RANCHO RS66402B User manual

89402 Rev A
INSTALLATION INSTRUCTIONS
For Rancho Suspension Systems:
RS66402B — 4½” Lift
2017-2013 Ram 1500 4WD
DOES NOT FIT VEHICLES EQUIPPED WITH AIR RIDE.
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.
895402 Rev A
Fits
Fits OE 17” and up rims
ONLY WITH OE TIRES

2
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
This manual presumes that all persons installing this suspension
s stem have a high level of mechanical training and experience, and
have available to them all necessar tools and safet equipment. This
manual is not and should not be construed as an exhaustive list of all
required safet measures. Personnel should rel primaril 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 originall accompanied the vehicle. Refer to such use,
operation, maintenance and safet manuals as necessar , and
especiall after installation is complete, to insure proper vehicle
operation.
The following terminolog has been used in this Manual:
ACCIDENT: An event which could cause personal injur or death to
an one installing or using the suspension s stem, as well
as to passengers and b standers, or otherwise ma result
in propert damage.
PRE-INSTALLATION WARNINGS and INSTRUCTIONS
WARNING: Only the following rim/tire sizes may be used with this
suspension system: 295/60R20 tire, 20x9-in 0 offset wheel.
Use of any other rim/tire combination increases the risk of a roll-over
and/or accident, resulting in severe personal injury or death.
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 ma not be
sufficient to properl install this suspension s stem. If ou have an
doubt whatsoever regarding our abilit to properl install the
suspension s stem, please consult a qualified mechanic.
2) Your brake lines and fuel lines should remain undisturbed during
and after installation. If ou think ou need to modif these
components in an wa , ou are mistaken. You are installing the lift
improperl and will be creating a significant risk of an accident. In case
of an doubt, consult a qualified mechanic.
3) If an component does not fit properl , something is wrong. You
are installing the lift kit improperl and will be creating a significant
risk of an accident. Never modif an component of the vehicle or
suspension s stem, except as instructed herein. Do not continue with
installation until ou have identified the problem.
4) Several of the procedures described herein require at least two (2)
persons to safel complete the task. If ou have an doubt about our
abilit to complete an operation b ourself, alwa s ask for help
from a qualified assistant.
5) Before starting an operation, confirm that all personal safet
devices and safet equipment are in proper condition and position.
6) Give our work undivided attention. Looking around, carr ing on a
conversation and "horse-pla " are careless acts that can result in an
error in installation and/or serious injur .
7) Install onl tires approved b the United States Department of
Transportation (“DOT approved”). Make sure the rim and tire size are
properl matched.
8) If an components of the vehicle or suspension s stem are
damaged in an wa during installation, immediatel replace the
component.
9) During installation, carefull inspect all parts of the vehicle and
replace an thing that is worn or damaged.
10) Nip points present the risk of the catching, lacerating, crushing
and/or amputating fingers, hands, limbs and other bod parts during
operations. Alwa s keep clear. Wear protective gloves.
11) Oil and h draulic 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 e es or skin. Should an oil or fluids be
swallowed or inhaled or come into contact with the e es,
immediatel follow the safet precautions on the label or call a poison
control center immediatel . Should an of the oil or fluids contact
our skin, immediatel wash thoroughl .
12) Never install the suspension s stem if ou are under the effects of
alcohol, medications and/or drugs. If ou are taking prescription or
over the counter medication, ou must consult a medical professional
regarding an side effects of the medication that could hinder our
abilit to work safel .
AFTER INSTALLATION WARNINGS AND INSTRUCTIONS
13) After installation is complete, drive the vehicle slowl in an area
free from heav traffic for at least three (3) miles. Likewise, before
traveling on an highwa s or at a high rate of speed, drive the vehicle
for ten (10) miles on side roads at moderate speed. If ou hear an
strange noise or feel unusual vibration, if a component of the
suspension s stem is not operating properl , or if an warning lights
illuminate or buzzers sound, stop the vehicle immediatel . Identif
the cause and take an necessar 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 s stems) are full 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 our dealer.
17) Confirm proper rear view and side view while seated in the driver
seat. Install supplemental mirrors as necessar .
18) Your original low tire pressure monitoring s stem ma be re-
installed in our new wheels. However, if ou choose to purchase a
new s stem, see our dealer to have them properl calibrated. Proper
tire pressure is critical to safe operation of the vehicle.
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 s stems designed in the vehicle ma
operate differentl 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 possibilit of an accident,
personal injur or death. Learn the vehicle’s operations and handling
characterizes and drive accordantl .

