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

6
FRONT SUSPENSION
Illustration 1 Illustration 2
V EHICLE P REPARATION & S WAY B AR R EMOVAL
1)  Park the vehicle on a level surface. Set the parking
brake and chock rear wheels. Measure and record the
distance from the center of each wheel to the top of the
fender opening. See Illustration 3.
Illustration 3
2)  aise the front of the vehicle and support the frame
with jack stands. emove the front wheels and set them
aside.
3)  If applicable, remove the front splash shields and / or
skid plates. emove splash shield brackets from side of
frame rails. See Illustration 4 and Illustration 5.
4)  Hold the hex stud and remove the nut attaching the
sway bar end link to the sway bar. See Illustration 2 and
Illustration 6. epeat for other side.
5)  emove the four nuts holding the sway bar to the
frame. emove the sway bar assembly. See Illustration 6.
Illustration 4
Illustration 5
Lower Control Arm
Upper Control Arm
Steering Knuckle
Caliper
Rotor Tie Rod End
Upper Shock Mount
Lower ShockMount
Axle Nut
Sway Bar
Lower Control Arm
Upper Control Arm
Caliper
Rotor
Steering Knuckle

7
Illustration 6
Illustration 7
Illustration 8
S TEERING K NUCKLE , S HOCK & L OWER C ONTROL A RM
R EMOVAL
1)  efer to Illustration 7.Separate the ABS wire from
brake hose (1). emove plastic clips holding ABS wire to
bracket (2) and frame (2). emove plastic clips holding
vacuum hose to bracket (3) and frame (3). emove vacuum
hose from hub (4). emove screws holding bracket to
frame, and lines to knuckle (5). emove brake line from
plastic clip at frame (6).
2)  emove the brake caliper anchor bolts. See
Illustration 8. emove the brake caliper and its mounting
bracket as an assembly. Hang the caliper assembly with
wire or a tie wrap.
WARNING: Do not allow the caliper to hang by the brake hose. You
could damage the hose, without this damage being visible to you,
resulting in sudden and unexpected brake failure and an accident.
3)  Label the brake rotor left or right. emove the brake
rotor.
4)  emove the dust shield. Disconnect the ABS sensor
from the wheel hub. See Illustration 8.
5)  emove the axle cap using a small chisel and hammer
to pry off. emove axle nut. See Illustration 8.
6)  Mark position of alignment cams (if equipped) and
loosen all four lower control arm pivot bolts.
7)  emove the nut from the outer tie rod stud. Using
Ford Service tool #204-592 separate tie rod end stud from
knuckle. Loosely re-install to keep steering knuckle from
turning. See Illustration 1.
WARNING: Do not hammer the ball studs to separate them from
components. You could damage the ball studs, without this damage
being visible to you, resulting in sudden and unexpected failure of the
ball studs and an accident.
8)  Loosen the nuts at the upper and lower ball joints.
Using Ford Service tool #204-592 separate ball joints from
knuckle.
9)  emove the upper and lower ball joint nuts. Carefully
remove the steering knuckle. Cover the exposed hub to
prevent contamination.
10)  Loosen the three shock absorber upper mount to
frame nuts. See Illustration 9
11)  emove the shock absorber lower mounting nuts
and swing lower control arm down off the shock studs.
12)  emove the three shock absorber upper mount to
frame nuts. emove the shock absorber and spring
assembly.
13)  emove the lower control arm pivot bolts. emove
the lower control arm. See Illustration 9.
Illustration 9
ABS Wire
Upper Mount
Lower
Brake Hose
Vacuum Hose
(1)
(2)
(3)
(4)
(5)
(5)
(6)

