Tuff Country 24821 - Ford 1997 F250 4 box kit - Manual (Page 5)

25. Next, remove the stock rear twin “I” beam axle pivot
drop bracket from the stock location and discard the
stock rear twin “I” beam axle pivot drop bracket and
hardware.
26. Working on the passenger 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.
27. Locate (2) MO2070 front spring eye shackle
bushings, (1) S10008 front spring eye shackle sleeve
and (1) polyurethane lube pack. Working on the
passenger 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 packs 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. Do not tighten at this point.
See Illustration # 2
28. 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.
29. Locate (1) new polyurethane lube pack. Spread the
new polyurethane over the new bushings that were
removed from step # 28 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.
30. Working on the passenger side, install the new front
spring back into the stock location and secure using the
stock hardware that was removed from step # 26.
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
31. Locate the new rear twin “I” beam axle pivot drop
bracket, (5) 9/16” x 1 1/2” bolts, (10) 9/16” flat washers
and (5) 9/16” unitorque nuts from hardware bag
F2507NB. Secure the new rear twin “I” beam axle pivot
drop bracket into the (2) upper stock holes using the new
9/16” x 1 1/2” bolts and hardware. Torque to 120 ft lbs.
Make sure to use thread locker or locktite on these
bolts. Using the (3) stock holes in the stock cross
member as a guide, carefully drill (3) 9/16” holes into
the new rear twin “I” beam axle pivot drop bracket.
Secure the new rear twin “I” beam axle pivot drop
bracket to the front cross member using the new 9/16” x
1 1/2” bolts and hardware. Torque to 120 ft lbs. Make
sure to use thread locker or locktite on these bolts.
See Illustration # 6
32. Carefully raise up on the both hydraulic floor jacks
that are supporting the rear twin “I” beam axle until the
stock rear twin “I” beam axle seats properly with the new
front spring pack.
33. Locate the upper and lower U-bolt plates that were
removed from step # 21, (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
passenger side, install the stock upper and lower U-bolt
plates into the stock location and secure the newly
installed front spring to the stock rear twin “I” beam using
the new 9/16” x 3” x 10 1/2” square U-bolts and
hardware. Torque to 110 ft lbs.
34. 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 rear twin “I” beam axle until the rear twin
“I” beam axle seats properly into the new rear twin “I”
beam axle pivot drop bracket. Secure the stock rear twin
“I” beam axle to the new rear 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 center for a proper front end
alignment.
See Illustration # 7
35. Carefully remove both hydraulic floor jacks from
under the stock rear twin “I” beam axle.
Special Note: If the vehicle that you are working on
is not equipped with a front sway bar, please skip to
step # 38
36. Locate (1) new front sway bar drop bracket and (2)
stock bolts and hardware that was removed from step #
4. Working on the driver side, install the new sway bar
drop bracket to the stock frame mount. Secure using the
stock hardware. Special Note: Do not tighten at this
point. Make sure to use thread locker or locktite on
these bolts. Repeat procedure on the passenger side.
See Illustration # 8