Tuff Country 24850 - Ford 91-94 Explorer 4 box kit - Manual (Page 8)

21. Locate the stock cotter pin and castle nut that connected
the stock tie rod to the stock pitman arm. Install the stock tie
rod to the newly installed pitman arm and secure using the
stock hardware. Torque the castle nut to 65 ft lbs. Now
install the stock cotter pin to the stock tie rod and castle nut.
Special note: If you are not able to install the stock cot-
ter pin because the hole in the tie rod does not line up
with the castle nut, DO NOT loosen, tighten the castle
nut until the stock cotter pin can be installed.
22. Locate the new front coil springs. Also, locate the stock
lower coil spring washer and hardware. Working on the driv-
er side, install the new coil spring into the stock upper loca-
tion then raise up on the hydraulic floor jack until the lower
portion of the coil springs can be attached to the front axle.
Secure using the stock hardware and add some thread lock-
er or loctite and torque to 145 ft lbs. Repeat procedure on the
passenger side.
23. Locate (1) 9/16” x 3 1/2” cam bolt, (2) cam washers and
(1) 9/16” unitorque nut from hardware bag CAM1NB.
Carefully raise up on the hydraulic floor jack that is support-
ing the driver side front twin eye beam axle until it slides up
into the newly installed bracket. Secure the axle to the new
bracket using the new cam bolt and hardware. Make sure to
use thread locker or loctite and torque to 85 ft lbs. Special
note: Make sure to install the bolt from the front of the
vehicle to the rear of the vehicle. Also, for now place the
cam washer in the center position.
24. Locate (1) 9/16” x 3 1/2” cam bolt, (2) cam washers and
(1) 9/16” unitorque nut from hardware bag CAM1NB.
Carefully raise up on the hydraulic floor jack that is support-
ing the passenger side front twin eye beam axle until it slides
up into the newly installed bracket. Secure the axle to the
new bracket using the new cam bolt and hardware. Make
sure to use thread locker or loctite and torque to 85 ft lbs.
Special note: Make sure to install the bolt from the rear
of the vehicle to the front of the vehicle. Also, for now
place the cam washer in the center position.
25. The brackets around the “D” bushings on the stock front
sway bar may need to be opened up to 7/16”. Try a 7/16” bolt
in each location to make sure that it will fit. If not, open the
holes up so that the new 7/16” bolts will fit.