INSTALLATION INSTRUCTION 88267

Transcription

1 INSTALLATION INSTRUCTION FOR RANCHO SUSPENSION SYSTEM RS6267: 2WD CHEVROLET SUBURBAN & TAHOE READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION Rev B IMPORTANT NOTES! 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. Extreme care must be used to prevent loss of control or vehicle rollover during abrupt maneuvers. 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. 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. Do not install a body lift kit with this suspension system or interchange Rancho components with parts from another manufacturer. Use the appropriate Rancho shock absorbers, contact your local dealer for the correct application. C. Do not chrome, cadmium, or zinc plate any of the components in this system. To change the appearance of components, enamel 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 on page 2. 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 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 on page 2. USE A TORQUE WRENCH for accurate measurements.

2 I. Some of the service procedures require the use of special tools designed for specific procedures. The following tools and supplies are recommended for proper installation of this system: Chevrolet Service Manual Coil Spring Remover & Installer J Ball Joint Separator J Tie Rod Puller J 6627-A Drill motor Assorted Drills: 1/8" through 1/2" Torque Wrench (250 FT-LB capacity) 1/2 Drive Ratchet and Sockets Assorted Combination Wrenches Heavy Duty Jack Stands Wheel Chocks (wooden blocks) Hydraulic Floor Jack Center punch File Bench Vise Hacksaw Hammer Wire Brush (to clean bracket mounting surfaces) Silicone Spray Lubricant Prevailing Torque Nuts Brake fluid Tape Measure Safety Glasses (wear safety glasses at all times) J. Suspension components that use rubber or urethane bushings should be tightened with the vehicle at normal ride height. This will prevent premature failure of the bushing and maintain ride comfort. K. The required installation time for this system is approximately 8 hours. 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. M. On some vehicles, the new Rancho coil spring may slightly rub the inside lip of the upper frame pocket. This contact will create a noise as the spring compresses and rebounds. If this condition exists, reshape the inside lip (with a hammer) at the contact point. N. If you are installing the Rancho RS9128 front shock, use the bushings and hardware from kit Do not use the bushings and hardware supplied with the shock absorber. O. Important information for the end user is contained in the consumer information pack. If you are installing this system for someone else, display the information pack by hanging it from the rear view mirror. P. 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 SUSPENSION IS NOT RESPONSIBLE FOR DAMAGE OR FAILURE RESULTING FROM AN IMPROPER OR MODIFIED INSTALLATION L. This suspension system was developed using the following tire and wheel combination: P265/75 R15 tire, 15 x 8 wheel with 3.75" of backspacing. Before installing any other combination, consult your local tire and wheel specialist. STANDARD BOLT TORQUE & IDENTIFICATION INCH SYSTEM METRIC SYSTEM Bolt Size Grade 5 Grade 8 Bolt Size Class 9.8 Class 10.9 Class /16 15 FT-LB 20 FT-LB M6 5 FT-LB 9 FT-LB 12 FT-LB 3/8 30 FT-LB 35 FT-LB M8 18 FT-LB 23 FT-LB 27 FT-LB 7/16 45 FT-LB 60 FT-LB M10 32 FT-LB 45 FT-LB 50 FT-LB 1/2 65 FT-LB 90 FT-LB M12 55 FT-LB 75 FT-LB 90 FT-LB 9/16 95 FT-LB 130 FT-LB M14 85 FT-LB 120 FT-LB 145 FT-LB 5/8 135 FT-LB 175 FT-LB M FT-LB 165FT-LB 210 FT-LB 3/4 185 FT-LB 280 FT-LB M FT-LB 240FT-LB 290 FT-LB 2

