RANCHO RS66505B User manual

INSTALLATION INSTRUCTION 89505
Rev C
Rancho Suspension Systems:
RS66505B — 2018-2015 Ford F150 4WD 4.5” Kit
EXCLUDES: Models equipped with 4A (4WD Auto), AWD models, SVT aptor
equires replacement ancho shock absorbers and replacement wheels
(Fits 18” and up OE wheels and spare with OE TI ES ONLY)
See page 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.

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
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. efer 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: Only the following rim/tire sizes may be used with this
suspension system: 35X12.50R18LT tires 18X9 +18 offset (5.6” Back-
spacing) 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 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 lift
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 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.
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.

3
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).
Have all suspension, steering and driveline components
inspected and replaced if worn or damaged
B. The components of ancho’s suspension system are designed
as a single integrated system. To avoid compromises in terms
of safety, performance, durability or function, do not install a
body lift kit with ancho’s suspension system or interchange
parts from this system with components from another
manufacturer. Use of other components will result in the
forfeiture of any type of warranty on the vehicle/suspension
system.
C. Some components required for the installation of this kit may
need to be purchased separately. See “SPECIFICATIONS &
REQUIREMENTS” on next page of this manual.
D. Compare the contents of this system with the parts list in these
instructions. If any parts are missing, contact the ancho
Technical Department at 1-734-384-7804.
E. 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.
F. 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.
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
assembly, place the USS washer against the slotted hole and
the SAE washer against the round hole.
H. Apply a drop of thread locking compound to all bolts during
installation. CAUTION: Thread locking compound may
irritate sensitive skin. ead 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 TO QUE W ENCH for accurate
measurements.
J. Do not weld anything to these components, and do not weld
any of these components to the vehicle unless specifically
stated in the instructions
K. 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.
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 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 “Tools and
Supplies” on next page of this manual
N. The required installation time for this system is approximately
8 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.
O. 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.
P. The lifespan of ancho 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.
Q. If any component breaks or bends, contact your local ancho
dealer or ancho for replacement parts or, contact the ancho
Technical Department at 1-734-384-7804.
Thank you for purchasing the best suspension system available. For the best installed system, follow these instructions. If
you do not have the tools or are unsure of your abilities, have this system installed by 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
EXCLUSION
Shock Absorbers
New ancho shock absorbers must be used with this kit, and must be purchased
separately
OE front shock absorbers can be re-used with ancho Strut Tower Kit S88519
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 ear
S9000XL
S999287
S7000MT
S7838 S7287
S5000X
S55838 S55287
S5000
S5287
Strut Tower
S886519*
*FO USE WITH OE F ONT SHOCK ONLY
Wheels and Tires
Available Accessories
Tools and Supplies (BECAUSE OF VEHICLE VARIATIONS, THIS MAY NOT BEA COMPLETE LIST)
Ford Service Manual
Die Grinder with cut-off blade or Sawzall
Vacuum Cap
Coil Spring Compressor
Torque Wrench (260 FT-LB capacity)
Ford Ball Joint Tool- part number- 204-592
1/2” Drive atchet and Sockets
Assorted Combination Wrenches
Heavy Duty Jack Stands
Wheel Chocks (wooden blocks)
Hydraulic Floor Jack
File
Hammer
Wire Brush (to clean bracket mounting
surfaces)
Black Enamel Paint
Silicone Spray Lubricant
Tape Measure
Safety Glasses--
Wear safety glasses at all times
This suspension system is not intended for the following vehicles:
Models equipped with 4A (4WD Auto) and AWD models due to driveshaft issues
SVT aptor models
This suspension system was developed using the following tire & wheel combination:
Tire: BFGoodrich All-Terrain T/A KO2 35X12.50 18LT
Wheel: 18 x 9 +18 Offset (5.6” Backspacing)
Because of manufacturer variances, before installing any combination,
consult your local tire and wheel specialist.
Compatible With OE
Wheels
Development Tire Size
(Actual)
Wheel Size
(Backspacing)
Yes
1
35X12.50 18LT
(34.8”x12.5”)
18x9
(5.6”)
1
Fits 18” and up OE wheels and spare with OE tires ONLY
ONLY WITH OE TI ES
RS6 5 1: Rancho Rear Add-A-Leaf – Provides an additional 1.5” – 2” of lift in rear.
If additional rear lift is desired, ancho Add-A-Leaf S60501 may be purchased separately.
Perfect for towing, the additional weight of a camper, or any time more lift is desired in the rear.

