Taking the Wrangler JK to a Whole New Level

Rancho Unleashes the Off Road Versatility of the Jeep Wrangler JK

For die hard Jeep enthusiasts, it’s the versatility of the vehicle that is the essence of what makes them so popular. Jeeps have long been considered the icon off-road vehicle, particularly when it comes to trail adventures and rock crawling. With the new models of Jeeps, particularly the popular Wrangler JK 4-door, traditional suspension performance kits simply do not work. The suspension designs are different and require a different approach, which usually also means the development of a more technologically advanced aftermarket suspension kit that is built exclusively for the vehicle, while providing the increased agility and articulation that Jeep owners demand.

The off road suspension experts at Rancho Suspension are pleased to announce the release of the newest suspension system for the 2007 JK Wrangler Unlimited 4-door 2WD/4WD. The Rancho JK 4-door sport suspension system is a complete bolt-on system that installs in approximately four hours. This uncompromising design features coil springs, forged pitman arm, front/rear track bar relocation brackets and front upper/lower link drop bracket assemblies. These Rancho features result in a simplified and time-saving installation. This new suspension system is designed to allow the use of up to a 35-inch tire.



One important element that should be disclosed is that the installation of this kit requires the removal of the lower suspension arm brackets in order to facilitate the installation of the new Rancho brackets. This means that you cannot return the suspension back to stock once you install the Rancho Suspension Wrangler JK kit. In addition, the kit eliminates the use of an upper suspension link arm in lieu of incorporating a stronger design based on a Y-link that extends from the a new axle truss and mounts to the rear bumper support. By doing so, the factory exhaust system cannot be used, and must be replaced with an aftermarket cat-back exhaust. Rancho has a new exhaust kit available to replace the factory exhaust.

To give you an idea of what the new Rancho Wrangler JK kit consists of and some of the installation procedures, we took the time to document some of the specifics of the kit on Rancho's own Wrangler JK prototype vehicle that can be seen on the trails of the upcoming Moab event. As you will see in the following steps, the Rancho Suspension kit is basically a complete suspension swap, not just a few pieces swapped out to increase ride height. The kit is designed to give the Jeep owner maximum articulation for off road use, as well as the ability to install larger off road tires. For Wrangler JK owners whose vehicle has the auto sway bar disconnect, the feature is still functional with this kit. Quick release pin adapters are available for those vehicles with standard sway bar set ups. It should also be noted that the suspension system shown here is in classic Rancho red where as the production parts will be powder coated black. Red will be available if special ordered.