8
F RONT D IFFERENTIAL R EMOVAL
1)  emove the four bolts that attach the cross-member
to the lower control arm pockets. emove the cross-
member. See Illustration 10.
Illustration 10
2)  Disconnect the electrical connections to the steering
rack. Slide the red clip lock out, then push down on the
black clip lever while pulling the plug. See Illustration 10 and
Illustration 11. Clips locks shown in out position.
WARNING: Do not pull on wires. Do not damage the plug, lever or clip.
The steering rack may not function properly, without the damage being
visible to you, resulting in loss of vehicle control and an accident.
Illustration 11
3)  Index-mark the front driveshaft flange to the front
differential pinion flange.
4)  emove the six bolts from the driveshaft flange.
Disconnect and support the front driveshaft with strap or
wire tie
5)  Disconnect the vent hose from the axle housing. See
Illustration 12.
6)  Support the front differential assembly with a floor
jack.
Illustration 12
7)  Loosen all three differential mounting bolts. See
Illustration 12
Note: A plastic shield covering the steering rack may need to
be removed to access bolt. This shield is fastened to the
frame with two plastic clips. SeeIllustration13. Shield shown
removed. Shield fits insame position, but inside of frame rail.
Illustration 13
8)  emove the front differential assembly aft mounting
bolt. See Illustration 12.
9)  emove the differential assembly passenger side
mounting bolt. Take care that flag-nut does not damage
metal transmission lines.
10)  Pushing up on the right side of the right axle housing,
remove the driver side mounting bolt.
ATTENTION! — TWO PEOPLE WILL BE NEEDED TO EMOVE
THE DIFFE ENTIAL ASSEMBLY!
11)  With the help of an assistant, remove the differential
assembly from the vehicle.
The differential will have to be tilted with the rear pinion
flange up, and the passenger side down to remove.
12)  eattach plugs to steering rack and push red clip lock
back over clip lever
Cross-member
Diff Aft. Mount
Drive Shaft Transmission Lines
Diff Pass. Mount
Steering Rack
Push
Push
Passenger
Driver
Aft
Vent

9
F RONT D IFFERENTIAL & S UBFRAME I NSTALLATION
Box S66505B-1 (Box 1 of 4)
Subframe S176880B
Box S66505B-4 (Box 4 of 4)
Left Diff Drop Bracket S176881B
ight Diff Drop Bracket S176882B
Skid Plate S176884B
Diff Drop Hardware S860783
Cam Bolt Hardware S860838
Skid Plate Hardware S860506
1)  If applicable, cut the driver side corner off the steering
rack skid plate and de-bur cut edge. einstall using OE
hardware. See Illustration 14.
Illustration 14
2)  Install skid plate S176884B to the bottom of
subframe S176880B using 10MM hardware from
S860506. Torque to 45 ft. lbs. See Illustration 15.
Illustration 15
3)  Draw a line, perpendicular to the bottom edge and ½”
from the edge of the slotted hole, on the front and back of
the driver side crossmember bracket. Connect the lines on
the top of the bracket providing a minimum of 6” clearance.
See Illustration 16.
Illustration 16
4)  Using a die grinder and Sawzall follow the line and cut
off the crossmember bracket. Do not remove aft differential
mount. See Illustration 17.
WARNING: Do not use a flame cutter or torch to remove bracket. You
could warp, weaken or damage the bracket without the damage being
visible to you, resulting in loss of vehicle control and an accident.
Illustration 17
5)  ound off any sharp corners and deburr edges. Paint
bare metal to prevent rust.
6)  Loosely attach diff drop bracket S176881B to the
driver side differential frame bracket, and S176882B to
passenger side frame bracket with the original hardware.
See Illustration 18 and Illustration 19.
Illustration 18
2.5”
1.5”
Driver Side
RS176884B
RS176880B
1/2”
6”
Minimum
Modified Bracket
Aft Differential
Mount
RS176881B
RS176882B

