INSTALLATION INSTRUCTIONS 88043 Rev E FOR RANCHO SUSPENSION SYSTEM RS6543: CHEVROLET K1500 READ ALL INSTRUCTIONS THOROUGHLY FROM START TO FINISH BEFORE BEGINNING INSTALLATION IMPORTANT NOTES! WARNING: This suspension system will enhance the off- D. Apply THREAD LOCKING COMPOUND to all road performance of your vehicle. It will handle differently, bolts during installation. One drop on the exposed both on and off-road, from a factory equipped passenger car threads of each bolt before installing the nut is or truck. Extreme care must be used to prevent loss of sufficient to provide an adequate bond. CAUTION: control or vehicle rollover during abrupt maneuvers. Failure Thread locking compound may irritate sensitive skin. to drive this vehicle safely may result in serious injury or death to the driver and passengers. ALWAYS WEAR your Read warning label on container before use. seat belts, REDUCE your speed, and AVOID sharp turns and other abrupt maneuvers. E. Install all nuts and bolts with a flat washer. When both SAE (small OD) and USS (large OD) washers are A. Before installing this system, have the vehicle’s used in a fastener assembly, place the USS washer alignment and frame checked at a state approved against the slotted hole and the SAE washer against facility. The alignment must be within factory the round hole. specifications and the frame of the vehicle must be sound (no cracks, damage or corrosion). F. Unless otherwise specified, tighten all bolts to the standard torque specifications listed at the end of the B. Do Not install a body lift kit with Rancho’s note's section. Do not use an impact wrench to tighten suspension system or interchange parts from this any of these bolts. They tend to over tighten smaller system with components from another manufacturer. bolts and under tighten larger bolts. USE A TORQUE Use the following Rancho shock absorbers with this WRENCH!!! system: RS5244 or RS9244 (front), RS5227 or RS9227 (rear) G. Do not powdercoat, chrome, cadmium, or zinc plate any of the components in this system. If you C. Compare the contents of this system with the wish to change the appearance of components, enamel parts list in these instructions. If any parts are missing, paint can be applied over the original coating. including fasteners, contact the Rancho Technical Department at 1-734-384-7804. Each hardware kit in H. This suspension system is a "bolt on assembly". this system contains fasteners of high strength and Do not weld any of these components to the vehicle. specific size. Do not substitute a fastener of lesser If any component breaks or bends, contact your local strength or mix one hardware kit with another. Rancho dealer or Rancho for replacement parts. I. Some of the service procedures require the use of at normal ride height. This will prevent premature special tools designed for specific procedures. The failure of the bushing and maintain ride comfort. following tools and supplies are recommended for proper installation of this system. 5 L. The exhaust crossover pipe requires modification to provide adequate clearance for the front drive shaft. Chevrolet Service Manual Have an exhaust shop fabricate and install the Torsion Bar Unloading Tool (J 36202) necessary pipe in accordance with your state and local Steering Linkage Puller (J 24319-01) emission regulations. Tie Rod Remover (J 6627-A) Knockout Removal tool (J 38794) M. On some vehicles (due to an OEM design change) New Prevailing Torque Nuts (for steering linkage) Die Grinder the barrel end of a newly installed front shock may Drill motor contact the upper control arm at full droop. If your Drills: 1/8", 21/64", 3/8", 7/16", 1/2" vehicle has the newer designed upper control arm and Torque Wrench (250 FT-LB capacity) shock clearance is a problem, install the shock with the 1/2” Drive Ratchet and Sockets barrel end at the top and the rod end at the bottom. Assorted Combination Wrenches Assorted Hex-Key Wrenches N. The required installation time for this system is Heavy Duty Jack Stands approximately 7 to 8 hours. Check off the box ( 5 ) at Wheel Chocks (wooden blocks) the beginning of each step when you finish it. Then Hydraulic Floor Jack