION INSTRUCTIONS
For Rancho Suspension Systems: RS66451R9
2.5” Leveling Kit - “ DIESEL MODELS ONLY”
2014 Dodge Ram 2500 4WD
— FMVSS 126 Certified —
Fits up to:
BFG KM2 35X12.5R17 Tires
On 17 x 9 x 5.5 Backspacing Wheel
Fits OE rims and spare
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.
Rancho Suspension
1
89451 Rev B
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.
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
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.
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.
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.
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.
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.
The following terminology has been used in this Manual:
I.
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.
7) Install only tires approved by the United States
Department of Transportation (“DOT approved”). Make sure
the rim and tire size are properly matched.
PRE-INSTALLATION WARNINGS and
INSTRUCTIONS
8) If any components of the vehicle or suspension system
are damaged in any way during installation, immediately
replace the component.
WARNING: Only the following rim/tire sizes
may be used with this suspension system:
35X12.5R17 tire, 17 x 9 x 5.5 Backspacing rim.
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.
Use of any other rim/tire combination increases the
risk of a roll-over and/or accident, resulting in severe
personal injury or death.
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.
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.
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.
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
WARNINGS AND INSTRUCTIONS AFTER
INSTALLATION
New Rancho shock absorbers are required on the front and must be
purchased separately.
Front
RS999044
RS7044
RS5044
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 (ten) 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.
Rear
RS999044
RS7044
RS5044
OE
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 on page 4.
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.
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 1-734-384-7804.
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.
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.
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.
17) Confirm proper rear view and side view while seated in
the driver seat. Install supplemental mirrors as necessary.
H.
Unless otherwise specified, tighten all nuts and bolts to the
standard torque specifications shown in the table on page 2. USE A
TORQUE WRENCH for accurate measurements.
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.
I.
Some of the service procedures require the use of special
tools designed for specific procedures. The following tools and
supplies are recommended for proper installation of this system: If
you do not know how to safely use any of these tools, stop the
project and consult a qualified mechanic.
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.
IMPORTANT NOTES
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.
3
Dodge Service Manual
Bench Vise
Drill motor
¼” Drills:
Torque Wrench (300 FT-LB capacity)
1/2” Drive Ratchet and Sockets
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)
Black Enamel Paint
Tape Measure
Safety Glasses (wear safety glasses at all times)
J.
It is extremely important to replace coil springs, CV flanges,
and front 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.
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.
K.
Suspension components that use rubber or urethane
bushings should be tightened with the vehicle at normal ride height.
This will prevent premature failure of the bushing and maintain ride
comfort.
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.
L.
The required installation time for this system is
approximately 5 to 6 hours. 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.
M.
This suspension system was developed using the following
tire & wheel combination: 35X12.5R17 BFGoodrich KM2 tire,
17 x 9 x 5.5 backspacing wheel. Maximum total backspacing is 6.8”.
Before installing any other combination, consult your local tire and
wheel specialist.
STANDARD BOLT TORQUE & IDENTIFICATION
Bolt Size
5/16
3/8
7/16
1/2
9/16
5/8
3/4
INCH SYSTEM
Grade 5
15 FT-LB
30 FT-LB
45 FT-LB
65 FT-LB
95 FT-LB
135 FT-LB
185 FT-LB
Grade 8
20 FT-LB
35 FT-LB
60 FT-LB
90 FT-LB
130 FT-LB
175 FT-LB
280 FT-LB
Bolt Size
M6
M8
M10
M12
M14
M16
M18
METRIC SYSTEM
Class 9.8
Class 10.9
5 FT-LB
9 FT-LB
18 FT-LB
23 FT-LB
32 FT-LB
45 FT-LB
55 FT-LB
75 FT-LB
85 FT-LB
120 FT-LB
130 FT-LB
165 FT-LB
170 FT-LB
240 FT-LB
Class 12.9
12 FT-LB
27 FT-LB
50 FT-LB
90 FT-LB
145 FT-LB
210 FT-LB
290 FT-LB
The driver of this suspension system recognizes and agrees that there are risks inherent in driving a vehicle with a
lifted 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.
4
4
5
5
2
1
3
PARTS LIST
RS66451R9
ITEM
1
2
3
4
5
PART #
RS830B
RS176729B
RS176730B
RS860753
RS770080
RS770259
RS770064
RS176741
RS860782
RS77032
RS7710
RS77841
RS999044
RS89451
RS94180
DESCRIPTION
Coilspring 2.5" - Diesel/Black.
Sway Bar Spacer, Left.
Sway Bar Spacer, Right
Sub Assy, Sway Bar Drop Brkt Hdwr.
HHCS, 10MM - 1.50 X 30MM
Nut, M10-1.50 NyLock Nut.
Washer, M10 (Hardened).
Coil Spring Locator
Sub Assy, Coil Spring Locator
BHCS, 1/4-20 X .75
Nut, 1/4-20 Nylock
Washer 1/4 SAE
Rancho RS9000XL Shock.
Instructions RS66451R7
Information Pack.
5
QTY
2
1
1
1
4
4
8
2
1
2
2
2
2
1
1
Ball Stud
Pitman Arm
Adjusting Barrel
Illustration 1
Isolator
Coil Spring
Vent Hose Clip
Shock Absorber
Radius Arm
Alignment Cam
Retainer Clips
Illustration 2
6
FRONT SUSPENSION
8)  Remove clip attaching wire to solenoid on passenger
side of axle. See Illustration 5.
