»Zone Offroad Products • 491 W. Garfield Ave., Coldwater, MI 49036 • 888.998.ZONE • www.zoneoffroad.com

Difficulty Leveleasy 1 2 3 4 5 difficult

Estimatedinstallation:6-8hours

Special Tools Required

Tire/Wheel FitmentTire:35x12.50

Wheel:16x8,4.5"BS

Read and understand all instructions and warnings prior to installation of product and operation of vehicle.ZoneOffroadProductsrecommendsthissystembeinstalledbyaprofessionaltechnician.Inadditiontotheseinstructions,profession-alknowledgeofdisassembly/reassemblyproceduresandpostinstallationchecksmustbeknown.Minimumtoolrequirementsincludethefollowing:Assortedmetricandstandardwrenches,hammer,hydraulicfloorjackandasetofjackstands.Seethe"SpecialToolsRequired"sectionforadditionaltoolsneededtocompletethisinstallationproperlyandsafely.

»Product Safety Warning

CertainZoneSuspensionProductsareintendedtoimproveoff-roadperformance.Modifyingyourvehicleforoff-roadusemayresultinthevehiclehandlingdifferentlythanafactoryequippedvehicle.Extremecaremustbeusedtopreventlossofcontrolorvehiclerollover.Failuretodriveyourmodifiedvehiclesafelymayresultinseriousinjuryordeath.ZoneOffroadProductsdoesnotrecom-mendthecombineduseofsuspensionlifts,bodylifts,orotherliftingdevices.

Youshouldneveroperateyourmodifiedvehicleundertheinfluenceofalcoholordrugs.Alwaysdriveyourmodifiedvehicleatre-ducedspeedstoensureyourabilitytocontrolyourvehicleunderalldrivingconditions.Alwayswearyourseatbelt.

»technical SuPPort

Live ChatprovidesinstantcommunicationwithZonetechsupport.Anyonecanaccesslivechatthroughalinkonwww.zoneoffroad.com.

www.zoneoffroad.commayhaveadditionalinformationaboutthisproductincludingthelat-estinstructions,videos,photos,etc.

Sendane-mailtotech@zoneoffroad.comdetailingyourissueforaquickresponse.

888.998.ZONE CalltospeakdirectlywithZonetechsupport.

»Pre-inStallation noteS

1. Specialliteraturerequired:OEServiceManualformodel/yearofvehicle.Refertomanualforproperdisassembly/reassemblyproceduresofOEandrelatedcomponents.

2. Adheretorecommendationswhenreplacementfasteners,retainersandkeepersarecalledoutintheOEmanual.

3. Largerrimandtirecombinationsmayincreaseleverageonsuspension,steering,andrelatedcomponents.Whenselectingcombi-nationslargerthanOE,considertheadditionalstressyoucouldbeinducingontheOEandrelatedcomponents.

4. Postsuspensionsystemvehiclesmayexperiencedrivelinevibrations.Anglesmayrequiretuning,slideronshaftmayrequirereplacement,shaftsmayneedtobelengthenedortrued,andU-jointsmayneedtobereplaced.

5. SecureandproperlyblockvehiclepriortoinstallationofZoneOffroadProducts.Alwayswearsafetyglasseswhenusingpowertools.

6. Ifinstallationistobeperformedwithoutahoist,ZoneOffroadProductsrecommendsrearalterationsfirst.

7. Duetopayloadoptionsandinitialrideheightvariances,theamountofliftisabasefigure.Finalrideheightdimensionsmayvaryinaccordancetooriginalvehicleattitude.Alwaysmeasuretheattitudepriortobeginninginstallation.

