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5

 LOWER SUSPENSION ARM ASSEMBLY 

Bushing & Sleeve Installation

1. 

 Lubricate the outside diameter of two red

urethane bushings, from kit 8597, with a
silicone spray or a mild solution of soap and
water.

 

2. 

 Press the bushings (Do Not Hammer) into

one end of a new lower suspension arm.  See
figure 1.

 

 

 

Figure 1

 

3. 

 Lubricate the outside diameter of a sleeve,

from kit 8597, and the inside diameter of the
installed urethane bushings.

 

4. 

 Press the sleeve into the bushings.

 
 

NOTE:  If necessary, use a bench vise or C-
clamp to press the bushings and sleeves into
the suspension arm.  Do not use a hammer.

 

5. 

 Pre-grease arm assembly with a grease

gun.  Make sure not to blow the bushings out
of the assembly.  Stop when grease appears
at the end of the bushing grooves.

 

6. 

 Repeat steps 1 through 5 for the remaining

suspension arm ends, bushings, and sleeves.

 FRONT SUSPENSION 

Shock & Spring Removal

1. 

 Park vehicle on a level surface, set the

parking brake and chock rear wheels.

 

2. 

 From inside the engine compartment,

remove the upper stud nut, retainer and
grommet from both front shock absorbers.

 

3. 

 Raise the front of the vehicle and support

the frame with jack stands.

 

4. 

 Remove the front wheels.

 

5. 

 Position a hydraulic jack under the front axle

for support.  Remove the stabilizer link lower
nut and bolt from both sides of the front axle.
See Figure. 2

 

 

 

Figure 2

 

6. 

 Remove the shock absorber lower nuts and

bolts from the axle bracket.  Remove both
shocks and discard.  DO NOT REUSE
ORIGINAL SHOCK ABSORBERS.

 

7. 

 Lower axle and remove hydraulic jack.

 

8. 

 Remove the rubber bump stops and bump

stop mounts.

 

9. 

 Remove the coil spring retainer bolts and

retainers.

 

10. 

 Push down on the axle and remove each

coil spring.

Lower Arm Replacement

 

1. 

 Support the front axle with a hydraulic jack.

 

2. 

 Paint or scribe alignment marks on the

adjustment cams and axle brackets for
installation reference.  See Figure 3.

 

Summary of Contents for RS6502

Page 1: ...resentative 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 lesser strength or mix one hardware kit with another E Appl...

Page 2: ...2 PO BOX 5429 LONG BEACH CA 90805 1 800 574 6257 ...

Page 3: ...l 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 M 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 N The required installation time for this system is a...

Page 4: ...0071 Shift Relocation Kit 1 Bracket 1 1 4 20x 75 BHCS 4 1 4 SAE Washer 4 1 4 20 Nyloc Nut 4 Thread Lock 2 P N DESCRIPTION QTY 860072 Track Bar Relocation Kit 1 Sleeve 1 7 16 14x1 0 HHCS 1 7 16 14 Stover Nut 1 7 16 SAE Washer 2 M12 1 75x70 HHCS 2 M12 1 75 Nut 2 SAE Washer 4 3 8 16x1 0 HHCS 1 3 8 16 Stover Nut 1 3 8 SAE Washer 2 860073 Skid Plate Spacer Kit 1 Skid Plate Spacer 6 1 2 Cone Washer 6 1 ...

Page 5: ...es FRONT SUSPENSION Shock Spring Removal 1 Park vehicle on a level surface set the parking brake and chock rear wheels 2 From inside the engine compartment remove the upper stud nut retainer and grommet from both front shock absorbers 3 Raise the front of the vehicle and support the frame with jack stands 4 Remove the front wheels 5 Position a hydraulic jack under the front axle for support Remove...

Page 6: ...rdware but do not tighten Figure 5 Note Position the arm so that the grease fittings are accessible Also the cam adjuster bolt may have to be installed from the opposite way 6 Repeat steps 4 and 5 for the other front suspension lower arm 7 If applicable drill a 23 64 hole into each lower arm and reinstall the ABS sensor wires Use the original clamps Shock Spring Installation 1 Lower the front axle...

Page 7: ...tment cams and lower arm axle brackets Tighten nuts to 85 FT LBS 13 Grease new lower suspension arms until you see a slight amount of grease coming out of bushings DO NOT OVER GREASE REAR SUSPENSION Shock Spring Removal 1 Chock front wheels 2 Disconnect the stabilizer bar links from the stabilizer bar 3 Disconnect the track bar from the frame bracket See figure 7 4 Raise the rear of the vehicle an...

Page 8: ...the original hardware 6 Bend gas tank skid plate away from track bar if necessary Lower Arm Replacement Note Remove and replace one suspension arm at a time 1 Support the rear axle with a hydraulic jack 2 Remove the lower arm axle and frame mounting bolts Remove the lower suspension arm 3 Install a new Rancho lower suspension arm along with four shims from kit 860070 to the frame and axle brackets...

Page 9: ...ach shocks to the axle brackets loosely 7 Install wheels and lower vehicle to the ground Do not remove wheel chocks Tighten lug nuts to 80 110 FT LBS 8 Tighten the lower shock mounting bolts and the track bar mounting bolts to 74 FT LBS 9 Reconnect stabilizer bar links Tighten nuts bolts to 40 FT LBS 10 Tighten all lower arm mounting nuts to 130 FT LBS 11 Grease new lower suspension arms until you...

Page 10: ...haft bracket off the torque shaft and remove the bearing plate gasket Drill out the two threaded holes in the torque shaft bracket to 9 32 4 Attach the shift relocating bracket from kit 860071 to the torque shaft bracket as shown in figure 14 Use the hardware from kit 860071 5 Attach the bearing plate with gasket to the shift relocating bracket See figure 14 Figure 14 6 Insert the torque shaft int...

Page 11: ...NTS 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 Readjust headlamps Have vehicle Aligned to manufacturer s specifications Alignment Specifications ADJUSTMENT PREFERRED RANGE Caster 7 1 0 Camber fixed angle 0 25 0 63 Toe In each wheel 0 15 0 15 Thrust Angle 0 0 15 NOTES ...

Page 12: ...RRANTY SHALL NOT APPLY TO ANY RANCHO PRODUCT WHICH HAS BEEN MODIFIED CUSTOMIZED OR IMPROPERLY INSTALLED WARRANTY DOES NOT APPLY TO ANY RANCHO COMPONENTS USED FOR RACING PURPOSED OR RACE TYPE ACTIVITIES WARRANTY DOES NOT APPLY TO ANY RANCHO INDUSTRIES RACING PRODUCTS The product time periods and or mileage under this warranty are as follows RS1000 RS5000 RS5600 RS7000 RS9000 LIMITED LIFETIME WARRAN...

Page 13: ...ifications or to make product changes as deemed necessary without prior notice Obligations or liabilities will not be assumed with respect to similar products previously advertised WARRANTY DOES NOT APPLY TO ANY RANCHO COMPONENTS USED FOR RACING PURPOSES OR RACING TYPE ACTIVITIES WARRANTY DOES NOT APPLY TO ANY RANCHO INDUSTRIES RACING PRODUCTS PRINTING ERRORS Every effort has been made to avoid pr...

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