RANCHO TENNECO
1 INTERNATIONAL DRIVE
MONROE, MI 48161

Shown here is the entire Rancho Wrangler JK 4-door suspension system which includes all parts required as well as mounting hardware, bump stops and longer braided brake lines.	Here we see the stock suspension 4WD JK. It should be noted that when using jack stands or a hoist lift, one must make sure the lifting/support pads are located properly to allow for the installation of the new frame brackets as well as positioned in such a way as to avoid vehicle tipping due to the short wheel base of the Jeep.	The new JKs use Jeeps newest suspension link arm type suspension which will be removed and replaced with new longer and stronger Rancho arms.
The only serious major modification that is necessary for this installation, and one that will prevent the return of the stock suspension, is the factory suspension arm brackets have to be removed. The yellow line shows the proper cut line. This is required for both the front and rear suspension brackets.	A plasma cutter was used to cut off the factory brackets from the frame. A grinder and sander are then used to clean up the modified area.	Installation of the Rancho suspension system begins with the replacement transmission cross member which doubles as the new mount locations for the suspension arms. The fuel tank skid plate will require the removal of the 2.25 inches of the mounting tab in order for the new cross member to be installed. Transmission support stands are necessary for this application.
The new cross member provides the rear mounting locations for the front suspension arms. Using the provided hardware, including the large washers, the arms are loosely installed into the cross member.	Attach the front barrel assembly to the front axle bracket using the original hardware. Once the new arms are completely installed the hardware should be tightened to 130 ft. lbs.	The Rancho suspension arms use a caster link. The rod end inserts into the bracket on the suspension arm while the bracket end of the caster arm attaches to the axle bracket.
Here is a shot of what the new suspension arm assembly looks like installed. The longer and much stronger arms are what allow for the use of the raised ride height along with providing the geometry for greatly increase articulation.	New taller front coil springs replace the stock springs. With the stock spring removed a 5/16" hole is drilled into the center of the coil spring axle pad so that a new bump stop can be installed.	The new spring is installed into the top spring perch while the bump stop is installed into the bottom. The bump stop must be installed with the spring. Once the spring is seated onto the spring pad the bump stop is permanently installed.
	With the increased suspension height, numerous other suspension features must also be modified to retain factory geometry. A new longer track bar bracket is required to relocate the track bar properly. This bracket installs into the factory track bar bracket.
Like the track bar, the steering drag link must also be modified via a new pitman arm. Rancho recommends centering the steering before removing the stock pitman arm, marking the position then installing the new pitman arm in the same position.	Some JKs have the electronic sway bar disconnect while other may not. Nothing really changes with the electronic version, other than the use of longer end links. For the non-electronic models, new quick-release pins are provided with the sway bar end links for manual disconnect when going off roading.	It should be noted that with the manual disconnecting sway bar that the end links must be rotated and stowed away from the active suspension components.
With the addition of a set of Rancho 5000 shocks, the front suspension is complete.	REAR: The JK rear suspension is in general the same design set up as the front, utilizing suspension arms and coil springs. It should be noted that with the installation of the Rancho JK suspension system, the factory exhaust will have to be removed and replaced with an aftermarket exhaust.	Like the front, the factory rear arm frame brackets have to be removed. Rancho advises not removing the entire bracket, but only the outer flange, leaving the inner flange as added protection for the gas tank. Due to the proximity of the fuel tank, do not use a flame cutter.
	The gas tank skid plate mount must also be trimmed as identified in the photo to allow for the new bracket to fit properly with the frame.	Some drilling is required to mount the frame bracket. The bolt on the left uses the factory hole while the bolts identified with arrows show where drilling will be required.
To make accessing the back side of the bolt inside the frame, Rancho includes nut brackets which insert through the hole in the center of the bracket and into the frame.		The front barrel of the rear suspension arm is inserted into the frame bracket. It is important to make sure and use all of the hardware provided in the kit, especially the large washers.
	With the grease fitting facing down, the lower suspension arm is installed into the axle bracket using the original hardware and tightened to 125 ft. lbs.	A new bump stop bracket is mounted to the axle pad using the factory holes.
	To strengthen the rear axle as well as provide the center pivot point for the Rancho suspension system design, a large axle truss bracket has been developed with attaches to the top side of the axle housing and secures using four of the differential cover bolts along with u-bolts on either side.
The rear suspension uses a Y-link system which faces to the rear of the vehicle. The rear attachment is a special cross member that has to be bolted to the rear bumper/hitch assembly. The bumper and hitch must be removed to install the bumper bracket. Mounting holes must also be drilled.	The Rancho Y-link is then installed into the axle truss then lifted into place in the bumper bracket mounts, then permanently bolted in place. Make sure the grease fittings are facing downward so the inner sleeves can be lubricated.
With the axle housing properly supported, the factory coil springs are replaced with the new taller Rancho springs.	While so many other features of the suspension are extended to complement the suspension system design, the rear sway bar frame mounting location must also be extended using provided drop down brackets which the factory sway bar mounts directly to.	New longer end links are provided which attach to the sway bar ends using flat socket head bolts to the spherical rod ends of the new links. It is important for the rod ends to be installed inboard of the sway bar and with the bolt facing outward to avoid contacting the frame during compression.
The extended end link then bolts to the factory sway bar end link location on the axle.	Double check the installation of the new end links to make sure the hardware won't contact the frame or your new, larger tires.	Like the front, the rear also accepts a new set of Rancho 5000 shock absorbers. Rancho mentioned that their 9000 series shocks will be available for the JK not long after releasing the kit.
Since the new suspension system raises the JK up by moving the axles further away from the frame, the brake lines must also be extended to avoid binding. The factory hard line is unbolted from the frame fitting followed by unbolting the hose from the caliper.	The factory hose assembly is then removed from the frame and discarded.	Rancho supplies a new braided hose assembly which mounts directly to the factory frame mount along with utilizing the factory banjo bolt on the calipers. It is extremely important to remember to have the brakes professionally bled prior to test driving.
	As was mentioned, the use of the Rancho JK suspension system voids the use of the factory exhaust system because of the new suspension component locations under the vehicle. An aftermarket exhaust is required. Rancho has a separate exhaust kit made just for the JK.	Rancho's DynoMax exhaust kit has been designed specifically for the JK and is a redirect replacement. This system is not part of the JK suspension system.
Here is a peek at the final set up under the JK. The system is very advanced, providing the use of up to 35-inch tall tires while providing greatly increased articulation and travel for off road adventures.