3 PARTS LIST ITEM PART DESCRIPTION QTY. NO. NO Bump Stop Riser Block Brake Hose, Right Brake Hose, Left Sway Bar End Link, Rear Subframe Front Wheel Spindle, Left Front Wheel Spindle, Right Rear Bump Stop Bracket Coil Spring U-Bolt Brake Hose Gasket Kit 1 Gasket Rear Hardware Kit 1 Sleeve 4 Bushing 4 5/16-24 Nut 4 3/8-16 x 1.25 HHCS 2 3/8-16 Stover Nut 2 3/8 SAE Washer Pin Kit x 1.50 Pin 2 ITEM NO. PART DESCRIPTION QTY. NO U-Bolt Hardware Kit 1 9/16-18 Nyloc Nut 8 9/16 Washer Subframe Hardware Kit 1 Bump Stop 4 M x 130 HHCS 4 M Stover Nut 4 SAE Washer 8 3/8-16 Nyloc Nut 4 3/8 SAE Washer 4 Cotter Pin End Link Hardware Kit 1 Sleeve 2 Bushing 8 Retainer 8 3/8-16 x 11.0 HHCS 2 3/8-16 Nyloc Nut Shock Absorber Hardware Kit 1 Bushing 4 Retaining washer 4 5/8-18 Stover Nut Instructions Consumer Information Pack 1 3

4 FRONT SUSPENSION VEHICLE PREPARATION, E ND LINK & S HOCK ABSORBER REMOVAL 5) Remove the lower shock absorber bolts. See illustration #3. Remove both front shock absorbers. Do Not reuse the original shocks. 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. Illustration #1 2) Remove the upper nut, washer and insulator from each of the front shock absorbers. 3) Separate the sway bar from the lower control arms by removing the end links. See illustration #2. Illustration #3 COIL SPRING & STEERING KNUCKLE REMOVAL 1) Remove the nut from the outer tie rod ball stud. Separate the tie rod end from the steering knuckle. Do not reuse the nut. 2) Separate the brake hose from the upper control arm. Remove the front disc brake caliper assembly. Tie the assembly up and out of the way with wire. CAUTION: Do not allow the brake caliper to hang by the brake hose. 3) Remove the front brake rotor. 4) Remove the three bolts attaching the splash shield to the steering knuckle. If an ABS sensor is attached to the shield, tie the shield up and out of the way. Illustration #2 4) Raise the front of the vehicle and support the frame with jackstands. Remove the front wheels and set them aside. WARNING: Make sure jack and jackstands are properly located to prevent the vehicle from falling. 5) Remove the steering knuckle seal. 6) Remove the coil spring as follows: Attach coil spring removing tool J to a suitable jack. Place the tool under the lower control arm bushings. See illustration #4. Raise the jack to remove the tension on the lower control arm pivot bolts. 4

5 Secure the spring to the lower control arm with a safety chain. Remove the rear pivot bolt then the front. Carefully lower the jack to remove the compression from the coil spring. Remove the safety chain then the coil spring and insulator. SUBFRAME & BUMP STOP INSTALLATION 1) Attach new bump stops 1429 to Rancho subframe using the 3/8 hardware from kit See illustration #6. 2) With an assistant s help, place the subframe into the lower control arm frame pockets as shown in illustration #6. Install the original lower control arm bolts and nuts. Illustration #4 7) Remove the lower ball joint cotter pin and castellated nut. Separate the ball joint from the steering knuckle using ball joint separator J (illustration #5). Remove the lower control arm. Illustration #6 3) Tighten the front then the rear subframe to frame bolts to 101 ft. lbs. 4) Drill a 3/8" hole through the upper control arm at the location shown in illustration #7. Illustration #5 8) Remove the upper ball joint castellated nut and cotter pin. Separate the ball joint from the steering knuckle using ball joint separator J Remove the steering knuckle. 9) Repeat steps 1 through 8 for the other side. Illustration #7 5) Attach bump stop 1429 to the underside of the control arm with the 3/8 hardware from kit ) Repeat steps 4 and 5 for the other side. 5