5
ITEM
PART #
DESCRIPTION
QTY
RS665 5B
-
1
Box 1 Of 4
1
1
S176880B
Subframe
1
RS665 5B
-
2
Box 2 Of 4
1
2
S1767
5
3
Knuckle
-
Left
4.5
"
1
RS665 5B
-
3
Box 3 Of 4
1
3
S1767
5
4
Knuckle
-
ight
4.5
"
1
RS665 5B
-
4
Box 4 of 4
1
S94180
Information Pack
1
S89505
Instruction
1
S94177
ollover Warning Label
1
S94119
Consumer/Warranty Information
1
- M0082-1112
Warranty Tag
1
S780281
ancho Decal
1
S780294
ed ancho Decal, Die Cut
1
S780294B
Black ancho Decal, Die Cut
1
4
S176881B
Fwd
Diff Drop Bracket, Left
1
5
S176882B
Fwd Diff Drop Bracket, ight
1
6
S176883B
Aft Diff Drop, Left
1
S860838
Sub Assy, Alignment Hardware
1
7
S176578
Cam Bolt Assembly
4
8
S176858
Hex Cam
4
S770123
Washer M18 SAE
4
S770118
Nut M18
-
2.5 Nylock
4
9
S176579
Sway Bar Drop Bracket
2
10
S176884B
Skid Plate
1
11
S176586
Front Driveshaft Spacer
1
12
S176780
Front Brake Line Bracket
2
S860788
Sub Assy, Lower Ball Joint
1
13
S176755
Lower Ball Joint Spacer
2
S860731
Sub Assy, ear Drive Shaft
1
1
4
S176691
ear Drive Shaft Spacer
1
S860732
Sub Assy, Spacer Hardware
1
S77035
HHCS M12
-
1.75X70MM
4
S7915
Washer M12
4
1
5
S740017
U
-
Bolt 9/16
-
18 X 3.16 X 12
4
ITEM
PART #
DESCRIPTION
QTY
1
6
S15104
Winged Spacer Block
2
S860837
Sub Assy, Hdwr Box
1
S860783
Sub Assy, Diff Drop
1
S770129
HHCS, M14
-
2.00X80MM
1
S770041
HHCS, M14
-
2.00X90MM
2
S7877
Nut, M14
-
2.00 Toplock
2
S770109
Washer, M14
5
S860506
Sub Assy, M10 Hadrware
2
S770080
HHCS, M10
-
1.50X30MM
4
S7657
Nut, M10
-
1.50 Nylock
4
S770064
Washer, M10
8
S860785
Sub Assy, Front Driveshaft Spacer
1
S770256
12pt. M10
-
1.5
Class 12.9
6
S770230
M10 Washer, 18MM OD
6
S42702
Thread Lock
1
S860786
Sub Assy, Front Brake line Bracket
1
S770127
HHCS, M8
-
1.25X20mm
2
S603112
Nut, M8
-
1.25 Nylock
2
S770128
Washer, M8
4
S860152
Sub Assy, 9/16 U
-
Bolt
1
S770062
Washer, 9/16 X 3/16 Thick
8
S7737
Nut, 9/16
-
18 Nylock
8
S860787
Sub Assy, ear Brake
1
1
7
S176748
Parking Brake Cable Drop
1
1
8
S176314
ear Brake Hose Drop
1
S770128
Washer, M8
5
S603112
Nut, M8
-
1.25 Nylock
3
S770127
HHCS, M8
-
1.25X20MM
2
1
9
S860749
Sub Assy, Vent Hose
1
S96327
Tube Fitting
1
S96328
ubber Tube
1
S1900
-
12
Kit Boot Tie Black 10/Pk
1
136763624
Tie Strap
-
Black
10
1
Parts List
2
3
4
5
6
7
7
7
7
9
9
10
11
12
12
14
15
16
17
18
19
16
8
8
8
8
13
13