Thanks for the input. I will try that and let you know how it comes out.

 

Any luck Wildcat??? So, the washers get put on the outside of the brackets??? Not between the shock and the bracket??? How would that help??? I have the noise, looseness too and would love to fix it.
BigMan69

 

I have not had the time to try it yet. I do have a 4 day week end this week end so I should be able to get it done by Tuesday. I have been building a much needed shed so I have had weight in the back of it for the last few weeks. But I will post my finds just as soon as I get it done.

 

I suppose the way the washers help out is to "clamp" down on the outer part of the bracket so when you crank them down to 100ft lbs the brackets dont dimple, it worked for me...try it.

 

Do you remember what size washers you used?

 

Well I finally got the time to fix this. I will update in about 2 weeks to let everyone know if it works.

 

Looking forward to hearing if this was a success or not. Also, what size fender washers did you use?

BigMan69

 

UPDATE: After 150 miles it is still holding. I did not use fender washers. After looking at the mounts there is a lip to the front of the mount. If I used frender washers I would have to bend them to clear that. This might not be the case on all of the Expo but it is on mine. Replacing the nut and bolt might have the same effect on it. I think the problem is when you replace the shocks the bolt is damaged. Not enough that you would see it but when you go to tighten it up you hit that spot on the bolt and thats it. I did buy 2 new class 8 bolts for it but have not used them as of yet. If they loosen back up I will pull the whole thing apart again and replace the bolts, nuts, and washers. At that time I will look at grinding down a fender washer to clear. But for now its working.

 

I have been watching/reading this thread and I installed the Rancho RSX shocks too. I also have been having this horrible rattling sound from the shocks being loose on the axle mounts. I called Rancho today and explained my (our) dilemma and was told that the shocks should seat FIRMLY in ALL of the mounts. The representative said the mounts should have a "vise-like" grip of the shocks and obviously the axle mounts don't. His suggestion was to pound the mount sockets closer together. I might try that or just go with the washers. From what I gather, from use and from uninstalling and installing the shocks, the mounts have widened themselves out. I dunno......

 

The sad part about this is that I like the Rancho shocks but they seam to be the wrong size. The part numbers on all the shocks match the part numbers in the books. The top bolt on the front shocks does not have enough thread to tighten it down. It does not compress the bushings at all. But add washers and it fine. The same thing with the rear shocks. Add washers to fix the problem. I have never had so many problems replacing shocks before. I have never had to add parts to make them fit. I have work on a lot of vehicles in my time and have never had to do any modification to replace a stock item. I have replaced the shocks on my 65 Buick, 67 Pontiac, and the struts on my 86 Tempo (just to name a few) with no problems or parts added at all. This should be as simple as pull the old shock off and replace it with the new ones. It should be a 30 min project, 45 if you want to take you time. It might be as simple as Rancho does not have good quality control. It might be they are cutting corners by make them a little smaller so they fit other vehicles. Or maybe its just the vehicle itself. I don't know but I will say if I buy another set for a different vehicle and have the same problem I will never buy Rancho again. But at this point I will give them a 2nd try. By the way I'm at 180 miles now and still no problems with the rear shocks after the mods.

 

I really don't think this is just a Rancho problem, My Monroes were the same way, on the rear lower mounts I had to squeez them using the big washers torqued down to 100+ ft lbs, no more problems.

 

From what I gather, from use and from uninstalling and installing the shocks, the mounts have widened themselves out. I dunno......

I don't think thats the case. The steel mounts under there are thick. I tried a sled hammer and it did not move them. But give it a try if you want to. The rattling noise is to much for me to listen to.

 

I would agree with you that why I said I would still try them again a another vehicle. I really think this is more of a Ford problem. More to the point these vehicles. Might even be just the 97 year. They did have at least 2 different rear axles for that year. Some of them had a recall. Mine was not part of the recall.

 

I have a '98 4X4 stock height and the Rancho front shocks/struts fit fine. Did you install the RSX 17020's?

 

Yes the 17020 on the front and the 17023 on the back. Mine is also stock height but it is a 97 model year (bought Nov 1996). I don't know if the year has anything to do with it but as long as this fixed it I'm ok with it. Don't get me wrong I'm not trying to bad mouth Rancho in the least. I'm just not sure why this has been such a problem. You should be able to take the old ones off and put the new ones on. Tighten them down to oe specs and go on with life. If the vehicle had been modified in any way then I could see have to extra things or mods to get it them to fit. I really think the problem is with the vehicle itself and not the shocks.