10
7)  With the help of an assistant, carefully raise the front
differential assembly up into the newly installed drop
brackets. Loosely attach the differential assembly to the
brackets with the hardware from kit S860783. Use the
shorter 80MM bolt on the driver side.
8)  With the help of an assistant, raise subframe
S176880B into the lower control arm frame brackets.
Attach sub frame to the lower control arm brackets with
original hardware.
9)  Loosely attach aft differential bracket S176883B to
the aft frame mount with OE hardware. See Illustration 20
and Illustration 21.
10)  Lift up on rear of differential and loosely attach
differential to subframe and aft differential bracket with
hardware from kit S860783. See Illustration 20 and
Illustration 21.
CAUTION: With sub frame inplace, verify that the differential
aft mount does not contactthe modified frame bracket. There
must be a minimum of ¼” clearance between frame and
differential. Contact may cause vibration. See Illustration 20
and Illustration 21.
11)  Push up on subframe and torque subframe to frame
bolts to 258 ft. lbs.
12)  Torque all differential mounting hardware to 85 ft.
lbs. (six bolts).
13)  Attach the lower control arm to the subframe with
the cam bolts and hardware from kit S860838. Insert front
alignment cam bolts from front to rear, and rear cam bolts
rear to front. Align cams straight up or down.
14)  Install hex cam and washer on each cam bolt,
aligning cam the same as the cam bolt. Apply grease or anti-
seize (not included) to the threads of cam bolts and install
nut. Hold head of cam bolt and tighten nut against hex cam
and washer. Control arm should remain loose enough to
rotate in subframe
CAUTION: Do not get grease or anti-seize on cam or sub-
frame where cam seats.
NOTES: Do not torque the lower control arm bolts until the
vehicle is at normal ride height.
F RONT D RIVESHAFT S PACER I NSTALLATION
Box S66505B-4 (Box 4 of 4)
Driveshaft Spacer S176586
Hardware from Sub Assy S860785
1)  Align index marks on front driveshaft, insert spacer
S176586 between driveshaft and pinion flange. Secure
together with OE torque plates and 12 point 10mm
hardware from kit S860785. Tighten bolts to 41 ft. lbs. See
Illustration 22. Use of blue thread lock is recommended
but not included.
Illustration 19
Illustration 20
Illustration 21
Min ¼” Clearance RS176883B
RS176880B
Min ¼” Clearance
RS176883B
FRONT
RS176882B
FRONT
RS176881B

11
Illustration 22
S HOCK A SSEMBLY
FOR OPTIONAL RANCHO REPLACEMENT SHOCK
ABSORBERS RS55388 or RS7838.
If reusing OE shock absorber, proceed to next section - “Strut
Tower Installation”
CAUTION: Follow instructions and warnings supplied with
shock absorber.
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.
1)  Mark alignment of shock, coil and upper mount. See
Illustration 23.
2)  Using a quality spring compressor, compress the coil
spring until the tension is released from the shock absorber.
See Illustration 23.
3)  emove the upper shock rod mounting nut. Slide the
shock absorber out of the spring assembly.
4)  Insert new shock absorber into spring assembly. Use
index marks to align shock with the coil and upper mount.
Install the original mounting nut. Tighten the nut to 22 ft.
lbs.
5)  emove spring compressor.
6)  Insert the shock absorber assembly into the upper
frame mount. Loosely install with OE nuts.
Illustration 23
S TRUT T OWER A SSEMBLY (RS886519)
FOR OE FORD SHOCK ONLY.
If replacing shock absorbers with Rancho shock absorber
RS55839 or RS7838, skip to next section - “Shock Absorber
Installation”
1)  Using OE nuts, install strut tower S176708B onto OE
shock absorber. Tighten to 30 ft. lbs. See Illustration 24 .
Illustration 24
2)  Insert the shock absorber and strut tower assembly
into the upper frame mount. Loosely install with nuts and
washers from hardware kit S860746. See Illustration 24
and Illustration 25.
Reference Marks
Reference
Marks
Rod Nut
Torque Plate
RS176586
Index Marks
RS176708B
OE Hardware
OE Shock

