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

and (1) polyurethane lube pack. Working on the driver
side, remove the stock front spring shackle from the
stock frame mount and save the stock hardware for later
re-installation. Carefully press out the stock bushing and
sleeve from the stock spring shackle and discard the
stock bushing and sleeve. Install the new bushings and
sleeve into the stock front spring eye shackle. Special
Note: Make sure to use the new polyurethane lube
pack prior to inserting the new bushings back into
the new front spring shackle. This will increase the
life of the bushing, prevent squeaking and help with
ride quality. Install the stock front spring eye shackle
back into the stock location using the stock hardware
that was removed earlier in this step. Make sure to use
thread locker or locktite on this bolt. Do not tighten
at this point.
See Illustration # 2
12. Locate (1) new front leaf spring. Working on the front
and rear eyelet’s of the new front leaf spring, remove the
new sleeves and bushings from each end of the new
front spring and set a side for later re-installation.
13. Locate (1) new polyurethane lube pack. Spread the
new polyurethane over the new bushings that were
removed from step # 12 and re-install them back into the
new front spring assembly. Re-install the new sleeves
back into the previously installed bushings. Special
Note: Make sure to use the new polyurethane lube
packs prior to inserting the new bushings back into
the new front springs. This will increase the life of
the bushing, prevent squeaking and help with ride
quality.
14. Working on the driver side, install the new front
spring back into the stock location and secure using the
stock hardware that was removed from step # 10.
Special Note: The new front spring has an off-set
centering bolt, the shorter end of the spring needs to
be installed towards the front of the vehicle. Make
sure to use thread locker or locktite on these bolts.
Torque the front spring eye hanger hardware to 120 ft
lbs. Special Note: Do not torque the front spring eye
shackle hardware at this time. Once the vehicle is
lowered to the ground, the upper and lower front
spring eye shackle hardware will be torque to 40 ft
lbs.
See Illustration # 2 / Front Spring Shackle
See Illustration # 3 / Rear Spring Hanger
15. Locate the new front twin “I” beam axle pivot drop
bracket, (4) 9/16” x 1 1/2” bolts, (8) 9/16” flat washers
and (4) 9/16” unitorque nuts from hardware bag F250NB.
Secure the new front twin “I” beam axle pivot drop
bracket into the stock location using the new 9/16” x 1
1/2” bolts and hardware. Make sure to use thread
locker or locktite on these bolts. Special Note: Due
to inconsistencies of the stock mounting points,
some holes in the stock cross member may need to
be enlarged to 9/16”. Also, do not tighten the
mounting hardware until all (4) bolts have been
installed. Once all (4) bolts have been installed,
torque the new 9/16” hardware 120 ft lbs.
See Illustration # 4
16. Carefully raise up on the both hydraulic floor jacks
that are supporting the front twin “I” beam axle until the
stock front twin “I” beam axle seats properly with the new
front spring pack.
17. Locate the upper and lower U-bolt plates that were
removed from step # 6, (2) 9/16” x 3” x 10 1/2” square U-
bolts, (4) 9/16” U-bolt high nuts and (4) 9/16” U-bolt
washers from hardware bag 916NW. Working on the
driver side, install the stock upper and lower U-bolt
plates into the stock location and secure the newly
installed front spring to the stock front twin “I” beam axle
using the new 9/16” x 3” x 10 1/2” square U-bolts and
hardware. Torque to 110 ft lbs.
18. Locate (1) 9/16” x 3 1/2” cam bolt, (2) cam washers
and (1) 9/16” unitorque nut from hardware bag CAM1NB.
Carefully raise up on the hydraulic floor jack that is
supporting the front twin “I” beam axle until the front twin
“I” beam axle seats properly into the new front twin “I”
beam axle pivot drop bracket. Secure the stock front twin
“I” beam axle to the new front twin “I” beam axle pivot
drop bracket using the new 9/16” x 3 1/2” cam bolt and
hardware. Make sure to use thread locker or locktite.
Torque to 115 ft lbs. Special Note: For now, adjust
the new cam bolt to the center position. After the
completion of the installation, take the vehicle
directly to an alignment shop for a proper front end
alignment.
See Illustration # 5
19. Carefully remove both hydraulic floor jacks from
under the stock front twin “I” beam axle.
20. Place a pair of hydraulic floor jacks under the rear
twin “I” beam axle.
21. Working on the passenger 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.
22. Working on the stock rear twin “I” beam axle pivot
drop bracket, remove the stock bolt that connects the
stock rear twin “I” beam axle to the stock rear twin “I”
beam axle pivot drop bracket and discard the stock
hardware.
23. Carefully lower down on the hydraulic floor jacks that
are supporting the rear 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