Tuff Country 24862 - Ford 83-97 Ranger/Explorer 4 box kit (performance kit) - Manual (Page 9)

31. Vise grip the bracket back to the frame rail making sure
that the hole in the bracket line up with the marks that were
scribed earlier. Using the bracket as a guide, carefully drill (5)
7/16” holes into the frame rail. (3) on the side of the frame rail
and (2) on the bottom side of the frame rail. Special note:
Take special care not to drill into any lines running down
the inside of the frame rail.
32. Locate (5) 7/16” x 1 1/2” bolts, (10) 3/8” USS flat wash-
ers and (5) 7/16” unitorque nuts from hardware bag R4XRB-
NB. Secure the passenger side extended radius arm to the
new location using the new 716” x 1 1/2” bolts and hardware.
Make sure to use thread locker or loctite and torque to 45 ft
lbs.
33. Locate (4) PB2408 poly bushings, (2) S10081 sleeve and
(2) SERT fittings from hardware bag 24862NB. Install the
new bushings, sleeves and sert fitting into each end of the
extended radius arm. Special note: Make sure to use a
lithium or moly base grease prior to inserting the bush-
ings and sleeves into the new extended radius arms.
This will increase the life of the bushing as well as pre-
vent squeaking. Also, take special care not to damage
the sert fitting during installation.
34. Working on the driver side, install the new driver side
extended radius arm into the stock location on the driver side
axle and secure using the stock hardware. Make sure to
install the stock sway bar bracket. Make sure to use
thread locker or loctite and torque the upper and lower
hardware to 135 ft lbs. Repeat procedure on the passenger
side.
35. Locate the new front coil springs. Also, locate the stock
lower coil spring washer and hardware. Working on the driv-
er side, install the new coil spring into the stock upper loca-
tion then raise up on the hydraulic floor jack until the lower
portion of the coil springs can be attached to the front axle.
Secure using the stock hardware and add some thread lock-
er or loctite and torque to 145 ft lbs. Repeat procedure on
the passenger side.
36. Locate (2) CAM-03, (4) CAM-02 and (2) 916UN. Working
on the driver side, secure the newly installed extended radius
arm to the newly installed extended radius arm bracket using
the new 9/16” x 4” cam bolt and hardware. Make sure to use
thread locker or loctite and torque to 85 ft lbs. Special note:
For now place the cam washer in the center position.
Once the installation is completed and the vehicle is
taken to the alignment center, they will set the alignment
where it needs to be. Repeat procedure on the passenger
side.
Tuff Country highly recommends installing an aftermar-
ket pitman arm once part # 24862 has been installed. If
you have not already ordered your new pitman arm,
please contact Tuff Country or your local Tuff Country
dealer and order part # 70200.
37. Working on the stock pitman arm, remove the stock cot-
ter pin and castle nut. Save the stock hardware. Carefully
remove the stock tie rod from the stock pitman arm. Special
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.
38. Remove the stock hardware that connects the stock pit-
man arm to the sector shaft on the stock steering box. Save
the hardware. Using a pitman arm puller, carefully remove
the pitman arm from the stock location. The pitman arm may
be discarded.
39. Locate the new pitman arm. Locate the stock hardware
that connected the stock pitman arm to the sector shaft on
the 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.