rec051815

#F2622 Installation Instructions1997-2003 Ford F-150 4WD6" Suspension System

F2622Installation-pg.2

Kit ContentsQty Part

1 SteeringKnuckle(Drv)1 SteeringKnuckle(Pass)1 FrontCrossmember1 RearCrossmember1 534BoltPack-LowerControlArmss

4 5/8"-11x5-1/2"boltgrade8

4 5/8"-11prevailingtorquenut

8 5/8"SAEflatwasher

1 535BoltPack-MainHardwarePack3 12mm-1.75x100mmboltgrade10.9

3 12mm-1.75prevailingtorquenut

12 12mm-1.75x45mmboltgrade10.9

18 12mmflatwasher

5 1/2"-13x1-1/4"boltgrade8

1 1/2"-13prevailingtorquenut

1 1/2"USSflatwasher

5 1/2"SAEflatwasher

2 1/4"-20x3/4"boltgrade5

2 1/4"SAEflatwasher

2 1/4"splitlockwashe

2 wireclip

2 BumpStop1 BoltPack580-BumpStops

2 7/16"-14x1-1/4"boltgrade5

2 7/16"-14prevailingtorquenut

4 3/8"USSflatwasher

2 3/8"-16x1-1/4"selftappingbolt

2 BrakeLineDropBracket1 BoltPack704-BrakeLineDrop

2 1/4"-20prevailingtorquenut

2 1/4"SAEflatwasher

2 CVSpacer1 DifferentialDropBracket1 DiffSkidPlate

Qty Part

2 TorsionBarDropBracket1 BoltPack536-TorsionBarDrop

4 7/16"-14prevailingtorquenut

4 7/16"-14x1-1/4"boltgrade8c

8 7/16"SAEflatwasher

2 1/2"-13x1-1/4"boltgrade8

2 1/2"-13prevailingtorquenut

4 1/2"SAEflatwasher

4 StemWasher4 StemBushing2 SwayBarLink2 SwayBarLinkBracket2 SwayBarLinkBushing2 0.750x0.090x1.575Sleeve1 BoltPack569-SwayBarLinks

2 3/8"-16nylocknut

2 7/16"-14nylocknutc

2 9/16"-12x2-3/4"boltgrade5c

4 9/16"SAEwasher

2 9/16"-12prevailingtorquenut

2 5/8"-11x1-3/4"boltgrade5

4 5/8"SAEwasher

2 5/8"-11nylocknut

1 RearBrakeLineDropBracket1 BoltPackRearBrakeLineDrop

1 3/8x1Bolt

2 3/8USSwasher

1 3/8Nu

2 3"RearBlock2 Add-a-leaf4 9/16"x3-1/4"x14"RoundU-bolt8 9/16"HighNut8 9/16"SAEWasher2 3/8"x4.5"Centerpinw/nut4 SpringClamps

*Important*Verifyyouhaveallofthekitcomponentsbeforebeginninginstallation.

F2622Installation-pg.3

INSTALLATION INSTRUCTIONS

»front inStallation

1. Parkthevehicleonaclean,flatsurfaceandblocktherearwheelsforsafety.

2. Raisethefrontofthevehicleandsupportwithjackstandsateachframerailbehindthelowercontrolarms.

3. Removethefrontwheels.

4. Measurethelengthofthetorsionbaradjusterbolts(topoftheadjusterboltheadtoadjuster)

5. Removetheadjusterbolts,keepdriver'sandpasssideboltsseparate.

6. Markthetorsionbarsforlocationandposition.

7. Usethetorsionbarremovaltooltoremovethethreadedadjusterassembly.Releasethepressurefromtorsionbarwiththeunloadingtool.Caution: There is an extreme amount of energy stored in the torsion bars. Use extreme care with the proper tools to avoid serious injury or death.

8. Slidethetorsionbarsforwardtoallowthekeystoberemoved.Itmaybeneces-sarytouseanairhammertogetthebarstobreakfree.

9. Removethesixbolts(3perside)mountingthetorsionbarcrossmembertotheframe.Figure 1Removethecrossmemberfromthevehicle.Savecrossmemberandhardware.

Figure 1

Important—measure before starting!Measurefromtheexposedlengthofthetorsionbaradjustersbeforestarting:

Drv_________Pass__________

Important—measure before starting!Measurefromthecenterofthewheeluptothebottomedgeofthewheelopening

LF__________RF__________

LR__________RR__________

F2622Installation-pg.4

10. Pullthetorsionbarsrearwardfromthelowercontrolarmsandoutoftheve-hicle.

11. Removetheswaybarlinksfromtheswaybarandcontrolarm.Thesewillnotbereused.Figure 2

Figure 2

12. Disconnectthefactoryshocksfromtheframeandlowercontrolarms.Savethelowerhardwareanddiscardtheupperhardwareandshocks.

13. Disconnectthetierodendfromthesteeringknuckle.Figure 3Removethenut.Strikethesteeringknucklewithahammernearthetierodendtoreleasethetaper.Removethetierodendandsavethenut.

