Ford 839 User Manual
1999 FORD SUPER DUTY TRUCK
INSTALLATION INSTRUCTIONS
KIT #893
WARNING
Installation of a Performance Accessories
body lift will change the center of gravity and
the handling characteristics of the vehicle.
Because of the higher center of gravity and
larger tires, the vehicle will handle and react
differently both on and off road. You must
drive it safely! Extreme care must be taken to
prevent vehicle rollover or loss of control,
which could result in serious injury or death.
Avoid sudden sharp turns or abrupt
maneuvers and always make sure all vehicle
occupants have their seat belts fastened.
WARNING
Read and understand all instructions,
warnings, cautions, and notes in this sheet
and in your owner's manual before you begin
the installation of this body lift kit.
CAUTION
Proper installation of a Performance
Accessories body lift kit requires knowledge of
the factory recommended procedures for
disassembly an assembly of original
equipment components. It is recommended
that the factory shop manual and any special
tools necessary to your vehicle be on hand
during the installation. Installation of this body
lift kit without proper knowledge of the factory
recommended procedures might affect the
performance of these components and the
safety of your vehicle. It is strongly
recommended that a certified mechanic who is
familiar with the installation of similar
components install this body lift kit.
WARNING
This body lift kit should only be installed on
vehicles that are in good working condition.
Before the installation begins, the vehicle
should be thoroughly inspected for evidence of
corrosion or deformation of the sheet metal
around the factory body mounts. This body lift
kit should not be installed on any vehicle that
is suspected to have been in a collision, or
misused. Off road use of your vehicle with this
body lift installed may increase the stress
applied to the factory body mounts. It is not
recommended that any vehicle, with a body lift
installed, be involved in any extreme off road
maneuvers. Failure to follow this warning may
result in serious personal injury and/or serious
damage to your vehicle.
WARNING
Performance Accessories strongly
discourages the use of a suspension lift kit or
any other lift device in addition to a body lift kit.
A vehicle that uses a combination of lift
devices not originally engineered to be used
together may result in unexpected and unsafe
handling characteristics. Many states now
have laws restricting bumper heights and
vehicle lifts. Local laws should be consulted to
determine if the changes you intend to make
to your vehicle complies with state laws.
WARNING
The installation of larger wheel and tire
combinations may reduce the effectiveness of
the Anti-lock Braking System.
NOTE
Performance Accessories recommends using
the Loctite® supplied in the kit, on all
hardware unless noted in the instructions.
WARNING
Always wear eye protection when operating
power tools.
1. Read all warnings and instructions
completely and carefully before you begin.
Check the kit for proper contents (refer to the
part’s list and the picture diagrams). Only
attempt to install this kit on the vehicle
described above. This kit is not designed to fit
vehicles equipped with diesel engines. If
anytime during the installation you encounter
something different from what is outlined in the
instructions, call technical support. (928) 6360979 or contact us on the Internet at
www.PerformanceAccessories.com.
WARNING
Make sure that your vehicle is properly
blocked and secured before you begin
installation of this lift kit.
2. Park the vehicle on a clean, dry, flat, level
surface. Block the tires so the vehicle cannot
roll in either direction.
WARNING
The Supplemental Restraint System (SRS, air
bag) must be deactivated before installation of
the lift kit to avoid accidental deployment of
the air bag while working near SRS sensors
and wiring. Do not allow anyone near the air
bag during installation of the lift kit. Accidental
deployment can result in serious personal
injury or death. Refer to your factory service
manual for the recommended procedure to
disable the SRS before installation of lift kit.
The SRS must be reactivated before driving
the vehicle.
3. Disconnect both battery cables. Be sure to
disconnect the negative cable first, then the
positive cable. Remove the airbag fuse from
the fuse box.
4. Before you begin lifting the vehicle, you
need to measure and record the bumper to
vehicle gaps and also the distance between
the cab and the bed. These dimensions will
allow you to retain the factory spacing at these
locations.
5. 4 wheel drive models only. Remove the
four screws that mount the shift boot to the
floorboard. Pull the boot up out of the way (It
will not slip over the shift knob). Remove the
four bolts that mount the inner shift boot to the
floorboard (there are two on top and two on
the side). Carefully pull the inner boot up
through the hole in the carpeting and out of
the way. Remove the bolts that mount the shift
lever to the transfer case shift linkage.
Remove the shift lever from the linkage.
6. Remove the doorjamb scuff plates by gently
pulling until the tabs release from the holes in
the floorboard. Remove the front kick panels
by gently pulling out from the side until the
tabs release. Pull the carpeting back to
expose the cab mounting bolt in the front
floorboard. It can be loosened at this time.
7. Super cab models only. The rear seat
must be removed to access the rear cab
mounting bolts. Remove the nut and bolt that
mount the seat to the floorboard. Lift the seat
off the studs protruding from the floorboard
and carefully remove it from the vehicle.
Carefully pull the carpeting back to expose the
back four cab-mounting bolts (Two on each
side. One is under the seat back and the other
is just behind the front seat in the floorboard).
These can be loosened at this time.
CAUTION
Be sure that the steering shaft does not turn
independently of the steering gearbox. This
could cause the air bag system to malfunction
causing possible personal injury and damage
to the vehicle.
8. Lock the steering column so the steering
wheel cannot turn independently from the
steering shaft. Loosen and remove the bolt
that mounts the steering shaft universal joint to
the steering column under the dash. Slide the
steering shaft down from the column. Install
the female side of the steering extension to
the male shaft at the steering column. It
should only go on one way. Install the Allen
head bolt in the steering extension. Be sure
that the bolt goes through the retaining groove
on the male shaft. Tighten the Allen head bolt
securely. Do not install the steering shaft to
the extension at this time. It will be installed
after the lifting operation is complete.