3
IMPORTANT NOTES
A. Before installing this s stem, have the vehicle’s alignment and
frame checked b a certified technician. The alignment must
be within factor specifications and the frame of the vehicle
must be sound (no cracks, damage or corrosion).
Have all suspension, steering and driveline components
inspected and replaced if worn or damaged
B. The components of Rancho’s suspension s stem are designed
as a single integrated s stem. To avoid compromises in terms
of safet , performance, durabilit or function, do not install a
bod lift kit with Rancho’s suspension s stem or interchange
parts from this s stem with components from another
manufacturer. Use of other components will result in the
forfeiture of an t pe of warrant on the vehicle/suspension
s stem.
C. Some components required for the installation of this kit ma
need to be purchased separatel . See “SPECIFICATIONS &
REQUIREMENTS” on next page of this manual.
D. Compare the contents of this s stem with the parts list in these
instructions. If an parts are missing, contact the Rancho
Technical Department at 1-734-384-7804.
E. Do not powder-coat or plate an of the components in this
s stem. To change the appearance of components,
automotive paint can be applied over the original coating.
F. Each hardware kit in this s stem 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.
G. Install all nuts and bolts with a flat washer. When both SAE
(small OD) and USS (large OD) washers are used in a fastener
assembl , place the USS washer against the slotted hole and
the SAE washer against the round hole.
H. Appl a drop of thread locking compound to all bolts during
installation. CAUTION: Thread locking compound ma
irritate sensitive skin. Read warning label on container before
use.
I. 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.
J. Do not weld an thing to these components, and do not weld
an of these components to the vehicle unless specificall
stated in the instructions
K. It is extremel 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 disassembl . A paint marker or light colored nail polish
is hand for this.
L. 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.
M. Some of the service procedures require the use of special tools
designed for specific procedures. If ou do not know how to
safel use an of these tools, or do not have them, stop the
project and consult a qualified mechanic. See “Tools and
Supplies” on next page of this manual
N. The required installation time for this s stem is approximatel
5 to 6 hours for two people. Check off the box () at the
beginning of each step when ou finish it. Then when ou stop
during the installation, it will be easier to find where ou need
to continue from.
O. Important information for the end user is contained in the
consumer/installer information pack. If ou are installing this
s stem for someone else, place the information pack on the
driver’s seat. Please include the installation instructions when
ou finish.
P. The lifespan of Rancho products depends on man factors.
Improper use, abuse or harsh use in general ma compromise
the integrit of the suspension s stem and significantl reduce
its lifespan. The suspension s stem is also subject to wear over
time. Have the suspension s stem regularl inspected and
maintained b qualified mechanics. If the inspection reveals
an damage or excessive wear, no matter how slight,
immediatel replace or repair the component. The suspension
s stem must be regularl maintained in order to optimize its
safe and efficient use. The more severe the conditions under
which the suspension s stem is operated, the more often it
must be inspected and maintained.
Q. If an component breaks or bends, contact our local Rancho
dealer or Rancho for replacement parts or, contact the Rancho
Technical Department at 1-734-384-7804.
Thank ou for purchasing the best suspension s stem available. For the best installed s stem, follow these instructions. If ou
do not have the tools or are unsure of our abilities, have this s stem installed b a certified technician. RANCHO IS NOT
RESPONSIBLE FOR DAMAGE OR FAILURE RESULTING FROM AN IMPROPER INSTALLATION
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
SPECIFICATIONS & REQUIREMENTS
Shock Absorbers
New Rancho shock absorbers must be used with this kit, and must be purchased
separatel
WARNING Use of the wrong shock absorbers cancause damage
to vehicle without the damage being visible to you, resulting in loss of
vehicle control and an accident
Required Rancho Shock Absorbers
Front
Rear
RS7000MT
RS7810 RS7369
RS5000X
RS55810 RS55369
RS5000
RS5810 RS5369
Wheels and Tires
Tools and Supplies (BECAUSE OF VEHICLE VARIATIONS, THIS MAY NOT BEA COMPLETE LIST)
Dodge Service Manual
Coil Spring Compressor
Ball Joint Removing Tools 8677 & 9360
(Miller or Mopar)
Drill motor
Reciprocating saw
Assorted Drills: 1/8" through 1/2"
Torque Wrench (250 FT-LB capacit )
1/2” Drive Ratchet and Sockets
Assorted Socket Extensions
(at least 18” combined)
21 mm Open End Crowfoot Wrench
(Snap-on SCOM21 or equivalent)
Assorted Combination Wrenches
Heav Dut Jack Stands
Wheel Chocks (wooden blocks)
H draulic Floor Jack
Center punch
File
Hammer
Wire Brush (to clean bracket mounting
surfaces)
Dot 3 Brake Fluid
Black Enamel Paint
Silicone Spra Lubricant
Tape Measure
Safety Glasses--
Wear safet glasses at all times
This suspension s stem was developed using the following tire & wheel combination:
Tire: LT295/60R20
Wheel: 90 x 9 x 0 Offset (5.0” Backspacing)
Before installing an other combination, consult our local tire and wheel specialist.