Figure 3

F2622Installation-pg.5

14. LocatetheABSwireconnectorattheinnerfenderanddisconnect.Figure 4 Dis-connecttheABSwirefromtheframeandcontrolarm.

Figure 4

15. RemovethefrontbrakelinebracketfromthesteeringknuckleandframeFigure 5.Savehardware.

Figure 5

16. RemovethebrakecaliperanchorbracketboltsandremovethecaliperfromtheknuckleFigure 6.Hangthecaliperoutoftheway.Donotletthecaliperhangbythebrakehoses.

F2622Installation-pg.6

Figure 6

17. Removethebrakerotorsandsave.Removethebrakedustshield.

18. Removethefrontaxleshaftcotterpin,axlenutretainerandaxlenut.Figure 7 Savehardware.Striketheendoftheaxleshaftwitharubbermallettobreakitfreefromthehub.

Figure 7

19. Loosenbutdonotremovethefour(2perarm)lowercontrolarmbolts.

20. RemovetheupperandlowerballjointcotterpinsandnutsFigure 3andreinstallafewturns. Striketheknuckleneartheupperandlowerballjointstodislodgethejointsfromtheknuckle.

21. Removetheupperballjointnut.Swingtheknuckle/lowercontrolarmdowntoremovetheCVshaftfromthehub.Retainballjointnutandstrutbolt.

22. Removethelowerballjointnutandremovetheknucklefromthevehicle.Savehardware.

23. Removethelowercontrolarmmountingboltsandremovethelowercontrolarmfromthevehicle.Savehardware.

24. RemovethesixboltmountingtheCVaxletothedifferential.Figure 8Removeaxle.

F2622Installation-pg.7

Figure 8

25. Loosebutdonotremovethetwodriver'ssideFigure 9A,Bandonepassenger'sside Figure 9C differentialmountingbolts.

Figure 9A

Figure 9B

F2622Installation-pg.8

Figure 9C

26. Locateandinstallthenewrearcrossmemberintothestockrearlowercontrolarmpockets.Looselyfastenwiththefactorylowercontrolarmboltsandnuts.Runboltsfromfronttorear.Figure 10

Figure 10

27. Locatethetwonewbumpstopextensions(theyareidentical).Attachthebumpstoptothebacksideofthemountingtabcomingofftherearcrossmember.Wheninstalledproperly,theholesinthebumpstopendsshouldbetowardtherearofthevehicle.Figure 11AFastenthebumpstoptothecrossmemberwitha7/16"x1-1/4"bolt,nutandwashers.Snughardwaresothebumpstoptabisflushagainstthecrossmembertabbutcanstillmoveforfinaladjustment.

Step 27 NoteBumpStophardwareislocatedinBoltPack#580

F2622Installation-pg.9

Figure 11A

28. Swingthebumpstopextensionupsoitisflushagainsttheoriginalbumpstopontheframe.Marktheholetobedrilled.Drilla5/16"holeatthemarkandfastenthebumpstopwitha3/8"x1-1/4"self-tappingbolt.Figure 11BTorquethe3/8"boltto20ft-lbsand7/16"hardwareto45ft-lbs.

Figure 11B

29. Locateandinstallthenewfrontcrossmemberintothestockfrontlowercontrolarmpockets.Looselyfastenwiththefactorylowercontrolarmbolts,nutsandwashers.

30. Removethefourboltsmountingthefactoryreardifferentialcrossmembertotheframerails.Figure 10Removethedriver'ssidereardifferentialboltandremovethecrossmemberfromthevehicle.

31. Withthehelpofanassistant,removeremainingtwodifferentialboltsandlowerthedifferentialintothenewfrontandrearcrossmembers.Looselyfastenthedifferentialtothecrossmemberswith12mmx100mmbolts,nutsandwashers.

32. Locatethenewpassenger'ssidedifferentialbracketandinstallinthefactoryframemountwiththeoriginalhardware.Figure 12Leaveloose.Wheninstalledthe"wing"ofthebracketwillpointtowardtherearofthevehicle.

