Tuff Country 24862 - Ford 83-97 Ranger/Explorer 4 box kit (performance kit) - Manual (Page 10)

40. Locate the stock cotter pin and castle nut that connect-
ed 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.
41. 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.
42. 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.
43. 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.
44. Locate the stock sway bar and the stock sway bar lower
hardware. Working on the driver side, install the stock sway
bar end link into the stock lower location and secure using
the stock hardware. Do not tighten at this point. Repeat
procedure on the passenger side. Let the stock sway bar
hang.
45. Locate the new driver and passenger side sway bar relo-
cation brackets. Also, locate the stock upper frame sway bar
mounting hardware. Working on the driver side, secure the
new sway bar relocation bracket to the stock location using
the stock hardware. Do not tighten at this point. Repeat
procedure on
the passen-
ger side.