889105 Rev B Requires the following for a complete installation: OE frame bracket removal Transmission Crossmember Kit (see below). 2012 and later models equipped with 3.6l V6 engine need exhaust modification kit RS720003, or replacement front driveshaft (driveshaft / exhaust clearance issue).
READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION IMPORTANT NOTES! G. Rancho parts come with a protective coating. Do not powder coat, chrome, cadmium, or zinc plate any of the components in this system. If you wish to change the appearance of components enamel paint can be applied over the original coating. Actual color of components may differ from illustrations. WARNING: This suspension system will enhance the offroad performance of your vehicle.
P. The RS66105 suspension system can only be installed on vehicles equipped with a Dana 44 rear axle in the JK factory configuration. Q. 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. R. During high articulation events, the front driveshaft may contact exhaust or transmission oil pan.
RS66105 BOX 1 OF 3 RS66105 BOX 2 OF 3 RS886101 RS66105 BOX 3 OF 3 RS886102 4
PARTS LIST P/N RS176446 RS176447 RS860588 RS176448 RS860589 RS602618 RS176650B RS860703 RS420067 P00932 RS7789 RS170110 RS170113 RS176443 RS860710 RS176088B RS860412 RS448 RS545 RS89105 RS94180 RS860275 RS520080 RS420080 RS520090 RS420090 RS860613 RS7852 RS170111 RS170112 RS176680 RS176681 RS860588 DESCRIPTION Box 1 Of 3 Left Front Arm Right Front Arm Suspension Arm Hardware Kit Washer, 9/16" Lock HHCS, M14-2.00 X 90 HHCS, M14-2.00 X 10 Nut, M14-2.
OE Front Suspension FRONT SUSPENSION TRANSMISSION CROSS MEMBER REPLACEMENT 1) Park vehicle on a level surface. Set the parking brake and chock rear wheels. Disconnect the negative ground cable from the battery. 2) Remove the end link to axle bracket nut and bolt. Remove the ball stud nut at the sway bar. Remove the end link. Repeat for other side. 3) Remove the track bar to axle bracket nut and bolt. 4) Raise the front of the vehicle and support the frame with jack stands.
) Remove nuts holding transmission mount to cross member. 7) Carefully lower the front axle and remove the coil springs. Push down on axle if necessary. 8) Remove the cross member to frame bolts. Remove the cross member. CAUTION: Do not allow the front axle to hang by any hoses or cables. 9) Insert new cross member RS176460B or RS176648B into frame brackets. Attach cross member to frame with the original hardware. See illustration 2.
3) Attach caster link assembly to the axle with the original hardware and to the new suspension arm with the 14mm hardware from kit RS860589. See illustration 7. Tighten nuts and bolts to 75 ft. lbs. Illus. 5 5) Apply a film of grease to the outside of the installed bushings. Place a shim from kit RS860275 against each bushing. Illus. 7 4) Center rod end and tighten jam nut.
FRONT TRACK BAR AXLE BRACKET INSTALLATION 1) Insert track bar bracket RS176650B over the original track bar axle mount bracket. See illustration 10. RS822B Illus. 8 7) Raise front axle and attach shock lower mounts to axle brackets with the original hardware. Tighten nuts and bolts to manufacturer’s specifications. 8) Reattach vent hose and electrical wiring if necessary. Illus.
2) Apply silicone lubricant and press a supplied sleeve into each bushing. 3) Remove the brake hose from the caliper. Discard copper washers. 3) For RS6756B, install a rubber washer from kit RS860580 on the lower end link. Connect upper and lower end links with the lynch pin from kit RS860580. 4) Attach left brake hose RS170110 to the caliper with the supplied banjo bolt and washers. 5) Attach left brake hose to the frame rail with the original bolt. Attach brake tube to hose.
Installed Front Suspension Front View Rear View 11
Rear Suspension springs. REAR SUSPENSION CAUTION: Do not allow the axle to hang by any hoses or cables. SHOCK ABSORBER & COIL SPRING REMOVAL 1) Disconnect track bar from axle bracket. SUSPENSION ARM REMOVAL 2) Chock front wheels. Raise the rear of the vehicle and support the frame with jack stands. See Important Note N on page 3. Remove the rear wheels. 1) Remove the lower suspension arm nut and bolt from the axle bracket. 2) Remove the flag nut at the frame rail bracket. See illustration 13.
4) Insert right suspension arm bracket RS176467B between the frame and skid plate bracket. Push bracket against frame and body mount. 5) Using bracket RS176476B as a template, mark the mounting hole locations on the frame and body mount. Mark the relief hole location on the skid plate for the suspension arm bolt. Remove bracket. 6) Drill two 1/2” holes into the frame, one 10mm hole through the body mount, and one 3/4” hole into the skid plate at the marked locations. See illustration 14.
FRONT Shims Illus. 16 SUSPENSION ARM INSTALLATION Shims Illus. 17 1) Lubricate bushings (RS520080) and longer sleeves (RS420080) from kit RS860275 with lithium grease. Insert bushings and sleeves into the barrels of lower rear suspension arms RS176680 and RS176681. See illustration 5. 9) Center rod end RS176647 and tighten jam nut. Tighten all nuts and bolts to 125 ft. lbs. 10) Repeat steps 1 through 9 for the driver side, using lower arm RS176681.
3) Using the U-Bolt from hardware kit RS860713, attach the top of bracket RS176655B to the rear axle tube using 3/8 washer and Nylock nuts. At this time just snug down attached hardware. Do not torque down. BUMP STOP BRACKET INSTALLATION 1) Using the original holes on the axle pad, attach bump stop bracket RS176478B to the axle with the 8mm hardware from kit RS860592. See illustration 19. Tighten nuts and bolts to 23 ft. lbs. 4) Using a clamp to hold bracket RS176655B snug to axle bracket.
1) Separate the driver side brake hose form the brake tube and frame rail. Plug tube to prevent brake fluid leakage. 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. 2) Remove the brake hose from the caliper. Discard copper washers. 3) Ensure that the vehicle brake system operates correctly.
Installed Rear Suspension Front view Rear View 17
