RANCHO RS84511 User manual

INSTALLATION INSTRUCTION RS84511
Rev B
RS64511 –Upper Control Arm Upgrade Kit
Fits 2022-2021 Ford F150 4WD & 2WD*
RS66512R9K –3” Suspension System
Use this instruction for front components RS66512R9-1 and RS66512R9-2.
For rear components RS66512R9-3 use instruction RS84511-1
Fits 2022-2021 Ford F150 4WD ONLY*
*Excludes SVT Raptor, Tremor, Continuously Controlled Damping (CCD) Adaptive Suspension
READ ALL INSTRUCTIONS THOROUGHLY FROM STARTTO FINISH BEFORE BEGINNING INSTALLATION
Parts List
P/N
DESCRIPTION
QTY.
RS176986B
UCA Left
1
RS520113
Bushing, K200353 (pre-installed)
2
RS602649
Upper Ball Joint, (pre-installed)
1
RS176987B
UCA Right
1
RS520113
Bushing, K200353 (pre-installed)
2
RS602649
Upper Ball Joint, (pre-installed)
1
RS176950
Shock Spacer, 1/4"
2
RS176959
Coil Spring Spacer, 1/2"
2
P01141
Parts Package
2
113900067
Nut - M10 X 1.5
3
P/N
DESCRIPTION
QTY.
RS860895
Sub Assy, Ball Joint Spacer
1
RS603518
Ball Joint Spacer (not used on 2021+ Models)
2
RS84511
Instructions
1
RS94180
Information Pack
1
RS94177
Rollover Warning Label
1
RS94119
Consumer/Warranty Information
1
RS780281
6" Rancho Decal - Color
1
RS780294
Red Rancho Die Cut Decal
1
RS780294B
Black Rancho Die Cut Decal
1

2
Advanced driver-assistance systems (ADAS) are electronic systems in a vehicle that use advanced technologies to assist the driver. Installation of a
Rancho lift kit in any vehicle that features this technology may impact or change the ADAS system, and requires immediate re-calibration by the dealer.
This product warranty is voided if the vehicle’s ADAS systems are not re-calibrated by a qualified technician after kit installation
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
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. 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 1-800-325-8886.
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.
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 componentsthat 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 number 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.
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, nomatter 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.
WARNING:

3
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
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.
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.
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.
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.
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.
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 DRiV, Inc. and its related companies harmless to the fullest extent
permitted by law against any resulting damages.

4
Required ModificationsMUST BE PURCHASED SEPARATELY)
Rancho Upper Control Arms RS176986B and RS176987B are designed to be used with Rancho Level It front struts RS999869UMM /
RS999870UMM, or RS66511R9*. These control arms will correct the caster and camber of a vehicle with 2-3.5” of lift, allowing for a
range of adjustment to achieve desired handling. When using larger tires, it is recommended to adjust caster to the higher end of the
spec, or a little over the specification.
*Compatibility cannot be guaranteed when using other lifts
Use on an OE height vehicle may damage upper ball joints, and make it difficult or impossible to achieve proper wheel alignment.
Please consult your Ranch dealer for correct applications.
Coil and Strut Spacers
Included 1/2" Coil Spring Spacer RS176959 and 1/4” Shock Spacer RS176950 are only for use with Rancho quickLIFT, quickLIFT LOADED,
and LEVEL-IT systems. Use of RS176950 and RS176959 is optional.
Net Lift*: RS999870UMM ≈ 2.50”
RS176959 ≈0.50”
RS176950 ≈ 0.25”
*Net lift may vary due to various vehicle and accessory options
Wheels and Tires
Optional Modifications(INCLUDED WITH RS66512R9K)
Rancho Rear Shocks –RS999073, Improves ride and performance.
Rancho Rear Upgrade Kit RS70511 –Rancho Rear Upgrade Kit RS70511 can be installed to gain 1.5” lift in the rear of the vehicle.
(included with RS66512R9K)
Please consult your Ranch dealer for correct applications. Component part number listing for 4WD only.
Tools and Supplies (BECAUSE OF VEHICLE VARIATIONS, THIS MAY NOT BE A COMPLETE LIST)
Ford Service Manual
Torque Wrench (260 FT-LB capacity)
Ball Joint Puller
1/2” Drive Ratchet and Sockets
Assorted Combination Wrenches
Assorted Metric Allen Wrenches
Rubber Mallet
File
Hammer
Heavy Duty Jack Stands
Wheel Chocks (wooden blocks)
Hydraulic Floor Jack
Wire Brush (to clean bracket mounting surfaces)
Silicone Spray Lubricant
Tape Measure
Safety Glasses--
Wear safety glasses at all times
Red LocTite
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.
RS66512R9K fits up to 295/70R18 (34.3X11.6) or 285/65R20 (34.6x11.2) on 9” wide 5.5”
backspacing wheel with trimming.
OE wheel is compatible with up to 33x12.5 tire.
Upper Control Arm RS64511 Is compatible with these tire sizes when using
Rancho Level-It Kit RS66511. Compatibility cannot be guaranteed when using other lifts.
Before installing any other combination, consult your local tire and wheel specialist.