12
S HOCK A BSORBER I NSTALLATION
1)  Attach the shock absorber to the lower control arm
with the original hardware. Tighten lower mounting bolts to
66 ft. lbs. Tighten nuts at upper mount to 30 ft. lbs. See
Illustration 25.
Illustration 25
S TEERING K NUCKLE I NSTALLATION
Box S66505B-2 (Box 2 of 4)
Left Steering Knuckle S176753
Box S66505B-3 (Box 3 of 4)
ight Steering Knuckle S176754
Box S66505B-4 (Box 4 of 4)
Sub Assy S860788
Lower Ball Joint Spacer S176755
1)  emove the integrated wheel end and wheel hub
from the passenger side steering knuckle. See Illustration 26.
CAUTION: Do not damage the O-ring on the wheel hub.
Illustration 26
2)  Align the ABS sensor hole to the top of the knuckle
and attach the wheel hub to right ancho knuckle S176754
with the original bolts. Tighten the bolts to 129 ft. lbs.
3)  Align vacuum port upward and attach the integrated
wheel end to the knuckle with the original hardware.
Tighten the bolts to 11 ft. lbs.
4)  Install knuckle on vehicle:
Carefully insert the axle into the hub until the threads
protrude from hub bearing. See Illustration 27
Insert lower ball joint stud into steering knuckle and loosely
attach with OE nut.
Insert upper ball joint stud into steering knuckle and
loosely attach with OE nut.
Pull, wiggle and turn axle to seat fully in hub bearing. See
Illustration 27
Illustration 27
Note: The axle splines must line up withthe integrated wheel
end. Do not force axle in. You may need to separate upper
ball joint and turn axle or integrated wheel end, then repeat
step 4.
Do not move on to next step until axle is seated in bearing.
Bearing
Axle
Shock
Lower Control Arm
Steering Knuckle
Wheel Hub
Integrated Wheel End
O-Ring
Hub

13
6)  Support knuckle and remove lower ball joint nut.
Place lower ball joint spacer S176755 from kit S860788
on lower ball joint stud with counter bore (recess) against
knuckle. einstall lower ball joint nut. Tighten the lower ball
joint stud nut to 111 ft. lbs. and the upper nut to 85 ft. lbs.
See Illustration 28.
Illustration 28
7)  Install the axle half shaft nut. Tighten the nut to 20 ft.
lbs. Install the axle cap.
8)  Loosen the jam nut on the tie rod and thread the tie
rod end out approximately 6 turns. Insert the tie rod end
from the top into the steering knuckle and install the
original nut. Tighten the ball stud nut to 85 ft. lbs. and the
jam nut to 76 ft. lbs.
9)  epeat steps 1 through 7 for the driver side using left
ancho knuckle S176753.
C ALIPER A ND B RAKE H OSE D ROP B RACKET I NSTALLATION
Box S66505B-4 (Box 4 of 4)
Front Brake line Brackets S176780
Hardware from Sub Assy S860786
Wire Ties from S1900-12
1)  eattach the ABS sensor to the wheel hub and the
vacuum hose to the integrated wheel end.
2)  Attach the dust shield with the original hardware.
Tighten the bolts to 12 ft. lbs.
3)  Install the right brake rotor on the passenger side
wheel hub.
4)  Install the brake caliper over the rotor. Attach the
caliper to the knuckle with the original anchor bolts using
red thread lock. Tighten the bolts to 175 ft. lbs. efer back
to Illustration 1 and Illustration 2.
Illustration 29
5)  Using the original bolt and location, attach brake hose
drop bracket S176780 to the frame rail. Tighten bolt
securely.
6)  Carefully re-shape metal brake lines and attach OE
brake hose bracket to drop bracket S176780 with
hardware from kit S860786. See Illustration 29.
7)  eattach the vacuum line clips to brake line brackets.
eposition line on clips if needed.
8)  eattach ABS and brake line to knuckle with original
hardware.
9)  Use wire ties from S1900-12 to attach ABS wire to
brake line and upper OE mount. Attach ABS wire and
vacuum line to frame at upper control arm mount with wire
ties. See Illustration 29.
10)  epeat for other side.
11)  Turn the front wheels completely left then right.
Verify adequate, ABS, brake, and vacuum line clearance and
length.
Wire Ties
Wire Tie
RS176780
RS176755
Steering Knuckle
Lower Control Arm

