Tuff Country 24820 - Ford 80-96 F250 4 box kit - Manual (Page 3)

Special Note: Tuff Country EZ-Ride Suspension
recommends running a 35” x 12.50” tire for
maximum tire clearance. Note: This tire size in not
100% accurate due to variations in wheel width,
wheel off set, tire diameters and driving habits.
Please Follow Instruction Carefully
Before installation begins, drive and check to make
sure there are no uncommon sounds and or frame
damage. Also at this time measure from the center of
the hub to the bottom of the fender well and record
measurements below.
Pre Installation Measurements:
Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post Installation Measurements:
Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________
Please follow instructions carefully:
Front End Installation:
1. To begin installation, block the rear tires of the vehicle
so that the vehicle is stable and can’t roll backwards.
Safely lift the front of the vehicle and support the frame
with jack stands. Place a jack stand on both the driver
and passenger side. Next, remove the wheels and tires
from both sides.
2. Working on the driver side, remove the stock shock
from the stock upper and lower mounting point and save
the stock hardware for later re-installation. The stock
shock may be discarded. Special Note: New longer
front shocks are needed after the completion of the
installation. If you have not already ordered your
front shocks, and the vehicle that you are working
on was manufactured from 1980-1987 please contact
Tuff Country or your local Tuff Country dealer and
order part # 61262. If the vehicle that you are working
on was manufactured from 1988-1996 please contact
Tuff Country or your local Tuff Country dealer and
order part # 61261. Repeat procedure on the passenger
side.
3. Working on the driver side, remove the stock castle
nut and cotter pin that connects the stock pitman arm to
the stock drag link. Save the stock castle nut and cotter
pin for later re-installation. Carefully break the taper on
the stock drag link and stock pitman. Special Note:
Take special care not to rip or tear the dust boot on
the stock drag link. Next, remove the stock nut and
washer that connect the stock pitman arm to the stock
sector shaft. Save the stock nut and washer for later re-
installation. Using a pitman arm puller, carefully remove
the stock pitman arm from the sector shaft on the stock
steering box. A new pitman arm is needed, the stock
pitman arm may be discarded. Special Note: The new
pitman arm is sold as a separate part number. If you
have not already ordered your new pitman arm,
please contact Tuff Country or your local Tuff
Country dealer and order (1) 70200.
See Illustration # 1
Special Note: If the vehicle that you are working on
is not equipped with a stock front sway bar, please
skip to step # 5
4. Working on the driver side, disconnect the stock sway
bar from the stock frame mount and save the stock
hardware for later re-installation. Repeat procedure on
the passenger side.
5. Place a pair of hydraulic floor jacks under the front
twin “I” beam axle.
6. Working on the driver side, remove the stock U-bolts
from the stock location. The stock U-bolts and hardware
may be discarded. Place the stock upper and lower U-
bolt plates a side for later re-installation.
7. Working on the stock front twin “I” beam axle pivot
drop bracket, remove the stock bolt that connects the
stock front twin “I” beam axle to the stock front twin “I”
beam axle pivot drop bracket and discard the stock
hardware.
8. Carefully lower down on the hydraulic floor jacks that
are supporting the front twin “I” beam axle approximately
5”. Special Note: Take special care not to kink or
over extend any brake lines and or hoses. This will
allow enough room for the new front springs and new
front twin “I” beam axle pivot drop bracket to be installed
into the stock location.
9. Next, remove the stock front twin “I” beam axle pivot
drop bracket from the stock location and discard the
stock front twin “I” beam axle pivot drop bracket and
hardware.
10. Working on the driver side, remove the stock spring
from the stock location. The stock spring may be
discarded. Save the stock spring eye hardware for later
re-installation.
11. Locate (2) MO2070 front spring eye shackle
bushings, (1) S10008 front spring eye shackle sleeve