VEHICLE PREPARATION & SWAY BAR REMOVAL
1)  Park the vehicle on a level surface. Set the parking
brake and chock the rear wheels. Measure and record the
distance from the center of each wheel to the top of the fender
opening. See Illustration 3 Record these measurements in
the space provided below.
Illustration 5
9)  Disconnect the front differential vent hose clip at driver
side shock/spring mount tower, and plastic clip on inside of
frame rail. See Illustration 2 and Illustration 6.
Illustration 3
Vent Hose Clip
2) Raise the front of the vehicle and support the frame with
jack stands. Remove the front wheels and set them aside.
3)  Remove the sway bar mounts at the frame.
See Illustration 1.
4)  Support the front axle with two floor jacks, one under
each coil spring.
5)  Mark position of alignment cam bolts on radius arms.
See Illustration 2.
6)  Loosen, but DO NOT REMOVE, radius arm to axle
mounting bolts
Illustration 6
7)  Remove the mounting bolts holding the front brake
hoses brackets to axle. There are 2 brackets on each side.
Disconnect the front differential vent hose. See Illustration 4.
10)  Remove the front shock absorbers starting at the axle.
11)  Carefully lower the axle enough to relieve the tension
on the coil springs and remove coils.
WARNING: Do not allow the axle to hang by
any hoses or ABS cables. You could damage the
hoses or ABS cables, without this damage being
visible to you, resulting in sudden and unexpected
failure of a hose or ABS system, and an accident.
Illustration 4
7
COIL SPRING & SHOCK ABSORBER INSTALLATION
Coil Spring Locators RS176741
1/4” Hardware
Hardware from Sub Assy RS860782
Front Coil Springs RS830B
New Rancho Front Shock Absorbers
NOTE: Both springs will have to be rotated 90° clockwise
(when looking from the top)
RS176741
1)  Remove the upper spring isolators and cut off locating
tabs. See Illustration 7.
Illustration 9
5)  Re-install the passenger side upper spring isolator
with the coil stop to the rear of the vehicle. See Illustration 10.
Cut
FRONT
Coil Pigtail
Illustration 7
RS830B
2)  Mark, center punch, and drill a ¼” hole on the outside
of the upper spring mount dimple, ¼” from the lower edge of
the dimple. De-bur inside of hole with a round or half-round file.
See Illustration 8.
Passenger side coil spring after rotating 90° from OE position
Illustration 10
6)  Place the passenger side spring RS830B in the lower
and upper mounts. The top of the spring will have a small flat
section on the edge. Align the upper pigtail to the isolator. See
Illustration 10.
1/4”
7)  Raise the passenger side of the axle just enough to
keep the spring from falling out.
8)  Re-install the driver side upper spring isolator with the
coil stop to the outside of the vehicle. See Illustration 11.
FRONT
Coil Pigtail
Illustration 8
3)  Install spring positioner RS176741 into hole of upper
spring mount. While holding positioner up against spring mount
drill a ¼” hole through positioner using previously drilled ¼”
hole as a guide.
RS830B
4)  Install spring positioner RS176741 using ¼” hardware
supplied it kit RS8860782. Install with button head out, and
washer under nut. See Illustration 9.
Driver side coil spring after rotating 90° from OE position
Illustration 11
8
9)  Place the driver side spring RS830B in the lower and
upper mounts. The top of the spring will have a small flat
section on the edge. Align the upper pigtail to the isolator. See
Illustration 11.
RS176729B
10)  Raise the driver side of the axle just enough to keep
the spring from falling out.
11)  Install new Rancho shocks in the upper shock mounts.
12)  Carefully raise the axle enough to install the shocks
on the lower mounts. Attach with the OE hardware and torque
to 120 ft. lbs.
RS176730B
FRONT
13)  Re-attach all OE brake line brackets to axle. Re-shape
brake line enough to take tension off of rubber line by pushing
up on the bend of the hard line. See Illustration 12.
Illustration 13
2)  Attach right sway bar drop bracket RS176730B to the
passenger side the frame with OE hardware. The Rancho logo
will face out, and the sway bar will be offset to the front of the
vehicle. See Illustration 13.
NOTE: Use loctite and take care not to strip out self-tapping
screws used on brake line mounts.
3)  Attach the sway bar to the drop brackets with 10mm
hardware from kit RS860753. Torque hardware to 40 ft. lbs.
LOWER VEHICLE
1)  Install the front wheels and lower the vehicle to the
ground. Tighten lug nuts to 165 ft. lbs.
Note: If installing aftermarket wheels, remove rotor retainer
clips from wheel studs to allow wheels to sit flush against rotor.
2)  Adjust cam bolts so lobe of cam points to rear of
vehicle (about ¼” turn from OE). Tighten radius arm bolts at
axle to 220 ft. lbs. See Illustration 14.
Illustration 12
14)  Re-attach axle vent hose clips at OE locations. See
Illustration 2 and Illustration 6.
SWAY BAR DROP BRACKET INSTALLATION
Front Sway Bar Drop Bracket RS17729B, RS176730B
Hardware from Sub Assy RS860753
1)  Attach left sway bar drop bracket RS176729B to the
driver side the frame with OE hardware. The Rancho logo will
face out, and the sway bar will be offset to the front of the
vehicle. See Illustration 13.
Illustration 14
9
6)  Measure and record the distance from the center of
each wheel to the top of the fender opening. See Illustration 15
Record these measurements in the space provided below.
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 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.
4)
 Readjust headlamps.
Illustration 15
5)  Center steering wheel. Have vehicle Aligned at a
certified alignment facility.
Please retain this publication for future reference. See
Important Note Q.
10
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement