Tuff Country 22958 - Ford 00-04 F250 / F350 Superduty 2.5 box kit - Manual (Page 3)

Please follow instructions carefully:
Before installation begins, drive and check to make
sure there are no uncommon sounds and/or frame
damage. Also at this time measure from the center of
the hub to the bottom of the fender well and record
measurements below.
Pre-installation measurements:
Driver side front: ___________________
Passenger side front: ___________________
At the end of the installation take the same measure-
ments and compare to the pre-installation measure-
ments.
Post installation measurements:
Driver side front: ___________________
Passenger side front: ___________________
Please follow instructions carefully:
Front end installation:
1. To begin installation, block the rear tires of the vehicle
so that the vehicle is stable and can’t roll backwards.
Safely lift the front of the vehicle and support the frame
with a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next, remove the tires and
wheels from both sides.
2. Place two hydraulic floor jacks under the front axle.
One on the driver side and one on the passenger side.
Raise up on both hydraulic floor jacks at the same time
until they come in contact with the front axle.
3. Working on the driver side, remove the stock shock
absorber from the stock upper and lower location and
save the stock hardware for later re-installation. Repeat
procedure on passenger side. Special note: New shocks
are not needed for the suspension system. If you
desire to install new shocks after the completion of
the suspension system, the stock shocks may be dis-
carded.
4. Working on the driver side, remove the stock sway bar
from the front lower axle location. Save hardware for later
re-installation. Repeat procedure on passenger side.
5. On the driver side, remove the stock bolt that connects
the stock brake line bracket to the inner frame rail and
save hardware for later re-installation. Repeat procedure
on passenger side.
6. Locate the stock front track bar bracket located on the
driver side of the vehicle. Remove the stock bolt that con-
nects the stock track bar to the stock track bar bracket
and save the bolt and hardware for later re-installation.
Next, remove the (3) stock bolts that connect the stock
track bar bracket to the stock frame rail and the stock
cross member. Special note: Do not use any air tools
when working with the 3 stock bolts that hold the
stock track bar bracket to the stock location. Also, if
need be, carefully heat up the (2) stock bolts that hold
the stock track bar bracket to the stock frame rail
location. This will help melt the thread locker or lock
tite that is on the stock bolts. Save the stock hardware
for later re-installation. Remove and discard the stock
track bar bracket.
7. Working on the driver side, remove the stock u-bolts
from the stock location. The stock u-bolts and hardware
may be discarded. Place the stock upper and lower u-bolt
plates aside for later re-installation. Repeat procedure on
the passenger side. Special note: There is not a stock
lower u-bolt plate on the driver side, it is welded to
the stock front axle.
8. Carefully lower down on both hydraulic floor jacks at
the same time about 3” allowing enough room for the new
add-a-leaf spring pack to be installed. Special note: Take
special care not to kink or over extend the stock
brake line.
9. Working on the driver side, place a pair of “C” clamp
vise grips on each side of the stock centering bolt.
Carefully remove the stock centering bolt and nut and dis-
card. Carefully remove the “C” clamp vise grips that are
holding the stock springs together. Special note: Be very
carefully when removing the “C” clamps, the stock
springs are under tension and can be dangerous.
Repeat procedure on passenger side.
10. Locate the new progressive add-a-leaf spring packs
and remove the centering bolt that is holding the progres-
sive add-a-leaf spring packs together and discard the bolt
and nut.
11. Locate (2) 7/16” x 6” centering bolts and (2) 7/16” cen-
tering bolt nuts from hardware bag CB716. Working on
the driver side, install the new progressive add-a-leaf
spring pack between the stock spring assembly and the
stock axle. Special note: The new progressive add-a-
leaf spring pack has a bend on one end of the main
leaf, the bend on the main leaf needs to be installed
towards the front of the vehicle. Secure the new pro-
gressive add-a-leaf spring pack to the stock spring
assembly using the new 7/16” centering bolt and nut.
Torque to 42 ft lbs. Special note: To make installation
easier, use a pair of “C” clamps to help bring the new
progressive add-a-leaf spring pack and stock spring
assembly together as one. Also Tuff Country E-Z Ride
Suspension highly recommends not using any air
tools when installing the new progressive add-a-leafs
into the stock spring assembly. If air tools are used,
the new centering bolt may strip, causing the stock
spring assembly to come apart. With a suitable
cutting tool, cut off the extra thread from the new center-