6 STEERING KNUCKLE & COIL SPRING INSTALLATION 1) Attach left steering knuckle to the driver side upper control arm. Tighten the ball joint castellated nut to 74 ft. lbs. Install a new cotter pin. 2) Attach the driver side lower control arm to steering knuckle Tighten the ball joint castellated nut to 94 ft. lbs. Install a new cotter pin. 6) Secure the coil spring to the lower control arm with a safety chain. Carefully raise the control arm into the subframe pockets. 7) Attach the lower control arm to the subframe with the 16mm hardware from kit See illustration #10. Verify coil spring clearance (Important Note N ). Remove the jack. 3) Install the coil spring insulator on top of a new Rancho spring. 4) Insert the coil spring assembly into the driver side frame pocket. Place the bottom of the spring on the lower control arm. Support the lower control arm with removing tool J attached to a suitable jack. See illustration #8. Illustration #10 NOTE: Do not torque lower control arm bolts until vehicle is at normal ride height. 8) Attach the outer tie rod end to the steering knuckle. Install a new prevailing torque nut. Tighten the nut to 46 ft. lbs. 9) Install the steering knuckle seal. Attach the left brake shield with the original bolts. Tighten the bolts to 19 ft. lbs. Illustration #8 5) Align the spring so that it leaves one of the drain holes (in the lower control arm) uncovered. See illustration #9. 10) Install the brake rotor. Adjust the wheel bearings. 11) Repeat steps 1 through 10 to install the right side components. BRAKE HOSE REPLACEMENT 1) Disconnect the left brake hose from the brake line at the frame bracket. See illustration #11. Plug line to prevent brake fluid leakage. NOTE: Do not allow the brake fluid to drain completely from the master cylinder. 2) Attach the caliper assembly to the steering knuckle. Tighten the mounting bolts to 38 ft. lbs. Illustration #9 3) Remove the bolt attaching the brake hose to the caliper. See illustrations #11. Remove the left front brake hose. Discard the copper washers. 6

7 Illustration #11 4) Attach left brake hose to the left caliper with the NEW copper washers from kit Tighten the original bolt to 32 ft. lbs. 5) Attach the hose bracket to the upper control arm. Attach the brake hose to the brake line. Tighten the fitting to 18 ft. lbs. 6) Repeat steps 1 through 5 to install the right brake hose on the passenger side. 7) Refill the master cylinder with approved brake fluid. Bleed the front brakes as follows: Attach a clear hose to the bleeder valve of the right front caliper. Submerge the other end of the hose into a container partially filled with clean brake fluid. Have an assistant slowly press the brake pedal one time and hold. While maintaining pressure, open the bleeder valve to purge air from the caliper. Tighten the bleeder valve and slowly release the pedal. Wait 15 seconds. Repeat this sequence, including the 15 second wait, until all air is purged from the caliper. Refill the master cylinder as necessary. Repeat the previous steps for the left front caliper. Check the brake pedal for sponginess and the brake warning lamp for an indication of unbalanced pressure. Repeat the bleeding procedure to correct either of these conditions. WARNING: Brake fluid contains Polyglycolethers and Polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. 7 CAUTION: Brake fluid is harmful to painted and plastic surfaces. END LINK & SHOCK ABSORBER INSTALLATION 1) Re-attach the sway bar to the lower control arm with the new end link hardware and bushings from kit Insert the bolt from the top. See illustration #12. Illustration #12 2) Install new Rancho shock absorber. Refer back to Important Note N on page 2. 3) Repeat steps 1 and 2 for the other side. 4) Install the front wheels and lower the vehicle to the ground. Tighten the lug nuts to ft. lbs. 5) Tighten the lower control arm pivot bolts to ft. lbs. REAR SUSPENSION