5
1) Park the 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 ofthe fender opening. See Illustration
1.
Note: This measurement is required later in the installation.
Illustration 1
3) Raise the front of the vehicle and support the frame with
jack stands. Remove the front wheels and set them aside.
STRUT REMOVAL
4) Disconnect sway bar at frame mounts and allow sway
bar to hang from end links. See Illustration 2.
NOTE: It is best to work on only one side of the vehicle until
you get to “SWAY BAR INSTALLATION”. This way you can
refer to the other side if questions arise about the way it was
assembled.
Illustration 2
5) Remove IWE (integrated wheel end) vacuum hose and
electrical wire clip from frame. See Illustration 3.
6) Remove ABS wire, and IWE vacuum hose and electrical
wire clip from bracket attached to steering knuckle. See
Illustration 3.
7) Remove brake line bracket from steering knuckle.
8) If equipped, remove height sensor bracket from upper
control arm by removing mounting bolt. Allow bracket to
hang down on link rod so it does not interfere with control
arm movement. See Illustration 4.
9) Mark location of all eight lower control arm mounting
bolts and nuts in the frame slots, or if equipped, mark
location of alignment cams. See Illustration 5.
TIP: Use scribe or paint pen to draw outline of all nuts and
bolts to mark position.
Illustration 3
Illustration 4
Illustration 5
10) Support lower control arm with jack.
11) Loosen lower control arm mounting.
12) Loosen outer tie rod stud nut. Using appropriate puller,
separate then remove tie rod stud from steering knuckle.
See Illustration 6.
Brake Line Bracket
Sway Bar Mounts
Lower Control Arm
ABS Wire
IWE Lines
Sensor Bracket
Mounting Bolt
Lower Control Arm
Mark Location (All Eight)