when you stop during the installation, it will be easier Center punch File to find where you need to continue from. Large "C" Clamps and Bench Vise Hacksaw O. Important information for the end user is Hammer contained in the consumer/installer information pack. Wire Brush (to clean bracket mounting surfaces) If you are installing this system for someone else, Silicone Spray Lubricant place the information pack on the driver’s seat. Please Tape Measure include the installation instructions when you finish. Brake Fluid (DOT 3) Safety Glasses--Wear safety glasses at all times P. Thank you for purchasing the best suspension system available. For the best installed system, follow J. It is extremely important to replace torsion bars, these instructions. If you do not have the tools or are CV flanges, and front drive shaft/pinion relationships unsure of your abilities, have this system installed by a as original. Be sure to mark left/right, front/rear, and certified technician. RANCHO SUSPENSION IS indexing of mating parts before disassembly. A paint NOT RESPONSIBLE FOR DAMAGE OR FAILURE marker or light colored nail polish is handy for this. RESULTING FROM AN IMPROPER OR MODIFIED INSTALLATION. K. Suspension components that use rubber or urethane bushings should be tightened with the vehicle STANDARD BOLT TORQUE SPECIFICATIONS INCH SYSTEM METRIC SYSTEM Bolt Size Grade 5 Grade 8 Bolt Size Class 9.8 Class 10.9 Class 12.9 5/16 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 M16 130 FT-LB 165FT-LB 210 FT-LB 3/4 185 FT-LB 280 FT-LB M18 170 FT-LB 240FT-LB 290 FT-LB BOLT IDENTIFICATION -2- PARTS LIST P/N DESCRIPTION QTY. P/N DESCRIPTION QTY. 15080 4" Riser Block 2 9/16-12 Stover Nut 2 170011 Bump Stop Spacer 2 9/16 SAE Washer 2 170080 Brake Hose 2 9/16 USS Washer 2 176060 Right Axle Tube Drop Bracket 1 860119 UCA Drop Bracket Hardware Kit 1 176061 Differential Drop Bracket 1 176070 Flanged Sleeve 2 176062 Subframe Aft Brace 2 D-Washer 2 176063 Right Torsion Bar Drop Bracket 1 9/16-18x3.5 HHCS 4 176064 Left Torsion Bar Drop Bracket 1 9/16-18 Stover Nut 4 176065 Relay Rod 1 9/16 USS Washer 8 176066 L. Upper Control Arm Drop Brkt 1 1/2-13x1.5 HHCS 2 176067 R. Upper Control Arm Drop Brkt 1 1/2-13 Stover Nut 4 176068 Differential Brace 1 1/2 USS Washer 4 176073 Aft Brace Bracket 2 1/2 SAE Washer 4 176071 Skid Plate Drop Bracket 1 1/2-13x5.5 HHCS 2 176257 Subframe 1 1/2x2.0 Shim Washer 8 740014 U-Bolt 4 .5cc Thread Lock 3 8063 CV Flange Hardware Kit 1 7877 M14-2.0 Stover Nut 4 M10-1.5x25mm SHCS 12 860120 T-Bar Drop Brkt Hardware Kit 1 Washer 12 3/8-16x1.0 HHCS 8 8102 U-Bolt Hardware Kit 1 3/8-16 Nyloc Nut 10 9/16-18 Nyloc Nut 8 3/8 USS Washer 10 9/16 SAE Washer 8 3/8 SAE Washer 10 8514 Drop Bracket Bushing Kit 1 3/8-16x2.25 HHCS 2 585 Bushing 4 7/16-14x1.0 HHCS 8 7869 .75x.2.23 Sleeve 2 7/16-14 Stover Nut 8 8574 Riser Block Pin Kit 1 7/16 USS Washer 12 Pin 2 7/16 SAE Washer 4 860070 Shim Kit 1 860121 Differential Hardware Kit 1 9/16-2.5 Shim Washer 16 9/16-12x4.5 HHCS 1 860086 Brake Hose Gasket Kit 1 9/16-12 Stover Nut 2 170078 Copper Washer 4 9/16 SAE Washer 3 860114 Subframe Hardware Kit 1 9/16-12x3.5 HHCS 1 420032 1.25x3.25 Sleeve 2 9/16 USS Washer 1 420033 1.25x2.395 Sleeve 2 1/2-13x1.25 HHCS 1 5/8-18x4.5 HHCS 2 1/2-13 Stover Nut 1 5/8-18 Stover Nut 4 1/2 SAE Washer 2 5/8 SAE Washer 8 860122 Aft Brace Hardware Kit 1 5/8-18x5.5 HHCS 2 9/16-12x4.0 HHCS 4 860115 Idler Hardware Kit 1 9/16-12 Stover Nut 4 420034 Threaded Sleeve 1 9/16 SAE Washer 8 602611 Rod End 2 860123 Aft Brace Bracket Hardware Kit 1 5/8-18x3.5 HHCS 1 1/2-13x1.25 HHCS 2 5/8-18 Stover Nut 2 1/2-13 Stover Nut 2 5/8 SAE Washer 4 1/2 SAE Washer 4 5/8-18x2.0 HHCS 1 860124 Rear Brake Line Hardware Kit 1 5/8-18 Jam Nut 2 170014 Brake Line Bracket 1 860117 Rear Bump Stop Hardware Kit 1 5/16-18x1.25 HHCS 1 1417 Bump Stop 2 5/16-18 Nyloc Nut 1 7/16-14x1.0 HHCS 4 5/16 SAE Washer 1 7/16-14 Stover Nut 4 860125 Aft Brace Bushing Kit 1 7/16 USS Washer 8 457 .75x.2.605 Sleeve 4 5/16-24 Nyloc Nut 4 553 Bushing 8 5/16 SAE Washer 4 860126 Sway Bar Hardware Kit 1 860118 Right Axle Tube Hardware Kit 1 3/8-16x1.0 SHCS 4 9/16-12x1.5 HHCS 2 3/8 -16 Nyloc Nut 4 -3- PARTS LIST P/N DESCRIPTION QTY.