8 RISER BLOCK INSTALLATION 1) Chock front wheels. Raise the rear of the vehicle, and support the frame with jack stands. Remove rear wheels and set them aside. 2) Support the rear axle assembly with a hydraulic jack. Remove both rear shock absorbers. Do not reuse OEM shock absorbers. 3) If applicable, remove the sway bar end links. See illustration #13. Save hardware for reuse. Illustration #14 7) Repeat steps 3 through 6 for the right side. 8) Install new Rancho rear Shock absorbers. Illustration #13 4) Remove the two U-bolts attaching the rear axle to the left leaf spring. Carefully lower the rear axle. BUMP STOP INSTALLATION 1) Remove the nut from the original bump stop mounting bolt. See illustration #15. CAUTION: Do not allow the axle to hang by any hoses or cables. 4) Insert a block pin from kit into the hole in the axle pad. Place riser block on the axle pad. See illustration #14. NOTE: To insert the block pin, it may be necessary to enlarge the hole in the axle pad. 5) Carefully raise the rear axle until the riser block makes contact with the leaf spring. Make sure center bolt is aligned with hole in block. 6) Attach leaf spring to axle with the new Rancho U-bolts, and original anchor plate. Alternate tightening the U-bolt nuts to 81 ft. lbs. Illustration #15 2) Attach bump stop 1417 to bracket with the 5/16" nuts from kit See illustration #16. 8

9 Illustration #16 3) Place the new bracket assembly over the original bump stop as shown in illustration #16. Temporarily attach the bracket to the frame with the original nut. 1) Lubricate a bushing and sleeve from kit with a silicone spray or a mild solution of soap and water. Press the bushing then the sleeve into end link See illustration #16. 4) Using bracket as a template, mark the location of the rear mounting hole on the bottom of the frame rail. Remove the bracket and drill a 3/8? hole at the marked location. 5) Reattach the bracket assembly with the original nut and the 3/8? hardware from kit Tighten the nuts and bolts to 35 ft. lbs. 6) Repeat steps 1 through 5 for the other side. END LINK ASSEMBLY & INSTALLATION NOTE: End link assembly & installation is only necessary on vehicles equipped with a rear sway bar. Skip steps 1 through 3 if your vehicle does not have a rear sway bar. 9 Illustration #16 2) Repeat step one to install the rest of the bushings and sleeves

10 3) Reattach the sway bar to the frame brackets with the new end link assemblies and the original hardware. Refer back to illustration #13. Tighten the nuts and bolts to 33 ft. lbs. 4) Install rear wheels and lower vehicle to the ground. Tighten lug nuts to ft. lbs. FINAL CHECKS & ADJUSTMENTS 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) Readjust headlamps. Have vehicle Aligned to manufacturer s specifications. ALIGNMENT SPECIFICATIONS Caster: 3.75º 1.0º Camber:.5º.5º (total) Toe-In:.24º.2º NOTES: 10