Step 31 NoteDifferentialhardwareislocatedinBoltPack#535

F2622Installation-pg.10

Figure 12

33. Attachthepassenger'ssideofthedifferentialtothenewbracketwitha12mmx100mbolt,nutandwashers.Leaveloose.

34. Attachthe"wing"ofthepassenger'ssidedifferentialbrackettothebackofthecontrolarmpocket.Thereisanexistingholeinthepocketthatwilllineupwiththemountholeinthe"wing".Fastenwith1/2"x1-1/4"bolt,nut,1/2"SAE(small)washerand1/2"USS(large)washer.Figure 12UsethelargeUSSwasherontheoutsidesurfaceofthecontrolarmpocket.

35. Withallofthedifferentialhardwareinstalled,gobackandtorquethe3differen-tialmountboltsandthe1/2"passenger'ssidebracketboltto70ft-lbs.

36. Installthelowercontrolarmsinthenewcrossmembersandfastenwiththeprovided5/8"x5-1/2"bolts,nutsandwashers..Runthefrontboltsfromfronttorearandleaveloose.

37. Installtheprovideddifferentialskidplatetothefrontandrearcrossmemberswith½”x1-1/4”boltsand½”SAEwashersintothethreadedholesinthecrossmembersFigure 13.Leavehardwareloose.

Figure 13

38. Torquethefourfactorycontrolarmpocketboltsto125ft-lbs.Torquethe1/2"differentialskidplateboltsto65ft-lbs.

39. Locatethenewprovidedsteeringknucklesandthecorrespondingfactoryknuckleassemblies.Removethethreeboltsmountingthehubbearingassembly

Step 34 NoteDifferentialbrackethardwareislocatedinBoltPack#535

Step 36 NoteLowercontrolarmhardwareislocatedinBoltPack#534

Step 37 NoteDifferentialskidplatehardwareislocatedinBoltPack#535

F2622Installation-pg.11

tothefactoryknuckleandinstallontheappropriateZoneknuckle.UseLoctiteonthefactoryboltsandtorqueto80ft-lbs.BesuretheABSlineisrunningoutthetopofthehubintotherecessintheknuckle.Figure 14

Figure 14

40. Removethefactoryhubsealfromthebackofthefactorysteeringknuckle.In-specttheseal.Ifitisgoodconditionitcanbereusedinthenewknuckleassem-bly.IfareplacementsealisneededtheycanbepurchasedataForddealership.

41. Installthenewknuckleassemblyonthelowercontrolarmballjointandlooselyfastenwiththeoriginalnut.InstalltheCVshaftinthehub,swingthewholeassemblyupandattachtheknuckletotheupperballjointwiththeoriginalnut.Leaveallhardwareloose.

42. Withtheknuckleinstalled,torquetheupperballjointnutto65ft-lbsandthelowerballjointnutto95ft-lbs.Installthecotterpins.Donotloosethenutstoalignthecotterpinholes,onlytighten.

43. EnsuretheCVshaftisseatedproperlyinthehub,installtheCVshaftnutandtorqueto190ft-lbs.InstalltheCVshaftnutretainerandcotterpin.

44. LocateandinstalltheprovidedCVshaftspacersbetweenthefactoryCVaxleshaftandthedifferentialoutputflanges.FastentheCVshaftandspacerstothedifferentialwith12mmx45mmboltsand12mmflatwashers.Figure 15UseLoctiteontheboltthreadsandtorqueto60ft-lbsinacrossingpattern.

Figure 15

Step 44 NoteCVspacerhardwareislocatedinBoltPack#535

F2622Installation-pg.12

45. RoutetheABSwireupthefrontsideoftheknuckle,throughthecontrolarmanduptotheconnectorattheinnerfender.ReconnecttheABSwireconnector.SecuretheABSwiretothebackoftheknucklewiththeprovidedwireclip,1/4"x3/4"bolt,lockwasherandflatwasher.Tightenboltto8-10ft-lbs.UsesuppliedziptiestosecuretheremainingportionoftheABSwireasneeded.

46. Installthebrakerotoronthehub.Installthebrakecaliperonthesteeringknucklewiththefactoryanchorbolts.UseLoctiteontheboltsandtorqueto125ft-lbs.

47. Attachtheprovidedbrakelinerelocationbrackettotheoriginalbrakelinemountingholeontheframe.Looselyfastenwiththefactorybolts.

