Full-On 2004 GMC 2500 Diesel Truck Buildup, Part 3 - Build It!

Grunion Fabrication in Phoenix used a lift to install our Rancho lift. We removed all four wheels and tires.

The Rancho kit comes in black or red. If you are going to modify the color, automotive paint can be added over the original coating.

When we installed this kit, we used thread-locking compound on all the bolts. We also used a torque wrench to tighten all nuts to the specified measurements.

Grunion used the GM torsion-bar unloading tool. This increased the tension on the torsion bar so the adjusting bolt and nut could be removed. We removed the torsion bars and crossmember and set them aside. Grunion then removed the front brake calipers and hung them from the frame. This will save us from having to bleed the brake system later. We removed the rotors and marked them. Grunion removed the hardware holding the sway bar and endlinks in place.

Next, Grunion removed the six bolts from the inboard flange. We removed the halfshaft through the lower control-arm opening and were careful not to damage the driveshaft boots. Grunion removed the nuts from the outer tie-rod stud and disconnected the tie-rod ends from the steering knuckle with a universal puller. We removed the hardware at the upper and lower ball joints and used a knuckle-separating tool to separate the two.

We removed the hardware holding the steering knuckle to the hub and steering assembly.

Grunion removed the lower control-arm pivot bolts, the front skidplate, and the rear support bracket. This is where we should have installed the Rancho steering stabilizer. Oops! Read on. We marked the front driveshaft U-joint to the differential yoke. We removed the bolts and retainers from the yoke and slid the shaft rearward to remove it. It's important not to forget to remove the electrical connector and the vent hose. We removed the axletube nuts and the differential lower mounting bolt. After supporting the front differential, we removed the upper mounting nut and bolt. Then, Grunion was able to remove the differential.

Grunion cut off the differential lower frame mount and welded the supplied box plate to the inside of the lower control-arm frame bracket. After the install was complete, we painted the plate to prevent rust. The 4WD model requires cutting the upper mount from the front differential. Our truck already had an aftermarket lift, so we did not have to cut it off.

We installed the Rancho bracket with bushings on the front differential. If oil seeps from the case, do not stop-just work a little faster.

Grunion attached the front differential to the new Rancho subframe with the original hardware, and we attached the OE bumpstops.

We, meaning four men, reinstalled the Rancho subframe and front differential using the OE hardware. We did not forget to reconnect the electrical connector and vent hose.

We placed the Rancho axle spacer against the differential flange and installed the axle with the supplied Rancho hardware.

Grunion installed the new Rancho steering knuckle on the hub and steering assembly. Make sure the ABS sensor is aligned between the splash shield and the new Rancho steering knuckle.

Grunion connected the steering knuckle to the lower and upper control-arm ball joints.

Grunion reinstalled the rotor and caliper and tightened the axle hub nut. We did not forget to attach the ABS sensor. This is where we installed the Rancho multi-shock absorber kit (PN RS6741).

Grunion attached the supplied Rancho bracket to the upper control arm, clamped it in place, and drilled the required holes. We used the supplied Rancho hardware to secure the Rancho bracket.