Compatible With
OE Wheels
Development Tire Size
(Actual)
Wheel Size
(Backspacing)
Yes
–
17” and up
with OE tires
1
LT295/60R20
(34”x11.7”)
20
x9
(5.0”)
1
OE wheels compatible with stock size tires onl .

5
Parts List
ITEM
PART # DESCRIPTION
QTY
RS66402B
-
1
Box 1
1
1
RS176588B
Sub
F
rame
1
RS66402B
-
2
Box 2
1
2
RS176230
Knuckle, Left
1
RS66402B
-
Box
1
3
RS176231
Knuckle, Right
1
RS66402B
-
4
Box 4
1
RS860562
Sub Ass
-
Subframe
1
RS7861
Washer, M16
8
RS770030
Nut, M16
-
2.00 Top Lock
4
136763624
Strap
-
Black
4
RS42702
.5 cc Thread Lock
2
4
RS176421
Subframe Washer
2
RS770040
HHCS, M16
-
2.0X140
4
RS770151
Washer, 5
/8 USS
6
5
RS602614
Outer Tie Rod End
2
6
RS602641
Inner
Tie Rod
2
RS860460
Sub Ass , Ram Hub Spacer
1
7
RS176232
Hub Spacer
2
8
RS176841
Right Diff Drop
–
Forward Bracket
1
9
RS176834
Right Diff Drop
–
Rear Bracket
1
10
RS176837
Right Drop
Diff Spacer
1
1
1
RS176651
Driver Side
Diff Drop
–
Right Bracket
1
1
2
RS176240
Driver Side
Diff Drop
–
Left Bracket
1
RS860820
Sub Ass ,
Diff Drop Brackets
2
RS770072
HHCS, M12
-
1.75X60
2
RS7915
Washer, M12
4
RS7911
Nut, M12
-
1.7
5 Top Lock
2
1
3
RS176653
Aft Diff Drop
Bracket
1
RS860707
Sub Ass
-
Aft Diff Drop
Bracket
1
RS770107
HHCS, M12
-
1.75X35
6
RS7915
Washer, M12
6
ITEM
PART # DESCRIPTION
QTY
1
4
RS176835
Front Drive Shaft Spacer
1
RS860822
Sub Ass , Dri
ve Shaft Spacer
1
RS770108
HHCS, M12
-
1.75X40
4
RS7915
Washer, M12
4
1
5
RS176419
Front Swa Bar
End L
ink
Extension
2
1
6
RS170108
Brake Line, Front Left
1
1
7
RS170109
Brake Line, Front Ram
1
RS860730
Sub Ass ,
Rear Brake Line
1
18
RS
176698
Rear Brake Line/Swa Bar Drop
2
RS770127
HHCS, M
8
-
1.25X20
2
RS603112
Nut, M8
-
1.25 N lock
2
RS770128
Washer, M8
4
136763624
Strap
-
Black
2
RS770247
HHCS M12
-
1.75X25
2
RS7807
Nut, M12Mm
-
1.75 N lo
ck
2
RS7915
Washer, M12
4
1
9
RS176589
Rear Bump
S
top Spacer
2
RS860670
Sub Ass ,
Rear Bump
S
top Spacer
1
RS770106
HHCS, M12
-
1.75X30
2
RS7807
Nut, M12
-
1.75 N lock
2
RS7915
Washer, M12
4
RS860671
Sub Ass , Rear Coil
2
20
RS821B
Rear Coil Spring
1
RS94180
Information Pack
1
RS89402
Instructions
1
RS94177
Rollover Warning L
abel
1
RS94119
Consumer/Warrant Information
1
RS780281
6" Rancho Decal
1
R-RM0082-1112
Warrant Tag
1
1
2
3
5 5
6
77
11
12
8
9
10
13
14
15 15
16
17
18 18
19 19
20
20
4
4