Tuff Country 22960 - Ford 00-04 Excursion 2.5 box kit - Manual (Page 5)

re-install the stock brake line bracket into the stock location
and secure using the stock hardware. Repeat procedure on
the passenger side.
19. Carefully remove both hydraulic floor jacks from under
the vehicle.
20. Install the tires and wheels and safely lower the vehicle
to the ground.
21. If you were not able install the stock track bar to the
new track bar relocation bracket in step # 15, perform step
# 15 now that the weight of the vehicle is on the ground.
22. If you were not able to install the stock sway bar into the
stock mounting location in step # 17, perform step # 17 now
that the weight of the vehicle is on the ground.
23. Check and double to check to make sure that all steps
associated with the front end were performed properly.
Front end installation complete.
Rear end installation:
24. To begin installation, block the front tires of the vehicle
so that the vehicle is stable and can’t roll forward. Safely lift
the rear 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.
25. Place two hydraulic floor jacks under the rear 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 rear axle.
26. 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. Discard the
stock shock. Special note: New longer rear shocks are
needed after this suspension system has been
installed and the rear shocks need to be ordered as a
separate part #. If you have not already ordered your
rear shocks, please feel free to contact Tuff Country or
your local Tuff Country dealer and order your rear
shocks. Tuff Country recommends installing a 30” fully
extended nitrogen gas shock in the rear end. Repeat
procedure on the passenger side.
27. Working on the driver side, remove the stock u-bolts
from the stock location. The stock u-bolts and hardware
may be discarded. Set the stock upper u-bolt plate aside for
later re-installation. Repeat procedure on the passenger
side.
28. Carefully lower down on both hydraulic floor jacks at the
same time allowing enough room for the new rear blocks to
be installed. Special note: Take special care not to kink
or over extend the stock brake line.
29. Working on the driver side, remove the stock block and
discard. Repeat procedure on the passenger side.
30. Locate the new rear blocks. Working on the driver side,
install the new block between the stock rear axle and the
stock spring packs. Special note: The new block is a flat
block so there is not a front or a rear to the block.
Repeat procedure on the passenger side.
31. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring pack seats properly with
the newly installed rear blocks.
32. Locate (4) 5/8” x 3 5/8” x 14 5/8” round u-bolts. Also,
locate (8) 5/8” u-bolt high nuts and (8) 5/8” u-bolt washers
from hardware bag 58NW. Also, locate the rear upper
u-bolt plates that were removed in step # 27. Working on
the driver side, install the new u-bolts into the stock location
and secure using the new u-bolt high nuts and washers.
Repeat procedure on the passenger side. Once the new
u-bolts have been installed, torque the new u-bolts on the
driver and passenger side to 120 ft lbs.
33. Carefully remove both hydraulic floor jacks from under
the vehicle.
34. Locate the new rear shocks. Special note: New longer
rear shocks are needed, if you have not already
ordered shocks, please contact Tuff Country or your
local Tuff Country dealer and order the proper shocks.
Tuff Country recommends using a 30” fully extended
nitrogen gas shock. Working on the new shocks, install
the new shock bushings into the upper and lower eyelets of
the new shocks. Next, install the new proper lower shock
sleeves into the previously installed shock bushing in the
lower eyelets. Locate (2) BP07 clevis mounts that were
packaged with the installer copy of the installation manual.
Install the BP07’s into the upper eyelets of the new shocks.
Special note: Make sure to use a lithium or moly base
grease prior to inserting the new shock bushing and
sleeves into the new shock eyelets. This will increase
the life of the bushing as well as prevent squeaking.
Working on the driver side, install the new shock into the
stock upper and lower location and secure using the stock
hardware that was removed in step # 26. Special note:
Make sure to use thread locker or lock tite and torque
the upper hardware to 18 ft lbs and the lower stock
mounting hardware to 75 ft lbs. Repeat procedure on
the passenger side. Special note: Tuff Country EZ-Ride
Suspension highly recommends that the shocks are
installed with shock boots. If shock boots are not
installed, damaged my occur to the piston of the new
shock.
35. Check and double check to make sure that all steps
were performed properly for the rear end and check again.