Tuff Country 24973 - Ford 05-07 F250/F350 5 box kit - Manual (Page 6)

of the new shocks.
36. Locate the stock lower shock mounting hardware.
Locate (2) PB8297 upper shock bushings and (2) S10107
upper shock washers from hardware bag 24973PL. Locate
(2) 1/2” USS flat washers from hardware bag 24973NB and
locate the new shock stem nuts that were packaged with
your new shocks. Working on the driver side, install the
new shock into the stock upper location using the upper
shock bushing, washers and nut. Torque to 28 ft lbs.
Secure the bottom of the new shock to the stock location
and secure using the stock hardware and the 1/2” washers
as a spacer. Make sure to use thread locker or lock tite.
Torque to 45 ft lbs.
Photo # 41 / Photo # 42
Photo # 43 / Photo # 44
37. Working on the driver side, carefully cut off the stock
clip on the stock ABS. Repeat procedure on the passenger
side.
Photo # 45
38. Locate (2) new zip ties from hardware bag 24973PL.
Working on the driver side, re-install the stock ABS line
back to the stock radius arm and then zip tie the stock ABS
line and breather hose together. Cut off the excess zip tie.
Repeat procedure on the passenger side.
Photo # 46
39. Working on the passenger side, remove the stock
steering stabilizer from the stock bracket on the passenger
side of the vehicle and save the stock hardware and the
stock steering stabilizer for later re-installation.
40. Working on the passenger side, remove the stock
steering stabilizer bracket from the stock cross member.
Save the stock hardware for later re-installation. The stock
bracket may be discarded.
41. Locate the new steering stabilizer relocation bracket
and the stock hardware. Install the new steering stabilizer
bracket to the stock location and secure using the stock
hardware. Make sure to use thread locker or lock tite and
torque to 45 ft lbs.
Photo # 47
42. Locate the stock tie rod hardware. Install the stock tie
rod to the newly installed pitman arm and secure using the
stock hardware. Make sure to add some thread locker or
lock tite and torque to 95 ft lbs. Now install the stock re-
taining nut and cotter pin. Special note: If the stock cot-
ter pin can not be installed because the hole in the
stock retaining nut does not line up with the stock ball
joint, DO NOT loosen the stock nut so that the cotter
pin can fit, tighten the stock nut some more so that the
stock cotter pin can be installed.
Photo # 48
43. Locate the stock steering stabilizer hardware and the
stock steering stabilizer. Install the stock steering stabilizer
to the newly installed steering stabilizer bracket and secure
using the stock hardware. Make sure to use thread locker
or lock tite and torque to 45 ft lbs.
Photo # 49
44. Locate the stock steering stabilizer hardware. Install the
stock steering stabilizer to the stock location and secure
using the stock hardware. Make sure to add some thread
locker or lock tite and torque to 45 ft lbs.
Photo # 50
45. Locate the stock track bar mounting hardware. Working
on the driver side, secure the stock track bar to the newly
installed track bar relocation bracket and secure using the
stock hardware. Make sure to use thread locker or lock tite
and torque to 145 ft lbs.
Photo # 51
46. Carefully remove both hydraulic floor jacks from under
the front differential.
47. Locate the new front sway bar end links. Also, locate (4)
MO220 poly bushings and (2) S10175 (.6875” x .565” x
1.500” sleeves) from hardware bag 24973PL. Install the
new bushings and sleeves into the new front sway bar end
links. Special note: Make sure to use a lithium or moly
base grease prior to inserting the bushings and
sleeves into the new front sway bar end links. This will
help with the life of the bushings as well as help pre-
vent squeaking.
48. Locate (2) 9/16”x 3” bolt, (4) 1/2” USS flat washers and
(2) 9/16 unitorque nuts from hardware bag 24973NB.
Working on the driver side, install the new front sway bar
end link to the outside of the stock sway bar and secure
using the new 9/16” x 3” bolts and hardware. Make sure to
use thread locker or lock tite and torque to 80 ft lbs.
Repeat procedure on the passenger side.
49. Locate (4) MO3808 bushings and (4) S10113 over size
washers from hardware bag 24973PL. Also, locate (2) 1/2”
unitorque nuts from hardware bag 24973NB. Working on
the driver side, install the new front sway bar end link to the
stock lower location and secure using the new bushings,
washers and 1/2” unitorque nut. Make sure to use thread
locker or lock tite and torque to 70 ft lbs. Repeat proce-
dure on the passenger side.
50. Check and double check to make sure that all steps
have been completed properly for the front end and check
again.
51. Install the tires and wheels and carefully lower the vehi-
cle to the ground.
Rear end installation:
52. To begin installation, block the front tires of the vehicle