Tuff Country 24950 - Ford 97-03 F150 4 system - Manual (Page 9)

74. Raise up on both hydraulic floor jacks at the same
time until the driver and passenger side stock spring
assembly seats flush with newly installed 5.5” block.
75. Locate (4) new 5/8” x 3 1/2” x 12 1/2” round u-bolts.
Locate (8) 5/8” u-bolt high nuts and (8) 5/8” u-bolt
washers from hardware bag 24950NB-2. Also, locate the
modified stock upper u-bolt plates. Working on the driver
side, install the new 5/8” x 3 1/2” x 12 1/2” round u-bolts
into the stock location and secure using the new 5/8” high
nuts and washers. Torque to 135 ft lbs. With a suitable
cutting tool, cut off the extra thread from the new u-bolts.
Repeat procedure on passenger side.
Illustration # 39
76. Locate the new rear 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
30” 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 # 68 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.
77. Carefully remove both hydraulic floor jacks from
under the vehicle.
78. Install the tires and wheels and carefully lower the
vehicle to the ground.
Step # 79 and # 80 needs to be performed with the
weight of the vehicle on the ground.
79. Working on the driver side, move back to the new
5/8” hardware attaching the stock lower control arms to
the newly installed one piece lower sub frame and torque
to 125 ft lbs. Repeat procedure on the passenger side.
Rear end installation:
66. To begin installation, block the front tires of the
vehicle so that the vehicle is stable and can’t roll forward.
Safely lift the rear 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.
67. Position a pair of hydraulic floor jacks under the rear
axle. Place one jack stand on the driver side and one on
the passenger side. Raise up on both hydraulic floor
jacks at the same time until they make contact with the
rear axle. Special note: You may need to remove the
plastic clip that holds the E-brake cable together.
68. 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
30” fully extended nitrogen gas shock. Repeat
procedure on the passenger side.
69. Working on the driver side, remove the stock rear u-
bolts from the stock location. The stock u-bolts and
hardware may be discarded. Set the stock upper u-bolt
plate aside for later re-installation. Repeat procedure on
passenger side.
70. Working on the driver side upper u-bolt plate, open
each hole 1/8” to the outside of the u-bolt plate. See
Illustration # 38 for proper placement. Set the upper u-
bolt plate a side for later re-installation. Repeat procedure
on the passenger side.
Illustration # 38
71. Lower down on both hydraulic floor jacks at the same
time until the stock springs separate from the stock rear
axle. Lower down approximately 4”. Special note: Make
sure not to over extended any brake lines or hoses
when lowering the stock rear axle.
72. Working on the driver side, remove the stock block
from the stock location and discard. Repeat procedure on
the passenger side.
73. Locate (2) new 5.5” lifted rear blocks. Working on the
driver side, install (1) new 5.5” lifted rear block between
the stock rear axle and the stock spring assembly.
Special note: The new 5.5” lifted block has a taper to
it, the small end of the new block needs to be
installed towards the front of the vehicle. Repeat
procedure on passenger side.
Illustration # 39