Tuff Country 22960 - Ford 00-04 Excursion 2.5 box kit - Manual (Page 3)

Hardware bag 916NW includes:
Description Quantity
9/16” u-bolt high nuts 8
9/16” u-bolt harden washers 8
Hardware bag 58NW includes:
Description Quantity
5/8” u-bolt high nuts 8
5/8” u-bolt harden washers 8
Hardware bag CB716 includes:
Description Quantity
7/16” x 6” centering bolt 2
7/16” fine nut 2
Please follow instructions carefully:
Before installation begins, Tuff Country EZ-Ride
Suspension highly recommends that the installer
performs a test drive on the vehicle. During the test
drive, check to see if there are any uncommon sounds
or vibrations. If uncommon sounds or vibrations occur
on the test drive, uncommon sounds or vibrations will
be enhanced once the suspension system has been
installed. Tuff Country EZ-Ride Suspension highly
recommends notifying the customer prior to
installation to inform the customer of these issues if
they exist.
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: ___________________
Driver side rear: ___________________
Passenger side rear: ___________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post installation measurements:
Driver side front: ___________________
Passenger side front: ___________________
Driver side rear: ___________________
Passenger side rear: ___________________
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
discarded. Tuff country highly recommends installing a
23” fully extended nitrogen gas shock in the front end.
4. Working on the driver side, remove the stock sway bar
from the front lower axle location. Save the stock 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
the stock 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
connects the stock track bar to the stock track bar bracket
and save the stock 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 passenger side, it is welded to
the stock front axle.