Tuff Country 24950 - Ford 97-03 F150 4 system - Manual (Page 4)

Before installation begins, measure from the center
of the hub, to the bottom of the fender well, and
record measurements below.
Photo # 1 / driver side front shown
Pre installation measurements:
Driver side front:______________________________
Passenger side front:__________________________
Driver side rear:______________________________
Passenger side rear:__________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post installation measurements:
Driver side front:______________________________
Passenger side front:__________________________
Driver side rear:______________________________
Passenger side rear:__________________________
Please follow instructions carefully:
Front end installation:
1. To begin installation, block the rear tires of the vehicle
so that the vehicle is stable and can’t roll backwards.
Safely lift the front of the vehicle and support the frame
with a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next, remove the wheels and
tires from both sides.
2. Working on the driver side, remove the stock hardware
on the top of the stock shock. The upper stock hardware
may be discarded. Remove the stock hardware on the
lower shock mount and save hardware for later re-
installation. The stock shock may be discarded. Special
note: New longer front shocks are needed, if you
have not already ordered shocks, please contact Tuff
Country or your local Tuff Country dealer and order
the proper shocks. Tuff Country recommends using a
23” fully extended nitrogen gas shock. Repeat
procedure on the passenger side.
3. Measure exposed threads on the torsion bar
adjustment bolt and record measurement here for a later
reference.
Record driver side measurement here:______________
Record passenger side measurement here:__________
Photo # 2
4. Working on the driver side, attach the torsion bar
removing tool to the stock torsion bar cross member,
making sure that the unloading bolt in the center of the
torsion bar removing tool is in the small divot of the stock
torsion bar key. Adjust the torsion bar key up high
enough so that the stock small metal adjusting block and
bolt can be removed. Set the stock torsion bar block and
bolt aside for later re-installation. Repeat procedure on
passenger side.
Photo # 3
5. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:
Driver vs. Passenger and front vs. rear. Tap the stock
torsion bars forward until the stock torsion bar cross
member can be removed. Once you tap the stock torsion
bar out of the stock torsion bar cross member, the stock
torsion bar key will fall out. Set the stock torsion bar key
aside for later re-installation. Slide the torsion bar forward
in the stock lower control arm far enough so that the
stock torsion bar cross member can be removed. Special
note: Take special care not to push the torsion bar
into the stock CV axle, if this happens, damage may
occur to the stock CV axle. Repeat procedure on the
passenger side.
Photo # 4
6. Working on the driver side, remove the stock bolts that
connects the stock torsion bar cross member to the stock
mounting point. Save the stock hardware for later re-
installation. Repeat procedure on the passenger side.
Remove the stock torsion bar cross member from the
stock location and set aside for later re-installation.
Photo # 5
7. Working on the driver side, slide the stock torsion bar
out of the stock rear lower control arm and set aside for
later re-installation. Repeat procedure on passenger side.
8. Working on the driver side, remove the stock sway bar
end link from the stock sway bar and the stock lower
control arm and discard the stock end link and all the
stock hardware. Repeat procedure on the passenger
side.
Photo # 6
9. Working on the driver side, remove the stock bolt that
connects the stock brake line bracket to the stock frame
rail. Save the stock hardware for later re-installation.
Photo # 7
10. Working on the driver side, locate the ABS line quick
disconnect located above the stock upper control arm.
Disconnect the ABS lines from each other. Also
disconnect the ABS line from any other mounting points.
Set the stock hardware aside for later re-installation. Let
ABS line hang. Special note: If the vehicle that you are
working on is not equipped with front ABS, please
skip this step.
11. Working on the driver side, loosen the stock nut that
connects the stock outer tie rod ball joint to the stock
steering knuckle. Do not remove the stock nut
completely. Carefully break the stock taper on the stock
outer tie rod ball joint. Special note: Slight tapping of
the stock knuckle will break the stock taper. Take