48. Carefullyreformthebrakehardlinestoallowfromthebrakelinetoattachtotherelocationbracket.Itmaybenecessarytoreformthehardlineatthecaliperslightlyaswellasthefactorybracket.Fastentotherelocationbracketwitha1/4"nutandwasher.Figure 16Tightenallhardwaresecurely.

Figure 16

49. Breaklooseandremovetheoutertierodendsfromtheadjustingsleeves.Figure 17Threadthejamnutupthetierodendabout1".Markandcut3/8"offofthetierodendthreads(endthatmateswiththeadjustingsleeve).Threadthejamnutofftocleanthethreads.

Step 45 NoteABSwirehardwareislocatedinBoltPack#535

Step 48 NoteBrakelinebrackethardwareislocatedinBoltPack#704

F2622Installation-pg.13

Figure 17

50. Markandcut3/8"offoftheouterendofthetierodendadjustingsleeve.Thiswillmatchtheamountremovedfromthetierodend.Reassemblethetierodend,jamnutandadjustingsleeve.Leavelooseforadjustmentlater.

51. Attachthetierodendtothenewsteeringknuckleusingthefactoryhardware.Torquethetierodnutto60ft-lbsandinstallthecotterpin.Donotloosethenuttoalignthecotterpinhole,onlytighten.

F2622Installation-pg.14

52. Installthenewprovidedshockswiththeincludedbushings,sleevesandup-perhardware.Usethefactorylowerhardware.Torquelowerboltto60ft-lbs.Tightenupperhardwareuntilthebushingsbegintoswell.

53. Locatetheprovidedswaybarlinkbrackets.Mountthebracketstotheoriginalswaybarlinkholeinthelowercontrolarmwiththeprovided5/8"hardware.Positionthebracketsotheclevistabsoffsettowardthecenterofthevehicleandthemountingholesareparalleltothelowercontrolarmmountingbolts.Torquehardwareto100ft-lbs.

54. Lightlylubricateandinstallthenewbushingsandsteelsleevesintotheeyeofthenewswaybarlinks.Installthelinksinthenewbracketatthelowercontrolarmandfastenwiththeprovided9/16"x2-3/4"bolts,nutandwashers.Torquehardwareto90ft-lbs.

55. Installaprovidedstemwasherthenastembushingonthetopendsoftheswaybarlinks.Alignthelinkswiththeswaybarholesandslidetheswaybaruntoboththelinks.Installasecondstembushingandthenawasherontheswaybarlinkends.Fastentheassemblieswiththeprovided7/16"nylocknuts.Tightennutsjustuntilthebushingsbegintoswell.Figure 18

Figure 18

56. Installthetorsionbarsintotheappropriatelowercontrolarms.Slidethemfor-wardapproximately12".

57. Locatethetwotorsionbardropbrackets.Looselyinstalltotheframerailsintheoriginaltorsionbarcrossmemberholes.Fastenwith7/16"x1-1/4"bolts,nutsandwashersintheouterholesand1/2"x1-1/4"bolts,nutsandwasherinthecenterholes.Figure 19A

Step 53-55 NoteSwaybarlinkhardwareislocatedinhardwarepack569.

Step 57 NoteTorsionbardrophardwareislo-catedinhardwarepack536.

F2622Installation-pg.15

Figure 19A

Figure 19B

58. Positionthetorsionbarcrossmemberinthetwonewdropbracketsandfastenwiththefactoryhardware.Besurethecrossmemberisorientedproperly.Withallthehardwareinstalled,torqueallhardwareto50ft-lbs(12boltstotal).Figure 19B

59. Reinstallthetorsionbarinthereverseofremoval.Setthetorsionbaradjusterboltheightasnotedatthebeginningoftheinstallation.

60. Installthewheelsandlowerthevehicletotheground.Torquelugnutsto100ft-lbsfor12mmnutsor150ft-lbsfor14mmnuts.

61. Bouncethefrontofthevehicletosettlethesuspension..Torquethelowercon-trolarmboltsto125ft-lbs.

62. Checkallhardwareforpropertorque.

63. Afullfrontendalignmentisrequired.Ifthevehicleisnotequippedwithuppercontrolarmeccentricboltstheyareavailableseparately-Zone#F8001.

