Tuff Country 24950 - Ford 97-03 F150 4 system - Manual (Page 8)

61. Locate the stock driver and passenger side torsion
bar key’s that were removed from step # 6. Working on
the driver side, install the stock torsion bar key back into
the stock torsion bar cross member. Holding the stock
torsion bar key into the stock location, slide the driver
side torsion bar into the stock torsion bar key. Repeat
procedure on the passenger side. Special note: Make
sure that the torsion bar is installed back into the
torsion bar key just as it was removed.
62. Locate the small metal adjusting blocks and bolts that
were removed from step # 4. Working on the driver side,
attach the torsion bar removing tool, making sure that the
unloading bolt in the center tool is in the small divot of the
torsion bar key. Adjust the torsion bar key up high
enough so that the small metal adjusting block and stock
bolt can be re-installed, Refer back to step # 3 and adjust
the stock bolt to the stock location. Repeat procedure on
passenger side. Remove the torsion bar removing tool.
63. Locate the new front shocks. 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. Locate (2)
S10014, (4) PB8297 upper shock bushings and (4)
S10107 upper shock washers from hardware bag
24950NB1. Working on the new shocks, install the new
lower shock bushing into the lower eyelet and install the
new S10014 shock sleeves into the previously installed
bushings. Special note: Make sure to use a lithium or
moly base grease prior to inserting the new lower
shock bushings and sleeves into the new lower
shock eyelet. This will increase the life of the bushing
as well as prevent squeaking. Working on the driver
side, install the new shock into the stock location using
the stock hardware on the bottom mount that was
removed in step # 2 and the new hardware on the top
mount. Repeat procedure on the passenger side.
Special note: Make sure to use the new upper
bushings and upper shock washers. Torque the lower
shock mount to 65 ft lbs. and the upper hardware to 22 ft
lbs. Repeat on passenger side. Special note: Tuff
Country EZ-Ride Suspension highly recommends
that the shocks are installed with shock boots. If
shock boots are not installed, damaged might occur
to the piston of the new shock.
Photo # 37
64. Install the tires and wheels and carefully lower the
vehicle to the ground.
65. There is still a couple of steps that need to be
completed on the front end but these steps will not be
completed until the rear end installation is completed and
the weight of the vehicle is on the ground. These steps
include: the installation of the front sway bar end links
and the tightening of the new hardware that connects the
lower control arms to the newly installed sub frame.
control arm and let hang. Special note: Make sure to
re-install the stock torsion bar back into the stock
location. Example: Driver vs. Passenger and front vs.
rear. 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.
57. Locate the stock torsion bar cross member and the
stock hardware that was removed in step # 6. Working on
the driver side, install the stock torsion bar cross member
to the newly installed torsion bar drop bracket and secure
using the stock hardware. Torque to 75 ft lbs. Make sure
to use thread locker or lock tite. Special note: Install
the stock torsion bar cross member to the inside of
the new torsion bar drop blocks. Repeat procedure on
the passenger side. Move back to the new hardware that
was installed in step # 55. Torque the 1/2” hardware to
85 ft lbs. Torque the 5/8” hardware to 95 ft lbs.
Photo # 36
58. Locate (2) new torsion bar drop blocks, (4) 1/2” x 1
1/2” bolts, (8) 7/16” USS flat washers, (4) 1/2” unitorque
nuts, (2) 5/8” x 1 1/2” bolts, (4) 9/16” flat washers and (2)
5/8” unitorque nuts from hardware bag 24950NB-2.
Working on the driver side, install the new torsion bar
drop block into the stock location on the bottom side of
the stock frame rail and secure using the new 1/2” x 1
1/2” bolts and hardware into the (2) outer holes. Do not
tighten at this point. Install the new 5/8” x 1 1/2” bolt
and hardware into the center hole. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Repeat procedure on the passenger side.
Photo # 35
59. Locate the stock driver and passenger side torsion
bars that were removed from step # 7. Working on the
driver side, slide the stock torsion bar into the stock lower
control arm and let hang. Special note: Make sure to
re-install the stock torsion bar back into the stock
location. Example: Driver vs. Passenger and front vs.
rear. 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.
60. Locate the stock torsion bar cross member and the
stock hardware that was removed in step # 8. Working on
the driver side, install the stock torsion bar cross member
to the newly installed torsion bar drop bracket and secure
using the stock hardware. Torque to 75 ft lbs. Make sure
to use thread locker or lock tite. Special Note: Install
the stock torsion bar cross member to the bottom
side of the new torsion bar drop blocks. Repeat
procedure on the passenger side. Move back to the new
hardware that was installed in step # 58. Torque the 1/2”
hardware to 85 ft lbs. Torque the 5/8” hardware to 95 ft
lbs.