89401 Rev A INSTALLATION INSTRUCTIONS For Rancho Suspension System RS66401B: 2013 - 2014 RAM 1500 4WD Fits OE 17” and up rims ONLY WITH OE TIRES 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.
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. WARNING: READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION.
of the vehicle must be sound (no cracks, damage or corrosion). 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. B. The components of Rancho’s suspension system are designed as a single integrated system.
Hydraulic Floor Jack Center punch File Hammer Wire Brush (to clean bracket mounting surfaces) Silicone Spray Lubricant Dot 3 Brake Fluid Enamel Paint Tape Measure Safety Glasses (wear safety glasses at all times) J. It is extremely important to replace coil springs, CV flanges, and front 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. N.
17 13 13 5 12 4 10 8 6 7 9 3 2 11 16 16 1 14 14 15 PARTS LIST Item 1 RS176588B Description Box 1 of 4 Sub-frame 2 RS860354 RS176230 Box 2 of 4 Knuckle, Left 1 3 RS860355 RS176231 Box 3 of 4 Knuckle, Right 1 RS170108 RS170109 RS176654 RS176239 RS176240 RS176651 RS176653 RS176419 RS176422 RS176589 RS602614 RS602641 RS860453 RS770072 RS7914 RS7911 RS7915 RS860707 RS770247 RS770107 RS7915 Box 4 of 4 Brake Hose, Left Brake Hose, Right Axle Tube Drop Bracket, Front Half Axle Tube Drop
FRONT SUSPENSION 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. VEHICLE PREPARATION 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 1. 2) Mark the brake rotor left or right. Remove the brake rotor.
6) Remove the nut at the lower ball joint. Using removing tool 8677, separate the ball joint from the steering knuckle. See illustration 5. 4) Remove the lower coil-over nut and bolt. See illustration 8. Lower jack and remove the coil-over assembly. Illustration 5 Illustration 8 7) Remove the steering knuckle. Hang the half shaft with wire or a tie wrap. 5) Mark the lower control arm pivot bolts for installation reference. Remove the lower control arm pivot bolts. Refer to illustration 8.
RS602614 RS602641 Illustration 10 5) Apply a small amount of thread lock to inner tie rod RS602641. Attach new tie rod assembly to rack. Tighten inner tie rod securely. Do not over tighten. Illustration 12 3) With an assistant’s help, raise sub-frame RS176588B up into the lower control arm frame brackets. See illustration 13. 6) Install boot in original location on rack and inner tie rod. Secure boot to rack with a tie wrap from hardware kit RS860562.
FRONT DIFFERENTIAL DROP BRACKET INSTALLATION WARNING: DO NOT allow differential to be supported only by the right/passenger side axle tube mount. DO NOT allow any twisting or side loading of the right/passenger side axle tube mount. Damage to the differential axle tube can result without the damage being visible to you, resulting in loss of vehicle control and an accident. 1) Support the front differential assembly with a jack. 2) Remove the differential housing rear mounting bolts.
12) FIFTH – Slowly snug the right/passenger axle tube mounting and spacer brackets while confirming that are installed correctly. The brackets must align properly with the mounts. If there is more than 1/16” (.063”) gap in any location, shimming will be required to prevent excessive side loads being applied to the differential axle tube. If the brackets and mount are not parallel to each other, loosen and re-torque the Tighten the differential housing rear mounting bolts.
5) Install axle hub spacer RS176232 on the passenger side axle shaft. See illustration 22. 2) Remove the bolt holding the brake hose to the frame. See illustration 24. 6) Support the lower control arm with a jack. Insert axle shaft through hub and install steering knuckle RS176231 onto the lower ball joint. Install lower ball joint nut. CAUTION: The ball joint studs must be free from residue (nylon) prior to installing new knuckle. Illustration 24 3) Install the brake rotor.
8) shock mounting bolt. Bleed the front brakes as follows: 5) Remove upper end link mounting bolt, brake line wire hanger, and ABS lines from holders. Fill master cylinder reservoir with approved brake fluid. Attach a clear hose to bleeder valve of right front caliper. Immerse other end of hose into glass container partially filled with brake fluid. 6) Repeat step 4 and 5 for other side. 7) Carefully lower the rear axle. Do not allow the axle to hang by any hoses or ABS cables.
Illustration 30 FINAL CHECKS & ADJUSTMENTS Illustration 28 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. 5) Attach new Rancho shock absorbers (RS5369 only) to the upper and lower mounts. Tighten securely. Note: Failure to use Rancho rear shocks RS5369 could lead to coil spring damage.
