Tuff Country 24820 - Ford 80-96 F250 4 box kit - Manual (Page 6)

Special Note: If the vehicle that you are working on
is not equipped with a front sway bar, please skip to
step # 38
36. Locate (1) new front sway bar drop bracket and (2)
stock bolts and hardware that was removed from step #
4. Working on the driver side, install the new sway bar
drop bracket to the stock frame mount. Secure using the
stock hardware. Special Note: Do not tighten at this
point. Make sure to use thread locker or locktite on
these bolts. Repeat procedure on the passenger side.
See Illustration # 8
37. Locate (4) 7/16” x 1 1/2” bolts, (4) 7/16” unitorque
nuts and (8) 7/16” flat washers from hardware bag
F450NB. Working on the driver side, secure the stock
front sway bar to the previously installed sway bar drop
bracket using the new 7/16” x 1 1/2” bolts and hardware.
Special Note: Do not tighten at this point. Make sure
to use thread locker or locktite on these bolts.
Repeat procedure on the passenger side. Also, if you
are not able to install the stock sway front bar to the
new front sway bar drop brackets, you may need to
perform this step once the weight of the vehicle is on
the ground. Once the stock front sway bar is attached to
the new front sway bar drop brackets torque the stock
and new 7/16” hardware to 45 ft lbs.
See Illustration # 8
38. Locate the new pitman, the stock pitman arm
hardware, the stock castle nut and the stock cotter pin
that was removed form step # 3. Install the new pitman
arm to the stock sector shaft located on the stock
steering box, secure using the stock hardware. Make
sure to use thread locker or lock tite. Torque to 140 ft
lbs. Next, install the stock drag link to the newly installed
pitman arm and secure using the stock hardware. Make
sure to install the stock cotter pin.
39. Locate the new front shocks and the stock hardware
that was removed in step # 2. Working on the driver side,
install the new longer shock into the stock upper and
lower location and secure using the stock hardware.
Repeat procedure on the passenger side. Special Note:
If the vehicle that you are working on uses a stud for
the upper mount, use the new hardware that is
provide in the new shock. Torque the upper and
lower hardware to proper torque specifications.
Refer to the torque setting sheet at the end of the
installation manual.
40. Check and double check to make sure that all steps
were preformed properly. Check and double check to
make sure that all stock and new hardware is torque to
proper torque specifications. Special Note: Refer to the
owners manual and the torque setting sheet at the
end of the installation manual.
41. Install the tires and wheels and carefully lower the
vehicle to the ground.
42. If you were not able to install the stock sway bar to
the new front sway bar drop brackets in step # 37,
perform this step once the weight of the vehicle is on the
ground.
43. Working on the driver side, inspect the stock front
brake lines to make sure that they are not over extended.
If the stock brake lines are over extended, carefully bend
the stock brake line bracket down for proper brake line
clearance. Repeat procedure on the passenger side.
Congratulations, Front End Installation Complete
Rear End Installation:
44. 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 jack stands. Place a jack stand on both the driver
and passenger side. Next, remove the stock wheels and
tires from both sides.
45. 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.
46. Working on the driver side, remove the stock shock
from the stock upper and lower mounting points and
save the stock hardware for later re-installation. The
stock shocks may be discarded. Special Note: New
longer rear shocks are needed after the completion
of the installation. If you have not already ordered
your new rear shocks, please contact Tuff Country
or your local Tuff Country dealer and order part #
61301. Repeat procedure on passenger side.
47. 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 a
side for later re-installation. Repeat procedure on the
passenger side.
48. Carefully lower down on both hydraulic floor jacks at
the same time allowing enough room for the new blocks
and add-a-leafs to be installed. Special Note: Make
sure not to over extended any brake lines or hoses
when lowering axle.
49. Locate (2) new rear add-a-leafs, (2) new 3/8”
centering bolts and nuts from hardware bag CB38.
Working on the driver side, place a pair of “C” clamps
around the rear springs about 2” from the stock spring
clamps. Safely remove the stock rear centering bolt and
discard. Install the new rear add-a-leaf into the stock
spring assembly. Secure the new rear add-a-leaf to the
stock spring assembly using the new 3/8” center bolt and
nut. Special Note: The new rear add-a-leaf should be
installed into the stock spring assembly in
progression in order. The new rear add-a-leaf has an