Tuff Country 82550 - Ford 04-08 F150 Add-a-Leaf - rear - Manual (Page 3)

At the end of the installation, take the same
measurements and compare to the pre-installation
measurements.
Post-installation measurements:
Driver side rear:______________________________
Passenger side rear:__________________________
1. To begin installation, remove the stock front end links from
the stock location and save the stock hardware. Now, 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 sup-
port 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. Position a pair of hydraulic floor jacks under the rear axle.
Place one jack stand on the driver side and one on the pas-
senger side. Raise up on both hydraulic floor jacks at the
same time until they make contact with the rear axle.
3. Working on the driver side, remove the stock shock from
the stock axle mount location. Save the stock hardware. The
upper mount does not need to be removed, let the shock
hang. Repeat procedure on the passenger side.
4. Working on the driver side, remove the (2) rear u-bolts.
Save the rear u-bolts and hardware. Set the stock upper u-
bolt plate aside. Repeat procedure on passenger side.
5. 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 axle.
6. Place a pair of “C” clamps on both sides of the new cen-
tering bolts and tighten until the “C” clamps hold the stock
springs together. Remove the stock centering bolts that con-
nect the stock together and discard. Carefully remove the
“C” clamps from the stock springs. Special note: Take spe-
cial care when removing the “C” clamps because the
springs are under tension.
7. Locate the new rear a-a-leaf. Also, locate (2) 1/2’ x 6” bolts
and (2) 1/2” fine nuts from hardware bag CB12. Working on
the driver side, install the new add-a-leaf between the stock
over load and the stock spring assembly. Secure using the
new 1/2” centering bolts and nuts. For now, just get the nuts
started. Then using a pair of “C” clamp vise grips, carefully
bring the new add-a-leaf and stock spring assembly togeth-
er. Once the new add-a-leaf and the stock springs have
been brought together, tighten the new 1/2” centering bolts
to 54 ft lbs. Special note: Using a die grinder, carefully
cut off the excess thread on the centering bolts so that
the upper u-bolt plate can be installed properly.
8. Repeat step # 5 - 7 on the passenger side.
9. Carefully raise up on both hydraulic floor jacks at the
same time until the rear axle makes contact with the stock
spring assemblies.
If you are installing this rear add-a-leaf on a rear end that
has no aftermarket blocks or u-bolts installed, the stock
rear u-bolts may not be long enough. If this is the case
on the vehicle that you are working on, please contact
Tuff Country or your local Tuff Country dealer and order
part # 27800.
10. Locate the u-bolts, u-bolt hardware and upper u-bolt
plates. Working on the driver side, secure the new rear add-
a-leaf and the stock spring assembly to the rear axle and
secure using the u-bolts, u-bolt hardware and upper u-bolt
plates. Torque to 120 ft lbs. Repeat procedure on the pas-
senger side.
11. Locate the stock lower shock hardware. Working on the
driver side, secure the stock shock into the stock lower
shock mounting point and secure using the stock hardware.
Make sure to use thread locker or loctite and torque to 85 ft
lbs. Repeat procedure on the passenger side.
12. Carefully remove both hydraulic floor jacks from under
the vehicle.
13. Check and double check to make sure that all steps have
been performed properly and check again.
14. Install the tires and wheels and carefully lower the vehi-
cle to the ground.
Congratulations, installation complete!
Special note: After the completion of the installation, Tuff
Country EZ-Ride Suspension recommends taking the vehicle
to an alignment shop and having a proper front end alignment
performed.
Tuff Country EZ-Ride Suspension recommends that a com-
plete re-torque is done on all bolts associated with this sus-
pension system. It is the customers responsibility to make
sure that a re-torque is performed on all hardware associated
with this suspension system after the first 100 miles of instal-
lation. It is also the customers responsibility to do a complete
re-torque after every 3000 miles or after every off road use.
Neglect of following these steps could cause brackets to come
loose and cause serious damage to the suspension system
and to the vehicle.
If you have any questions or concerns, please feel free to con-
tact Tuff Country or your local Tuff Country dealer.
After completion of the installation, Tuff Country EZ-Ride
Suspension highly recommends that the installer informs the
customer that whenever they have their vehicle lifted in the air
by the frame rail, the front sway bar end links need to be dis-
connected from the stock sway bar. If this is not done, damage
will occur to the stock front end links.