Rough Country 481.20 User Manual

92148100

00-05 Ford Excursion 5” Suspension Kit

Thank you for choosing Rough Country for your suspension needs.
Rough Country recommends a certified technician installs this system. In addition to these instructions, professional

knowledge of disassemble/reassembly procedures as well as post installation checks must be known. Attempts to install
this system without this knowledge and expertise may jeopardize the integrity and/or operating safety of the vehicle.

Please read all the instructions before beginning the installation. Check the kit hardware against the parts list. Be sure
you have all the needed parts and understand where they go. Also please review the tools needed list and make sure
you have needed tools.

PRODUCT USE INFORMATION

As a general rule, the taller a vehicle is the easier it will roll. We strongly recommend, because of rollover possibility, that
the vehicle be equipped with a functional roll-bar and cage system. Seat belts and shoulder
harnesses should be worn at all times. Avoid situations where a side rollover may occur.

Braking performance and capabilities are decreased when significantly larger/heaver tires and wheels are used. Take
this into consideration while driving. Also, speedometer recalibration is necessary when larger tires are installed.

Do not add, alter, or fabricate any factory or after-market parts which increase vehicle height over the intended height of
the Rough Country product purchased. Mixing component brands, lifts, and/or combining body lift with suspension lifts
voids all warranties. Rough Country makes no claims regarding lifting devices and excludes any and all implied claims.
We will not be responsible for any product that is altered.

This 5” suspension system was developed for 35”x12.50x17” tire on an after market wheel with 4.5” of back spacing. If
using any other combination of tire/wheel, please check tire / wheel fitment.

NOTICE TO DEALER AND VECHICLE OWNER

Any vehicle equipped with any Rough country product must have the “Warning to Driver” decal installed on the sun visor
or dash. The decal is to act as a constant reminder for whoever is operating the vehicle of its unique handling character­istics. INSTALLING DEALER—It is your responsibility to install the warning decal and to forward these installation in­structions on too the vehicle owner for review and to be kept in the vehicle for its service life.

KIT CONTENTS

2-Fr Leaf Springs (8057)
7582 Box Kit:
1-Track Rod
2-Sway Bar Drop Brackets
1481:
Pitman Arm
Rear Blocks
4-Rr U-bolts
4-Fr U-bolts
1481Box2:
2-Fr Hydro Shock
2-Rr Hydro Shock

TOOLS NEEDED:
13mm Socket 22mm Socket
13mm Wrench 24mm Socket
15mm Socket 30mm Socket
15mm Wrench 32mm Wrench
16mm Wrench 34mm Socket
18mm Wrench 4 Ton Floor Jack
18mm Socket 2 Jack Stands
19mm Wrench
19mm Socket
21mm Wrench
7/8 Deep Well Socket

FRONT INSTALLATION INSTRUCTIONS

1. The tools needed , and parts for this installation are on the front cover. Make sure you have all of the proper tools
and an understanding of these directions before you proceed.

2. Place the truck on a clean level surface and set the parking brake. Chock the rear wheels and using a floor jack
raise the front of the truck and support the frame rails with approved jack stands. NEVER WORK UNDER AN UN-
SUPPORTED VEHICLE, Using a 7/8 deep well socket remove the front wheels.

3. Using a 18mm and 13mm socket, remove the front bumper. Using a clip tool or a large flat head screwdriv er, discon­nect the rubber valance panel from underneath the front bumper. Disconnect the block heater plug from the bumpe r.
(if equipped).

4. Using a 21mm socket, remove front crash bar. ( if equipped).

5. Using a 30mm socket, unbolt the track rod from the frame mount and let the bar hang. Using a 15mm wrench, unbolt
the track rod bracket from the frame

6. Using a 18mm socket and 15mm wrench, remove the sway bar links from the sway bar, and the frame mounts on
the frame rail.

7. Using a 18mm socket and wrench, remove the factory shock absorbers.

8. Leaf spring removal is done one side at a time starting with the drivers side. Position the floor jack under the driver
side knuckle. Slightly load the jack so that it supports, not raises the axle. Make sure the frame rails are still secure
on the frame stands.

9. Using a 22mm socket, remove the leaf spring u-bolts that secure the spring to the axle. Now remove the spring
plate/ shock plate and the bottom u-bolt cradle. See PHOTO 1

10. Using a 21mm and a 24mm wrench, remove the spring shackle bolt and swing the shackle back away from the
spring. See PHOTO 2

Photo 1

11. Using a 15mm socket remove the front spring hanger to allow the spring bolt to come out.

12. Using a 24mm socket and wrench, unbolt the spring’s front eye from the hanger, then lower the jack enough to allow
the spring to be removed. See PHOTO 3.

13. Install the new springs, with the double wrap end towards the front of the truck. Insert the spring from the front of the
vehicle and position the front spring eye in the spring hanger and install the factory bolt from the inside facing out­ward. Install the factory nut, do not tighten at this time. Using a 15mm socket re-install the spring hanger. See

PHOTO 4.

Photo 2

Photo 3 Photo 4