»rear inStallation

1. Blockthefrontwheelsandraisetherearofthevehicle.Placejackstandsundertheframerailsaheadofthespringhangers.

Figure 19B NoteStandardcabshortboxmodelshaveanadditionalbracketthatmountsthecrossmembertotheframe.Inthiscase,mountthezonedropbracketstothefactorycross-memberbracket.

F2622Installation-pg.16

2. Removethewheels.

3. Removethebrakelineretainingclipfromthebrakelinemountonthedriver’ssideframerail.Figure 20

Figure 20

4. Pullthelinebackoutofthebracketsothatthehardlineisinthehole.Cutaslotintheeyeletofthebracketandbenditopenenoughtoremovethebrakeline.Bendthebracketbackshut.

5. Supporttheaxleunderthedifferentialwithahydraulicjackandremovethefac-toryshocks.

6. Removethepassenger’ssidespringU-bolts.Figure 21

Figure 21

7. Lowertheaxleandremovethefactoryliftblock.Takecarenottoover-extendthebrakelines.

8. Removethefactoryleafalignmentclamps.Figure 22

F2622Installation-pg.17

Figure 22

9. UseC-clampsoneithersideofthecenterpintoholdtherearspringfirmlytogether.RemovethecenterpinandreleasetheC-clampstoallowtheleafpacktospreadopen.

10. Installtheprovidedadd-a-leafintheleafpacksothattheleafaboveislongerandtheleafbelowisshorter.

11. UsetheC-clampstocompresstheleafpackinthesamemannerasbeforeandinstalltheprovidedcenterpin.Figure 23 Donotdrawtheleafpacktogetherwiththecenterpin.Torquethecenterpinto25ft-lbs.Cutoffanyexcesscenterpin.

Figure 23

12. Installthenewtaperedliftblockontheaxlespringperchsothattheshortendistowardthefront.Installthefactoryblockontopofthenewliftblock.Figure 24

F2622Installation-pg.18

Figure 24

13. Lifttheaxleuptothespringandalignthecenterpinintheblockhole.FastentheassemblywiththenewU-bolts,nutsandwashers.Snugbutdonotcomplete-lytorquetheU-bolts.

14. Repeattheprocedureonthedriver’ssideofthevehicle.

15. Withbothsidescomplete,installthenewshockswiththefactorymountinghardware.Checkforclearancebetwentheshockandaxle.Itmaybenecessarytoreindexthelowermountforadequateclearance.

16. InstalltheprovidedHendricks(factorystyle)clampsonthesprings.Installtwoperspring(oneinfrontofaxle,onebehind).Slipthematingpartstogetherandbendthetabsovertosecuretheclamps.

17. Installthenewbrakelinerelocationbracketinthefactorybracketwiththelargeslottedholepointingdown.Fastenwitha3/8”x1”bolt,nut,andwashersandtightensecurely.Figure 25

Figure 25

18. Installthebrakelineintheslottedholeandfastenwiththefactoryretainingclip.

19. Installthewheelsandlowerthevehicletotheground.Torquelugnutsto100ft-lbsfor12mmnutsor150ft-lbsfor14mmnuts.

F2622Installation-pg.19

20. Bouncetherearofthevehicletosettlethesuspension.

21. Torquetheu-boltsto100-120ft-lbs.

22. Checkallhardwareforpropertorque

23. Checkhardwareafter500miles.

24. Acompletefrontendalignmentisnecessary.

25. Adjustheadlights

Post-Installation Warnings1. Checkallfastenersforpropertorque.Checktoensureforadequateclearancebetweenallrotating,mobile,fixed,andheatedmembers.Verifyclearancebetweenexhaustandbrakelines,fuellines,fueltank,floorboardsandwiringharness.Checksteeringgearforclearance.Testandinspectbrakesystem.

2. Performsteeringsweeptoensurefrontbrakehoseshavead-equateslackanddonotcontactanyrotating,mobileorheatedmembers.Inspectrearbrakehosesatfullex-tensionforadequateslack.Failuretoperformhosecheck/replacementmayresultincomponentfailure.

3. Performheadlightcheckandadjustment.

4. Re-torqueallfastenersafter500miles.Alwaysinspectfastenersandcomponentsduringroutineservic-ing.