11 RANCHO INDUSTRIES USA LIMITED WARRANTY ABOUT OUR WARRANTY Rancho Industries USA, warrants the listed products for the listed time period and/or mileage to the original retail purchaser against defect and wear-out when used on passenger cars and light trucks under normal operating conditions. The warranty does not apply to Rancho products which have been improperly applied or installed. The consumer will be responsible for removing from the vehicle and returning any defective item(s), transportation costs prepaid, to the dealer from which it was purchased or a Rancho Authorized Installer, and for reinstallation of the part upon return. A copy of the sales receipt is required for all warranty adjustments. Rancho Industries will, without charge, repair or replace at its option, defective products or component part(s). In the case that the customer is unable to return to the original place of purchase or an Authorized Installer, the consumer may contact Rancho Industries at to obtain a Return Authorization Number prior to shipping. The consumer will be responsible for removing from the vehicle and returning any defective item(s), transportation cost pre-paid, to the following address: 1 International Drive, Monroe MI A copy of the sales receipt is required for any warranty adjustments. Rancho Industries will, without charge, repair or replace at its option, defective products or component part(s). Such item(s) will be returned with transportation costs prepaid within the United States from Rancho Industries. The customer will be responsible for reinstallation. Exclusions from this warranty are sales outside of the United States, the finish, any condition(s) caused by abnormal use or service, and productspecific limitations, if any, listed below. THE LOSS OF USE OF THE PRODUCT, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS OR CONSEQUENTIAL DAMAGES ARE NOT COVERED. RANCHO INDUSTRIES RESERVES THE RIGHT TO CHANGE THE DESIGN OF ANY PRODUCT WITHOUT ASSUMING ANY OBLIGATION TO MODIFY ANY PRODUCT PREVIOUSLY MANUFACTURED. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS, WHICH EXTEND BEYOND THIS WARRANTY PERIOD. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE FACE HEREOF. SELLER DISCLAIMS IMPLIED WARRANTY OF MERCHANTABILITY. THIS WARRANTY SHALL NOT APPLY TO ANY RANCHO PRODUCT WHICH HAS BEEN MODIFIED, CUSTOMIZED OR IMPROPERLY INSTALLED. WARRANTY DOES NOT APPLY TO ANY RANCHO COMPONENTS USED FOR RACING PURPOSED, OR RACE TYPE ACTIVITIES. WARRANTY DOES NOT APPLY TO ANY RANCHO INDUSTRIES RACING PRODUCTS. RC9000 REMOTE CONTROL LIMITED 2 YEAR, 24,000 MILE WARRANTY Limited 2 year, 24,000 mile warranty on these Rancho products. Rancho Industries warrants each new RS4000, Air Rancho shock and RC9000 Remote Control System against factory defects in material and workmanship (except for finish, including shock boot) for the first to occur of 2 years or 24,000 miles after the date of purchase. SUSPENSION COMPONENTS LIMITED LIFETIME WARRANTY Limited lifetime warranty on all of Rancho s suspension products. Rancho Industries warrants each new Suspension Component against factory defects in material and workmanship (except finish) for as long as the original retail purchaser owns the vehicle on which the products were originally installed. THIS LIMITED WARRANTY DOES NOT COVER THE FOLLOWING: Any component that has been modified, customized, or improperly installed Any part that is obsolete and is no longer available or supplied by Rancho RANCHO GEAR Disclaimer Statement Grille Guards, Side Steps, Skid Plates and Taillight Guards are designed as decorative accessories to enhance the styling of the vehicle and are not intended as collision protection devices. These products offer no significant incremental collision protection beyond that provided by the original vehicle design as produced by the vehicle manufacturer. Buyer assumes all risk and liability whatsoever resulting from the installation and use of Rancho Gear products. Rancho assumes no liability for injury, collision or other road hazard. These products are not a substitute for safe and careful driving. Vehicles equipped with supplemental restraint systems (air bags) that are deployed by impact rather than a sudden velocity decrease should not be modified or altered with any aftermarket grill guard or brush bar. Such modification could alter the deployment of the airbag(s) in the event of a frontal impact, collision or other road hazard. Limited 5 Year Warranty Limited 5 year warranty on Rancho Gear products. Rancho Industries warrants each new Grille Guard, Side Step, Taillight Guard and Skid Plate against factory defects in material and workmanship (except finish) for 5 years after the date of purchase. RIGHTS RESERVED Rancho Industries reserves the right to make changes in design, material and specifications or to make product changes as deemed necessary without prior notice. Obligations or liabilities will not be assumed with respect to similar products previously advertised. PRINTING ERRORS Every effort has been made to avoid printing errors in our literature. However, if there are any specification or application errors, we must disclaim responsibility. The product, time periods and/or mileage under this warranty are as follows: RS5000 / RS5600 / RS9000 / RSX LIMITED LIFETIME WARRANTY Limited lifetime warranty on these Rancho shock absorbers. Rancho Industries warrants each new shock against factory defects in material and workmanship (except for finish, including the shock boot) for as long as the original retail purchaser owns the vehicle on which the units were originally installed. 11

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