Tuff Country 24862 - Ford 83-97 Ranger/Explorer 4 box kit (performance kit) - Manual (Page 11)

46. Locate (4) 7/16” x 1 1/2” bolts, (8) 3/8” USS flat washers
and (4) 7/16” unitorque nuts from hardware bag R4NB.
Working on the driver side, swing the stock sway bar up and
secure it to the newly installed sway bar relocation brackets.
Secure using the new 7/16” x 1 1/2” bolts and hardware. Do
not tighten at this point. Repeat procedure on the passen-
ger side. Once the sway bar has been attached to the new
sway bar relocation brackets on both sides, add some thread
locker or loctite to the stock and new bolts and torque the
stock and new bolts on the driver and passenger side to 38
ft lbs. Special note: If you are not able to attach the stock
sway bar to the newly installed sway bar relocation
brackets, this step may need to be done once the instal-
lation is completed and the weight of the vehicle is on
the ground.
47. Move back to the stock lower sway bar end link mount-
ing hardware and add some thread locker or loctite on both
the driver and passenger side and torque to 65 ft lbs.
48. Slight adjustments may need to be done to the outer tie
rods so the vehicle can be driven to an alignment shop. If
this is the case on the vehicle that you are working on,
loosen the stock hardware on the adjusting sleeve and using
a pair of pliers, adjust the toe close enough so that the vehi-
cle can be driven.
Special note: This kit comes with a front and rear brake
line relocation kit. Sometimes the brake line relocation
kit is not needed. Check the stock brake lines and if they
are too tight, then the new front and rear brake line relo-
cation kit will need to be installed. If the brake line relo-
cation kit does not need to be installed, please skip to
step # 53. Also, the following pictures are used from a
F150 which uses the same style brake line and brake
line relocation brackets but the F150 brake line is posi-
tioned towards the rear of the coil springs but on the
Rangers and Explorer’s are positioned towards the front
of the coil springs.
49. Working on the driver side, carefully remove the stock e-
clip from the stock brake line The stock e-clip may be dis-
carded. Repeat procedure on the passenger side.
50. Locate the new front brake line relocation brackets from
hardware bag FBLNB2. Working on the driver side, slide the
open end of the new brake line over the stock brake line.
Now measuring from the stock brake line hole up 2 1/2”,
carefully drill a 5/16” hole into the stock shock/coil spring
bucket. Repeat procedure on the passenger side. Special
note: Take special care not to damage the stock brake
line when performing this step.
51. Locate (2) 5/16” x 1” bolt, (4) 1/4” USS flat washers and
(2) 5/16” unitorque nuts from hardware bag FBLNB2.
Working on the driver side, secure the new front brake line
relocation the to the previously drilled hole using the new
5/16” x 1” bolt and hardware. Make sure to use thread lock-
er or loctite and torque to 12 ft lbs. Repeat procedure on the
passenger side.
52. Locate (2) e-clips from hardware bag FBLNB2. Working
on the driver side, install the new e-clips to the stock brake
line on the back side of the newly installed brake line reloca-
tion bracket. Repeat procedure on the passenger side.
Special note: Once the installation of this suspension is
completed and the weight of the vehicle is on the
ground, check to make sure that the stock brake line
does not rub on the inside of the tire.