Tuff Country 24821 User Manual

INSTALLATION MANUAL

1997 FORD F250

4” SUSPENSION SYSTEM

PART # 24821

020303rev.01

PART NUMBER : 24821
1997 FORD F250
4” SUSPENSION SYSTEM

Part # Description Qty.

F4250-05 Rear Twin “I” Beam Axle Pivot
Drop Bracket 1
F4250-06 Front Twin “I” Beam Axle Pivot
Drop Bracket 1
F405 Front Sway Bar Drop Bracket 2
BL403 4” Rear Lifted Blocks 2
TCI-R22 Rear Add-A-Leafs 2
5U-3814R 5/8” x 3 5/8” x 14 1/2” Round U-Bolts 4
5U-2510S 9/16” x 3” x 10 1/2” Square U-bolts 4
S10008 Front Spring Eye Shackle Sleeve 2
MO2070 Front Spring Eye Shackle Bushings 4
916NW Hardware Bag 1
58NW Hardware Bag 1
CB38 Hardware Bag 1
CAM1NB Hardware Bag 1
F4250NB Hardware Bag 1
F2507NB Hardware Bag 1
LUBE Poly Lube Pack 4
24821INST Instruction Sheet 1

Special Note: This box kit includes the rear lifted
blocks, rear add-a-leafs, front and rear U-bolts, front
and rear twin “I” beam axle pivot drop brackets, front
sway bar drop brackets and necessary hardware.
Tuff Country EZ-Ride Suspension offers two styles
of front springs, a spring used in conjunction with a
gas engine and a spring used in conjunction with a
diesel engine. If you have not already ordered your
front springs, please contact Tuff Country or your
local Tuff Country dealer and order (2) 28480 (Gas
Engine) or (2) 28481 (Diesel Engine). Also, some
vehicles with a 460 engine, may need to install (2)
28481 springs due to the weight of the engine.

A new pitman arm is needed once the suspension
systems has been installed. The new pitman arm is
sold as a separate part number. If you have not
already ordered your new pitman arm, please
contact Tuff Country or your local Tuff Country
dealer and order (1) 70200

Congratulations on your selection to purchase a Tuff
Country EZ-Ride Suspension System. We at Tuff
Country are proud to offer a high quality product at
the industries most competitive pricing. Thank you
for your confidence in us, and our product.

Make sure to use locktite on all new and stock
hardware associated with this installation.

IMPORTANT CUSTOMER INFORMATION

Tuff Country EZ-Ride Suspension highly
recommends that a qualified and or certified
mechanic performs this installation.

If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware.

This vehicles reaction and handling characteristics
may differ from standard cars and/or trucks.
Modifications to improve and/or enhance off road
performance may raise the intended center of
gravity. Extreme caution must be utilized when
encountering driving conditions which may cause
vehicle imbalance or loss of control. DRIVE SAFELY!
Avoid abrupt maneuvers, such as sudden sharp
turns which could cause a roll over, resulting in
serious injury or death.

It is the customers responsibility to make sure that a
re-torque is performed on all hardware associated
with this suspension system after the first 100 miles
of installation. It is also the customers responsibility
to do a complete re-torque after every 3000 miles or
after every off road use. Also, after the original
installation, Tuff Country EZ-Ride Suspension also
recommends having the alignment check every 6
months to ensure proper tracking, proper wear on
tires and front end components. Tuff Country EZ­Ride Suspension take no responsibility for abuse,
improper installation or improper suspension
maintenance.

It is the customers/installers responsibility to read
and understand all steps before installation begins.
OEM manual should be used as a reference guide.

The Tuff Country EZ-Ride Suspension product safety
label that is included in your kit box must be
installed inside the cab in plain view of all
occupants.

It is the responsibility of the installers to make sure
that the rear view mirror hanger is hung from the
rear view mirror. The rear view mirror hanger has
instructions on proper post installation procedure.

It is the responsibility of the customer or the
mechanic to wear safety glasses at all times when
performing this installation.

LIMITED LIFETIME WARRENTY

Notice to all Tuff Country EZ-Ride Suspension
customers: It is your responsibility to keep your
original sales receipt! If failure should occur on any
Tuff Country EZ-Ride Suspension component, your
original sales receipt must accompany the warranted
unit to receive warranty. Warranty will be void if the
customer can not provide the original sales receipt.
Do not install a body lift in conjunction with a
suspension system. If a body lift is used in
conjunction with any Tuff Country EZ-Ride
Suspension product, your Tuff Country EZ-Ride
Suspension WARRANTY WILL BE VOID.
Country Inc. (“Tuff Country” ) suspension products
are warranted to be free from defects in material and
workmanship for life if purchased, installed and
maintained on a non-commercial vehicle; otherwise,
for a period of twelve (12) months, from the date of
purchase and installation on a commercial vehicle,
or twelve thousand (12,000) miles (which ever occurs
first). Tuff Country does not warrant or make any
representations concerning Tuff Country Products
when not installed and used strictly in accordance
with the manufacturer’s instructions for such
installation and operation and accordance with good
installation and maintenance practices of the
automotive industry. This warranty does not apply to
the cosmetic finish of Tuff Country products nor to
Tuff Country products which have been altered,
improperly installed, maintained, used or repaired, or
damaged by accident, negligence, misuse or racing.
(“Racing is used in its broadest sense, and, for
example, without regards to formalities in relation to
prizes, competition, etc.) This warranty is void if the
product is removed from the original vehicle and re­installed on that or any other vehicle. This warranty
is exclusive and is in lieu of any implied warranty of
merchantability, fitness for a particular purpose or
other warranty of quality, whether express or
implied, except the warranty of title. All implied
warranties are limited to the duration of this
warranty. The remedies set forth in this warranty are
exclusive. This warranty excludes all labor charges
or other incidental of consequential damages. Any
part or product returned for warranty claim must be
returned through the dealer of the distributor from
whom it was purchased. Tuff Country reserves the
right to examine all parts returned to it for warranty
claim to determine whether or not any such part has
failed because of defect in material or workmanship.
The obligation of Tuff Country under this warranty
shall be limited to repairing, replacing or crediting, at
its option, any part or product found to be so
defective. Regardless of whether any part is
repaired, replaced or credited under this warranty,
shipping and/or transportation charges on the return
of such product must be prepaid by the customer
under this warranty.