14
V ENT H OSE E XTENSION I NSTALLATION
Box S66505B-4 (Box 4 of 4)
Hardware from Sub Assy S860749
1)  Insert tube fitting into rubber tube from kit S860749.
2)  Insert other end of tube fitting in OE vent hose.
3)  Install lengthened vent hose on differential in OE
location. See Illustration 30.
Illustration 30
S WAY B AR I NSTALLATION
Box S66505B-4 (Box 4 of 4)
Sway Bar Drop Brackets S176579
Hardware from Sub Assy S860506
1)  Attach sway bar drop brackets S176579 to the frame
with the original hardware. Tighten the nuts to 35 ft. lbs.
2)  Attach the sway bar to the drop brackets with 10MM
hardware from kit S860506. Torque to 35 ft. lbs. See
Illustration 31.
3)  Attach the sway bar end links to the sway bar. Tighten
the nuts to 59 ft. lbs.
4)  Attach the sway bar end links to the sway bar. Tighten
the nuts to 59 ft. lbs.
5)  Install front wheels and turn the front wheels
completely left then right. Verify adequate tire, wheel, and
ABS, brake, and vacuum line clearance and length.
Illustration 31
6)  Lower vehicle to ground. Tighten the lug nuts to 150
ft. lbs.
7)  Align the cam bolts and cam nuts in the center using
a 27mm wrench on both cam bolt and cam nut, and tighten
the lower control arm pivot nuts to 240 ft. lbs. See
Illustration 32.
— ATTENTION! —
THE ALIGNMENT CAMS ARE NOT D BOLTS.
The cam nut can rotate independent of the cam bolt.
When adjusting alignment cams, you MUST use a
27mm (or 1-1/16”) wrench on BOTH cam bolt and
cam nut.
INFORM ALIGNMENT TECH OF THIS WARNING.
NOTE: If full torque cannot be achieved with vehicle at ride
height, tighten cam bolts as much as possible on ground to
lock bushing and alignment in place, and then raise front of
vehicle onto jack stands to apply final torque.
WARNING: Failure to fully torque lower control arm cam bolts can
cause a sudden and unexpected change of vehicle alignment, resulting
in loss of vehicle control and an accident.
OE Vent Hose
Tube Fitting
Rubber Tube
RS176579
Sway Bar

15
Illustration 32
REAR SUSPENSION
V EHICLE P REPARATION
1)  Chock front wheels. aise the rear of the vehicle and
support the frame with jack stands. emove the rear
wheels.
2)  On the driver side, separate the parking brake cable
bracket from the bottom of the leaf spring mount. See
Illustration 33.
Illustration 33
3)  emove the brake hose bracket from the inside of the
driver side frame rail. Disconnect plastic clips holding brake
line and wire harness to inside of frame rail. See Illustration 36.
R ISER B LOCK I NSTALLATION
S66505B-4 (Box 4 of 4)
iser Blocks S15104
U-Bolts S740017
Hardware from Sub Assy S860152
1)  Support the rear axle assembly with a floor jack.
2)  emove both rear shock absorbers. Do not reuse
OEM shock absorbers.
3)  Loosen the U-bolt nuts on both sides of the vehicle 2
turns.
4)  emove the passenger side U-bolts only. Carefully
lower the rear axle and remove the original riser block. See
Illustration 34.
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.
Parking Brake Cable Bracket
Cam Bolt
Cam Nut

16
Illustration 34
5)  Place riser block S15104 on the axle pad. Loosely
attach the leaf spring to the axle with U-bolts S740017 and
the hardware from kit 860152. See Illustration 35
Illustration 35
6)  epeat steps 4 - 5 for the driver side.
7)  Cross tighten all U-bolt nuts evenly to 85 ft. lbs.
8)  Install new ancho shock absorbers and torque to 66
ft. lbs.
B RAKE D ROP B RACKETS I NSTALLATION
S66505B-4 (Box 4 of 4)
ear Brake Hose Drop Bracket S176314
Parking Brake Cable Drop Bracket S176748
Hardware from Sub Assy S860787
1)  Attach rear brake hose drop bracket S176314 to the
frame with the original bolt Tighten the bolt to 12 ft. lbs.
See Illustration 36.
Illustration 36
2)  Attach the original brake hose bracket to drop bracket
S176314 with the 8mm hardware from kit S860787.
Insert plastic clip on wire harness back into frame.
3)  Attach parking-brake cable drop S176748 to the leaf
spring mount using OE bolt and hardware from kit
S860787. See Illustration 37
Illustration 37
4)  Attach original parking brake cable bracket to
S176748 using 8mm hardware from kit S860787. Tighten
the bolt to 12 ft. lbs.
RS176314
FRONT
RS176748
FRONT