6
Illustration 6
13) Remove the three upper strut mounting nuts. Loosely
re-install one of the upper strut mounting nuts. See
Illustration 8.
CAUTION: Do not turn center strut rod nut!
14) Remove lower strut mounting nuts See Illustration 6.
If lower mount ofshock is attachedwith studs (OE), continue
to step 15.
If lower mount is attached with bolts (Aftermarket), skip to
step 19.
15) Remove lower control arm mounting bolts.
16) Lower jack and swing lower control arms down and out
of frame mounts and off of strut mounting studs. See
Illustration 7.
Illustration 7
NOTE: Studs may need to be pried out of control arm.
17) Remove strut from vehicle.
18) Loosely re-attach lower control arm to frame mounts
using OE hardware or alignment cam kit hardware.
19) Loosen but do not remove upper ball joint stud nut. If
required, use puller to separate upper ball joint stud from
steering knuckle. See Illustration 6.
Illustration 8
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.
20) Pry down on upper control arm, remove ball joint nut,
and remove ball joint stud from knuckle.
21) Remove strut from vehicle if not done previously.
STRUT ASSEMBLY AND COIL SPACER INSTALLATION
(FOR RANCHO LEVEL-IT AND QUICKLIFT ONLY)
WARNING: If installing new strut, follow instructions and
warnings supplied with strut.
22) Reference mark top mount, coil spring and strut. See
Illustration 9.
WARNING: SPRING IS UNDER COMPRESSION LOAD
WHEN INSTALLED. ATTEMPTS TO REMOVE SPRING
WITHOUT PROPERLY RESTRAINING THIS LOAD MAY
RESULT IN INJURY. NEVER REMOVE THE CENTRAL
LOCK NUT OF THE UPPER MOUNTING PARTS BEFORE
THE SPRING IS COMPRESSED.
IF A SUITABLE SPRING COMPRESSOR TOOL IS NOT
AVAILABLE, OR A QUALIFIED OPERATOR IS NOT
AVAILABLE, MOST REPAIR SHOPS CAN SWAP THE
COIL FOR A SMALL CHARGE.
Lower Control Arm
Jack
Upper Ball Joint Nut
Tie Rod End Nut
Strut Lower Nut
Adjuster Knob
FRONT
Upper Mount
Coil Spring Spacer

7
Illustration 9
23) Using a suitable spring compressor tool, compress
spring slightly to relieve initial tension.
24) With initial spring tension relieved, loosen rod nut
slightly. Compress spring until loose from lower spring seat
and then completely remove nut.
25) Remove all upper mounting parts and spring from strut
assembly; save for reuse. Note position of all parts as
removed to ensure proper installation of replacement
parts. Inspect all original parts as removed for wear and
damage. Obtain replacements when necessary.
26) If applicable, install coil spring spacer RS176959
between lower spring seat and isolator with bevel/chamfer
down. See Illustration 8.
27) Install strut on spring and upper mount assembly using
reference marks to align components. Spring may need to
be compressed more to fit strut. See Illustration 9. Torque
center rod nut to 41 lb-ft.
NOTE: Knob faces to front of vehicle.
WARNING: DO NOT OVER TIGHTEN ROD NUT.
EXCESSIVE TORQUE CAN DAMAGE THE THREADS ON
THE NUT OR PISTON ROD. USE TORQUE VALUE FROM
OE MANUFACTURER.
28) Slowly release spring compressor checking for proper
alignment of components.
UPPER CONTROL ARM REPLACEMENT
29) Remove upper control arm nuts and bolts and remove
control arm. See Illustration 10.
Illustration 10
30) Loosely install new Rancho upper control arm to frame
brackets using OE hardware.
RS176986B is the driver side arm, and RS176987B is the
passenger side. The ball joint is offset toward the rear of the
vehicle when installed correctly. See Illustration 8.
31) Loosely attach upper ball joint to steering knuckle.
32) Use jack to raise lower control arm until the spindle to
fender measurement is 2.5” greater than OE measurement
from step 2.
NOTE: If a quickLIFT or Level It strut was previously
installed, the spindle to fender measurement should be 1/2”
greater than the measurement from step 2.
if vehicle was already lifted 2.5-3”, then raise to
measurement recorded in Illustration 1.
33) Align lower control arm bolts with previously made
marks and torque to 258 lb-ft.
34) Torque upper control arm mounting hardware to 122
lb-ft.
35) Remove upper ball joint nut from steering knuckle and
lower jack until stud is clear of knuckle.
STRUT REPLACEMENT
WARNING: If installing new strut, follow instructions and
warnings supplied with strut
36) If using 1/4” shock spacer RS176950, place on top of
strut’s upper mount. See Illustration 11.
37) Install strut in upper frame mount and loosely attach
with nuts. If using shock spacer RS176950, use nuts from
parts pack P01141.
Note: OE nuts will not fully thread onto studs with Shock
Spacer RS176950 installed.
Upper Control Arm Mounting Bolts
Reference Marks
Reference
Marks
Rod Nut
Knob