Tuff

Hardware Bag 916NW Includes:

Disription Quanity

9/16” U-Bolt High Nuts 8
9/16” U-bolt Harden Washers 8

Hardware Bag 58NW Includes:

Disription Quanity

5/8” U-Bolt High Nuts 8
5/8” U-bolt Harden Washers 8

Hardware Bag CB38 Includes:

Disription Quanity

3/8” x 6” Rear Centering Bolts 2
3/8” Fine Nuts 2

Hardware Bag F4250NB Includes:

Disription Quanity

7/16” x 1 1/2” Bolts 4
7/16” Unitorque Nuts 4
7/16” Flat Washers 8

Hardware Bag F2507NB Includes:

Disription Quanity

9/16” x 1 1/2” Bolts 10
9/16” Unitorque Nuts 10
9/16” Flat Washers 20

Hardware Bag CAM1NB Includes:

Disription Quanity

9/16” x 3 1/2” Cam Bolts 2
Cam Washers 4
9/16” Unitorque Nuts 2

Special Note: Before installation begins, it is the
customers/installers responsibility to make sure that
all parts are on hand. If any parts are missing, please
feel free to call one of our customer service
representative @ [phone].

Drilling Required: Due to the inconsistencies and
different variations in Ford’s mounting location for
the stock twin “I” beam axle pivot drop brackets, the
new twin “I” beam axle pivot drop brackets will
require (3) 9/16” holes drilled into each bracket prior
to installation.

Special Note: Tuff Country EZ-Ride Suspension
recommends running a 35” x 12.50” tire for
maximum tire clearance. Note: This tire size in not
100% accurate due to variations in wheel width,
wheel off set, tire diameters and driving habits.

Please Follow Instruction Carefully

Before installation begins, drive and check to make
sure there are no uncommon sounds and or frame
damage. Also at this time measure from the center of
the hub to the bottom of the fender well and record
measurements below.

Pre Installation Measurements:

Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________

At the end of the installation take the same
measurements and compare to the pre-installation
measurements.

Post Installation Measurements:

Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________

Please follow instructions carefully:

Front End Installation:

1. To begin installation, block the rear tires of the vehicle
so that the vehicle is stable and can’t roll backwards.
Safely lift the front of the vehicle and support the frame
with jack stands. Place a jack stand on both the driver
and passenger side. Next, remove the wheels and tires
from both sides.

2. Working on the driver side, remove the stock shock
from the stock upper and lower mounting point and save
the stock hardware for later re-installation. The stock
shock may be discarded.

Special Note: New longer
front shocks are needed after the completion of the
installation. If you have not already ordered your
front shocks, please contact Tuff Country or your
local Tuff Country dealer and order part # 61261.

Repeat procedure on the passenger side.

3. Working on the driver side, remove the stock castle
nut and cotter pin that connects the stock pitman arm to
the stock drag link. Save the stock castle nut and cotter
pin for later re-installation. Carefully break the taper on
the stock drag link and stock pitman.

Special Note:
Take special care not to rip or tear the dust boot on
the stock drag link. Next, remove the stock nut and

washer that connect the stock pitman arm to the stock
sector shaft. Save the stock nut and washer for later re­installation. Using a pitman arm puller, carefully remove
the stock pitman arm from the sector shaft on the stock
steering box. A new pitman arm is needed, the stock
pitman arm may be discarded. Special Note: The new

pitman arm is sold as a separate part number. If you
have not already ordered your new pitman arm,
please contact Tuff Country or your local Tuff
Country dealer and order (1) 70200.

See Illustration # 1

Special Note: If the vehicle that you are working on
is not equipped with a stock front sway bar, please
skip to step # 5

4. Working on the driver side, disconnect the stock sway
bar from the stock frame mount and save the stock
hardware for later re-installation. Repeat procedure on
the passenger side.

5. Place a pair of hydraulic floor jacks under the front
twin “I” beam axle.

6. Working on the driver 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 U­bolt plates a side for later re-installation.

7. Working on the stock front twin “I” beam axle pivot
drop bracket, remove the stock bolt that connects the
stock front twin “I” beam axle to the stock front twin “I”
beam axle pivot drop bracket and discard the stock
hardware.

8. Carefully lower down on the hydraulic floor jacks that
are supporting the front 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
front twin “I” beam axle pivot drop bracket to be installed
into the stock location.

9. Next, remove the stock front twin “I” beam axle pivot
drop bracket from the stock location and discard the
stock front twin “I” beam axle pivot drop bracket and
hardware.

10. Working on the driver 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.

11. Locate (2) MO2070 front spring eye shackle
bushings, (1) S10008 front spring eye shackle sleeve
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.

12. Locate (1) new front leaf springs. 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 re­installation.

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, (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 front 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 front twin “I” beam axle pivot drop bracket.

Secure the new front 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

sure to use thread locker or locktite on these bolts.

120 ft lbs. Make

See Illustration # 4

16. Carefully raise up on 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 U­bolts, (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 U­bolts 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
rear twin “I” beam axle pivot drop bracket to be installed
into the stock location.

24. 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.