9. Remove the cover over the throttle body on
the intake manifold. Loosen the clamp that
attaches the air duct to the throttle body.
Release the clamp that holds the two halves of
the air filter housing together. Remove the air
duct from the throttle body. Lay the air duct
back out of the way.
10. Remove the two bolts that mount the fan
shroud to the radiator. Pull the fan shroud up
out of the clips on the bottom of the radiator.
Lay the fan shroud over the fan away from the
radiator.
WARNING
Use extreme caution when working with the
engine cooling system. Never remove the
radiator cap from a hot radiator. Wait until the
engine and radiator has cooled and the
pressure in the system has dissipated. Use
care not to spill any antifreeze/coolant while
draining system. Antifreeze can be harmful to
the environment. Take care to store the
drained antifreeze/coolant in a place away
from children and animals. Antifreeze/coolant
can be fatal if swallowed.
11. Be sure that the radiator has cooled
sufficiently to prevent injury. Remove the
radiator cap. Drain the coolant into a clean
container. Remove the upper and lower
radiator hoses from the radiator. Remove the
upper radiator mounting bolts. Remove the
radiator from the vehicle. Remove the fan
shroud from the vehicle.
12. Pull down the air flap between the bumper
and the bottom of the core support to reach
the front bumper mounts. Be careful not to
damage the plastic mounting tabs. Disconnect
any wires going to the front bumper (driving
Lights, etc.). Remove the four nuts that mount
the front bumper to the frame mounts.
Remove the front bumper from the vehicle.
Remove the tow hooks from the frame rails
and place the bolts back into the frame and
secure them using the supplied 12mm nuts.
13. Remove the wire loom that goes to the
battery from the bracket on top of the
passenger side frame rail. Cut electrical tape
holding harness to ground cable on passenger
side frame rail.
14. A steel brake line runs along the drivers
side frame rail from the engine to the rear of
the vehicle. Remove the line from the front two
mounting brackets. This should allow the line
to flex while lifting. Separate the parking brake
cable at the clip connecting the rear cable to
the front cable. The parking brake adjuster
(located in front of the rear drivers' side tire)
must be loosened (approximately three to four
inches) to allow enough slack to unhook the
connector. Remove the front cable from the
hole in the frame mount (squeeze the tabs
together).
15. Remove the fuel cap. Remove the three
screws that mount the fuel filler to the body.
Loosen the clamp that mounts the filler hose
to the fuel tank. Loosen the clamp that mounts
the vent hose to the fuel tank. Remove the
entire assembly from the vehicle and cap the
fuel tank to prevent anything from falling into
the tank. The filler hose will need to be
lengthened after lifting.
16. Disconnect the license plate lights from the
rear bumper. Remove the four bolts that
mount the rear bumper to the frame. Remove
the rear bumper from the vehicle.
17. Loosen but do not remove all cab
mounting bolts. They are located as follows:
Beside the radiator screwing up from the
bottom (The forward spring hangar mounting
bolt must be removed to access this bolt and it
must be replaced after the cab is lifted). In the
front floorboard, behind the front seat. And on
extra cab models at the very rear of the cab
below the rear seatback.
18. Remove the cab mounting bolts from the
passenger side of the cab. Check for any
wires, hoses, cables, etc. that may be too
short and that may have not been covered in
the instructions. Using a hydraulic jack and
wooden block, slowly lift the cab just high
enough to place the spacers on the mounting
pads. Be sure to continuously to check for any
wires, cables, hoses, etc. that may be binding.
Remove the front cab bushing from the frame
mount. Using a 1/2" drill, drill the threads out
of the bushing sleeve. This will allow the new
bolt to slide through the sleeve. Replace the
bushing on the frame mount. Place the
spacers on the cab bushings. Install the new
mounting bolts with a 7/16" washer in the
following manner: 12mm x 180mm at the front
mount, 12mm x 140mm in the front floorboard,
12mm x 140mm behind the front seat, 12mm x
200mm at the rear of the cab on super cab
models.
19. Repeat step #18 for the driver's side of the
cab.
20. Refer to the measurements recorded
earlier and align the cab to the bed. Remove
cab-mounting bolts, one at a time, apply
Loctite®, reinstall bolt and tighten to vehicle
manufacturer torque specifications
21. Loosen, but do not remove all eight bedmounting bolts (six on short bed models).
22. Remove the bed mounting bolts from the
passenger side of the bed only. Using a
hydraulic jack and a wooden block, slowly lift
the bed high enough to place a spacer block
between the bed and the frame. If the vehicle
is equipped with 14mm bed bolts, remove the
bed-bolt nut-clips from the frame. Once all
clips have been removed, place the lift blocks
on the frame under the bed mounting pads.
The small block goes on the mounting pad at
the rear of the bed. Install the 12mm x 200mm
bolts with ½” washers at the front of the bed
the 12mm x 160mm bolts with ½” washers in
front of and behind the rear axle, and the
12mm x 180mm bolts with ½” washers at the
rear of the bed. Do not tighten at this time.
Place bed support blocks on the frame under
the cross supports of the bed (there are four
on long bed models, and two on short bed
models) and secure with a 5/16" x 1" bolt, a
5/16" washer, and Loctite.
23. Repeat step #22 for the driver's side of the
bed. Refer to the measurements recorded
earlier and align the bed to the cab. Remove
bed-mounting bolts, one at a time,( If the bedbolt frame-clips were removed, install the
supplied ½” washers and 12mm nuts on the
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