17
D RIVESHAFT S PACER I NSTALLATION
S66505B-4 (Box 4 of 4)
Sub Assy S860731
ear Driveshaft Spacer S176691
Hardware from Sub Assy S860732
1)  Measure pull-out of rear output shaft slip joint. If pull-
out exceeds 1¼” follow steps 2-5 to install rear driveshaft
spacer S176691. See Illustration 38.
Illustration 38
2)  Index-mark the rear driveshaft flange to the rear
differential pinion flange.
3)  Support rear driveshaft with floor jack.
4)  emove rear driveshaft flange to the rear differential
pinion flange mounting bolts
5)  Align index marks on rear driveshaft, insert rear
driveshaft spacer S176691 between driveshaft and pinion
flange. Secure together with 12mm hardware from kit
S860732. Tighten bolts to 75 ft. lbs. See Illustration 39. Use
of blue thread lock is recommended but not included.
Illustration 39
6)  Install rear wheels.
7)  Lower vehicle to ground. Tighten the lug nuts to 150
ft. lbs.
F INAL C HECKS & A DJUSTMENTS
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 steering and brake systems
operate correctly.
4)  eadjust headlamps.
5)  Have vehicle aligned at a certified alignment facility.
— ATTENTION! —
THE ALIGNMENT CAMS ARE NOT D BOLTS.
The cam nut can rotate independent of the cam bolt.
When adjusting alignment cams, you MUST use a
27mm wrench on BOTH cam bolt and cam nut.
INFORM ALIGNMENT TECH OF THIS WARNING.
ecommended Alignment Specifications
Caster (degrees): 3.60°± 1.00°
Camber (degrees): -0.10°± 0.75°
Sum Toe In (degrees): 0.2°± 0.2°or 0.10” ±0.10”
6)  Park the vehicle on a level surface Measure and
record the distance from the center of each wheel to the
top of the fender opening. See Illustration 40 and
Illustration 3.
Illustration 40
Measure
Rear Output Shaft
RS176691

18
Torque Specs
Front Components
Skid Plate RS176884B 45 ft. lbs
Subframe RS176880B to Frame
258 ft. lbs.
Lower Control Arm to Subframe RS176880B 240 ft. lbs.
D
ifferential
Aft
Mount
to
Subframe
RS176880B
85 ft. lbs.
Differential Drop Bracket RS176745B 85 ft. lbs.
Driveshaft to Pinion Flange 41 ft. lbs.
Shock Mount, Upper
30 ft. lbs.
Shock Mount, Lower 66 ft. lbs.
Shock Spacer RS176750B
30 ft. lbs.
Wheel Hub to Steering Knuckle 129 ft. lbs.
Integrated Wheel End to Hub 11 ft. lbs.
Lower Ball Joint
111 ft. lbs.
Upper Ball Joint 85 ft. lbs.
Tie Rod
End Ball Stud
85 ft. lbs.
Tie Rod Jam Nut 76 ft. lbs.
Axle Shaft 20 ft. lbs.
Dust Shield toSteering Knuckle
12 ft. lbs.
Brake Caliper to Steering Knuckle 175 ft. lbs.
Brake Line Bracket
12 ft. lbs.
Sway Bar Drop Bracket RS176746B
35 ft. lbs.
Sway Bar End Link 59 ft. lbs.
Wheel Lug Nuts
150 ft. lbs.
Rear Components
Brake Hose Drop Bracket RS176314 12 ft. lbs.
Parking
-
Brake Cable Drop BracketRS176748
12 ft. lbs.
Driveshaft to Pinion Flange 75 ft. lbs.
Leaf Spring Center Bolts
65 ft. lbs.
Leaf Spring U-bolt 85 ft. lbs.
Shock Absorbers 66 ft. lbs.
Wheel Lug Nuts
150 ft. lbs
STANDARD BOLT TORQUE & 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

19
ancho Technical Department 1-734-384-7804.