Tuff Country 24950 - Ford 97-03 F150 4 system - Manual (Page 5)

special care not to rip or tear the stock outer tie rod
ball joint dust boot.
Photo # 8
12. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock knuckle.
Save the stock hardware for later re-installation. Using a
bungee cord, carefully tie the stock brake caliper up and
out of the way in the fender well. Special note: Take
special care not to kink or over extend the stock
brake line.
Photo # 9
13. Working on the driver side, remove the stock rotor
and set aside for later re-installation.
14. Working on the driver side, remove the stock dust
shield from the stock hub assembly. Set the stock dust
shield hardware aside for later re-installation. The stock
dust shield needs to be trimmed. Refer to photo # 11 and
12 for proper cut line. Using a die grinder, carefully cut
along the cut line. Once trimming has been performed,
set the modified stock dust shield aside for later re-
installation. Special note: Make sure to wear safety
glasses when performing this step.
Photo # 10 / removal of dust shield
Photo # 11 / pre cut view
Photo # 12 / post cut view
15. Working on the driver side, remove the stock cotter
pin that holds the stock cap and nut to the stock axle and
hub assembly. Save the stock nut and cotter pin for later
re-installation.
16. Working on the driver side, remove the stock cotter
pin on the stock upper control arm ball joint. Set the stock
cotter pin aside for later re-installation. Loosen the stock
nut that connects the stock upper control arm ball joint to
the stock steering knuckle. Do not remove the stock
nut completely. Carefully break the stock taper on the
stock upper control arm ball joint. Special note: Slight
tapping of the stock knuckle will break the stock
taper. Take special care not to rip or tear the stock
ball joint dust boot.
Photo # 13
17. Working on the driver side, remove the stock cotter
pin on the stock lower control arm ball joint. Set the stock
cotter pin aside for later re-installation. Loosen the stock
nut that connects the stock lower control arm ball joint to
the stock steering knuckle. Do not remove the stock
nut completely. Carefully break the stock taper on the
stock lower control arm ball joint. Special Note: Take
special care not to rip or tear the stock ball joint dust
boot.
Photo # 14
18. Working on the driver side, move back to the stock
nuts holding the upper control arm ball joint and the lower
control arm ball joint to the stock steering knuckle and
remove completely. Save the stock hardware for later re-
installation.
19. Working on the driver side, remove the stock axle
from the hub assembly. Special note: Take special care
not to damage the stock threads on the stock axle.
20. Carefully remove the stock hub assembly and the
stock steering knuckle from the stock location.
21. Working on the driver side stock hub assembly,
remove the (3) stock bolts that connect the stock hub
assembly to the stock steering knuckle. Set the (3) stock
bolts aside for later re-installation. Carefully separate the
stock hub assembly from the stock steering knuckle.
Carefully remove the stock seal from the stock steering
knuckle. Set the stock seal aside for later re-installation.
A new steering knuckle is used, the stock steering
knuckle can be discarded.
Photo # 15 / hub assembly bolts
Photo # 16 / seal removal
22. Locate the new driver side steering knuckle and the
stock seal that was removed from step # 21. Install the
stock seal into the new driver side steering knuckle.
Photo # 17
23. Using the stock hardware that was removed from
step # 21, secure the new driver side steering knuckle to
the stock hub assembly. Torque to 92 ft lbs. Special
note: Make sure to use thread locker or lock tite.
Photo # 18
24. Set the new driver side steering knuckle and the
stock hub assembly aside for later re-installation.
25. Working on the driver side, scribe a mark on the CV
plate and another directly across to the stock differential,
this will allow you to re-install the stock CV back into the
stock location at a later step.
Photo # 19
26. Working on the driver side, unbolt and remove the (6)
stock bolts holding the inner CV to the stock differential.
Save the stock hardware for later re-installation. Set the
stock axle aside for later re-installation.
27. Working on the driver side, remove the stock
hardware that connects the stock lower control arm into
the stock front and rear lower control arm location. Set
the stock lower control arm and the stock hardware aside
for later re-installation.
Photo # 20 / driver side front shown
28. Repeat step’s 9 - 27 on the passenger side.
29. Working on the driver side, remove the stock bolt that
connects the lower rear portion of the front differential to
the stock rear cross member. Save the stock hardware
for later re-installation.
Photo # 21