Tuff Country 22960 - Ford 00-04 Excursion 2.5 box kit - Manual (Page 4)

8. Carefully lower down on both hydraulic floor jacks at the
same time about 3” allowing enough room for the new front
add-a-leaf spring packs 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 discard.
Carefully remove the “C” clamp vise grips that are holding
the stock springs together. Special note: Be very
careful 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.
Special note: The new front progressive add-a-leaf
spring packs need to be ordered as a separate part #. If
you have not already ordered your new front progres-
sive add-a-leaf spring packs, please contact Tuff
Country or your local Tuff Country dealer and order (2)
82200 if the Excursion that you are working on has a
gas engine or (2) 82201 if the Excursion that you are
working on has a diesel engine. Remove the centering
bolt that is holding the progressive 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”
centering 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 front 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 progressive 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” clamp vice grips 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 front 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 centering
bolt. Repeat procedure on passenger side.
Photo # 1
12. Carefully raise up on both hydraulic floor jacks at the
same time until the stock axle perch seats properly into the
newly installed progressive spring packs.
13. Locate (4) 9/16” x 3” x 10” semi-round u-bolts. Also,
locate (8) 9/16” u-bolt high nuts and (8) 9/16” u-bolt
washers from hardware bag 916NW. Working on the driver
side, re-install the upper and lower u-bolt plates into the
stock location and secure using the new 9/16” hardware.
Torque to 120 ft lbs. Special note: If the progressive
add-a-leaf spring pack that you are working on has not
had the spring clamps bent around the stock springs,
bend the spring clamps around the stock spring.
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.
14. Locate the new upper driver side track bar relocation
bracket and the stock hardware that was removed from
step # 6. Install the new upper driver side track bar
relocation bracket to the stock location on the bottom side
of the stock frame rail and secure using the stock
hardware. Do not tighten at this point. Make sure to use
thread locker or lock tite. Next, secure the ear of the
new track bar relocation bracket to the back side of the
stock cross member and secure using the stock hardware.
Make sure to use thread locker or lock tite. Special
note: The stock track bar relocation bracket was
installed towards the front of the stock cross member,
the new track bar relocation bracket is going to be
installed towards the rear of the stock cross member.
Torque the stock bolt to the stock cross member to 80 ft
lbs. Torque the stock bolts that hold the new track bar relo-
cation bracket to the bottom side of the stock frame to 68
ft lbs. Special note: Do not use any air tools when
working with the (3) stock bolts that hold the new track
bar bracket into the new location. If air tools are used,
the stock hardware may strip. Also make sure to use
lock tite.
Photo # 2
15. Locate the stock track bar hardware that was removed
in step # 6. Install the stock track bar to the previously
installed track bar relocation bracket and secure using the
stock hardware. Make sure to use thread locker or lock tite
and torque to 135 ft lbs. Special note: If you are not able
to install the stock track bar into the newly installed
track bar relocation bracket, you may need to perform
this step once the weight of the vehicle is on the
ground.
16. Locate the stock shocks and stock upper and lower
shock hardware that was removed in step # 3. Working on
the driver side, install the stock shock into the stock upper
and lower location and secure using the stock hardware.
Special note: Make sure to use thread locker or lock
tite and torque the lower mounting hardware to 65 ft
lbs. and the upper stock shock hardware to 45 ft lbs.
Also, if you are installing new shocks, Tuff Country
E-Z Ride Suspension recommends installing a 23” fully
extended nitrogen gas shock.
17. Locate the stock sway bar mounting hardware that was
removed in step # 4. Working on the driver side, re-install
the stock sway bar to the stock sway bar location and
secure using the stock hardware. Repeat procedure on the
passenger side. Torque the stock hardware to 14 ft lbs.
18. Locate the stock brake line mounting hardware that
was removed in step # 5. Working on the driver side,