8
Illustration 11
38) Pry lower strut mount into position and attach to lower
control arm. Lower jack under the control arm if needed.
CAUTION: Take care not to damage CV boot.
NOTE: Knob faces to front of vehicle. See Illustration 8.
39) Torque upper mounting hardware to 52 lb-ft.
40) Attach outer tie rod end to steering knuckle with OE
hardware. Torque nuts to 66 lb-ft.
41) Re-install brake hose and ABS wire brackets in original
locations. Torque nuts to 22 lb-ft.
42) If equipped with height sensor, remove ball stud from
bracket and attach to Rancho upper control arm. See
Illustration 12.
SWAY BAR INSTALLATION
43) Re-attach sway bar at frame mounts and torque to 46
lb-ft.
LOWER VEHICLE
44) Install front wheels.
45) Turn the front wheels completely left then right. Verify
adequate tire, wheel, brake hose clearance. Check for
proper CV axle operation and clearance. Inspect steering
and suspension for tightness and proper operation.
46) Inspect and rotate all axles and drive shafts.
47) Lower vehicle to ground.
48) Tighten lug nuts to 150 ft. lbs.
Illustration 12
FINAL CHECKS &ADJUSTMENTS
49) Turn the front wheels completely left then right. Verify
adequate tire, wheel, brake hose clearance. Check for
proper CV axle operation and clearance. Inspect steering
and suspension for tightness and proper operation.
50) Inspect and rotate all axles and drive shafts.
51) Ensure that the vehicle brake system operates
correctly.
52) Readjust headlamps and have vehicle aligned at a
certified alignment facility.
NOTE: Alignment cam kit may be required to align vehicle.
Recommended Alignment Specifications
Caster (degrees): 5.2° ± .75°
Camber (degrees): -0.10° ± 0.75°
Sum Toe In (degrees): 0.2° ± 0.2° or 0.10” ± 0.10”
53) Park the vehicle on a level surface. Set the parking.
Measure and record the distance from the center of each
wheel to the top of the fender opening. See Illustration 13.
Illustration 13
54) Have any Advanced Driver-Assistance Systems (ADAS)
recalibrated by Ford Technician.
RS176950
Strut
Ball Stud

Vehicle Torque Specifications
Lower Control Arm
258 lb-ft.
Upper Control Arm
122 lb-ft
Strut Rod Nut
41 lb-ft.
Upper Strut Mounting Nuts
52 lb-ft.
Lower Strut Mounting Bolts
66 lb-ft.
Tie Rod End Ball Stud Nut
66 lb-ft.
Upper Ball Joint Nut
46 lb-ft.
Sway Bar End Links
111 lb-ft.
Sway Bar Mounting Bolts
46 lb-ft.
Brake Hose Bracket at Knuckle
22 lb-ft
Wheel Lug Nuts
150 lb-ft.
STANDARD BOLT TORQUE AND IDENTIFICATION
INCH SYSTEM
METRIC SYSTEM
Bolt Size
Grade 5
Grade 8
Bolt Size
Class 8.8
Class 10.9
Class 12.9
5/16
15 LB-FT
20 LB-FT
M6
5 LB-FT
9 LB-FT
12 LB-FT
3/8
30 LB-FT
35 LB-FT
M8
18 LB-FT
23 LB-FT
27 LB-FT
7/16
45 LB-FT
60 LB-FT
M10
32 LB-FT
45 LB-FT
50 LB-FT
1/2
65 LB-FT
90 LB-FT
M12
55 LB-FT
75 LB-FT
90 LB-FT
9/16
95 LB-FT
130 LB-FT
M14
85 LB-FT
120 LB-FT
145 LB-FT
5/8
135 LB-FT
175 LB-FT
M16
130 LB-FT
165 LB-FT
210 LB-FT
3/4
185 LB-FT
280 LB-FT
M18
170 LB-FT
240 LB-FT
290 LB-FT

Rancho Technical Department 1-800-325-8886
www.gorancho.com