Tuff Country 26814 - Ford 80-96 6 box kit - Manual (Page 11)

note: Take special care not to damage the stock tie rod
dust boot. If the stock tie rod dust boot looks damaged,
it would be a good time to replace it.
44. Remove the stock hardware that connects the stock pit-
man arm to the sector shaft on the stock steering box. Save
the stock hardware. Using a pitman arm puller, carefully
remove the stock pitman arm from the stock location. The
stock pitman arm may be discarded.
45. Locate the new pitman arm. Locate the stock hardware
that connected the stock pitman arm to the sector shaft on
the stock steering box. Install the new pitman arm into the
stock location and secure using the stock hardware. Make
sure to use thread locker or loctite and torque to 145 ft lbs.
46. Locate the stock cotter pin and castle nut that connected
the stock tie rod to the stock pitman arm. Install the stock tie
rod to the newly installed pitman arm and secure using the
stock hardware. Torque the castle nut to 65 ft lbs. Now
install the stock cotter pin to the stock tie rod and castle nut.
Special note: If you are not able to install the stock cot-
ter pin because the hole in the tie rod does not line up
with the castle nut, DO NOT loosen, tighten the castle
nut until the stock cotter pin can be installed.
47. Slight adjustments may need to be done to the outer tie
rods so the vehicle can be driven to an alignment shop. If
this is the case on the vehicle that you are working on,
loosen the stock hardware on the adjusting sleeve and using
a pair of pliers, adjust the toe close enough so that the vehi-
cle can be driven.
48. Locate the new front shocks. New longer front shocks
are needed after this suspension system has been
installed and the front shocks need to be ordered as a
separate part #. If you have not already ordered your
front shocks, please feel free to contact Tuff Country or
your local Tuff Country dealer and order your front
shocks. Tuff Country recommends installing a 23” fully
extended nitrogen gas shock in the front and a 26” fully
extended cellular shock in the front for the auxiliary
shock. Working on the new shocks, install the new bushings
and proper sleeves that are packaged with the new shocks
into the eyelet end of each new shocks. If the vehicle that
you are working on has the auxiliary shock, no sleeve will be
installed in the eyelet of the shock, it will just be the bushing
only. Special note: Make sure to use a lithium or moly
base grease prior to installing the new bushings and
sleeves into the eyelet of the new shocks. This will help
with the life of the bushings as well as prevent squeak-
ing. Locate the stock lower shock mounting hardware. Also,
locate the new upper stem mount hardware that was pack-
aged with the new shocks. Working on the driver side, install
the new shocks into the stock location using the stock lower
hardware and the new upper hardware. Make sure to use
thread locker or loctite and torque the bottom hardware to 65
ft lbs. and the upper hardware to 18 ft lbs. Repeat proce-
dure on the passenger side. Special note: Tuff Country
highly recommends installing shock boots onto the new
shocks. If shocks boots are not installed, damage may
occur to the piston of the new shock. If you have not
already ordered your new shocks boots, please contact
Tuff Country or your local Tuff Country dealer and order
some new shock boots. Tuff Country offers, dark blue,
light blue, gray, black, red or yellow shock boots.
49. Working on the driver side, carefully remove the stock e-
clip from the stock brake line The stock e-clip may be dis-
carded. Repeat procedure on the passenger side.
50. Working on the driver side, carefully pull the hard line out
so that the new front brake line relocation bracket can be