FORD F150 COIL SPRING LEVELING KIT INSTALLATION INSTRUCTIONS 2004-2009 2â€‌ KIT .2012-05-30  Kit

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  • FORD F150COIL SPRING LEVELING KITINSTALLATION INSTRUCTIONS 2004-2009 2 KIT# FL221PA

    WARNINGInstallation of a Performance Automotive Group level-ing kit may change the vehicles handling characteris-tics both on- and off-road. Extreme care must be takento prevent vehicle rollover or loss of control, whichcould result in serious injury or death. Avoid suddensharp turns or abrupt maneuvers and always makesure all vehicle occupants have their seat belts fas-tened.

    WARNINGBefore you install this kit, read and understand allinstructions, warnings, cautions, and notes in thisinstruction sheet and in the vehicle owners manual.

    CAUTIONProper installation of this kit requires knowledge of thefactory recommended procedures for removal andinstallation of original equipment components. We rec-ommend that the factory shop manual and any specialtools needed to service your vehicle be on hand duringthe installation. Installation of this kit without properknowledge of the factory recommended proceduresmay affect the performance of these components andthe safety of the vehicle. We strongly recommend thata certified mechanic familiar with the installation of sim-ilar components install this kit.

    WARNINGCompressed coil springs can expand quickly andcause serious personal injury. Use extreme cautionwhen working with compressed springs.

    WARNINGThis kit should only be installed on a vehicle that is ingood working condition. If the vehicle is suspected tohave been in a collision or misused, do not install thiskit. We do not recommend that any vehicle with a level-ing kit installed be involved in any extreme off-roadmaneuvers such as jumping. Failure to observe thiswarning may result in serious personal injury and/orsevere damage to your vehicle.

    WARNINGMany states and municipalities have laws restrictingbumper heights and vehicle lifts. Consult state andlocal laws to determine if the changes you intend tomake to the vehicle comply with the law. Before com-bining a leveling kit with a suspension lift, consult aninstallation professional to see how this will affect thevehicle.

    WARNINGThe installation of larger tires may reduce the effective-ness of the Braking System.

    WARNINGAlways wear eye protection when operating powertools.

    WARNINGBefore you install this kit, block the vehicle tires to pre-vent the vehicle from rolling.

    WARNINGAccidental deployment of the air bag can result in seri-ous personal injury or death. To avoid accidentaldeployment during installation of the kit, the Supple-mental Restraint System (SRS, or airbag) must remaindeactivated. Do not allow anyone near the airbag dur-ing installation. Refer to the factory service manual orowner's manual for the recommended procedure todisable the SRS. After you install the kit, reactivate theSRS before driving the vehicle.

    NOTEPerformance Automotive Group recommends usingthe Loctite supplied in the kit on the threads of all kitnuts and bolts unless specified otherwise in theseinstructions.

    1 04-09 Ford F150 Leveling Kit - Kit FL221

    3651 N. Highway 89 Chino Valley, AZ 86323(928) 636-7080 www.p-a-g.net

  • 2 04-09 Ford F150 Leveling Kit - Kit FL221

    Before starting installation.

    1. Carefully read all warnings and instructions com-pletely before beginning.

    2. Verify all parts have been received in this kit bychecking parts list at the end of this document.

    3. Only install this kit on the vehicle for which it isspecified. If anytime during the installation youencounter something different from what is outlinedin the instructions, call technical support at (928)636-7080

    4. Special tools needed:

    a. Coil spring compressor

    5. Park the vehicle on a clean, dry, flat, level surfaceand block the tires so the vehicle cannot roll in eitherdirection.

    6. Disconnect both battery cables.

    a. Disconnect negative cable first, then positivecable from battery.

    NOTEKit parts are prefaced by the word kit and appear inbold print.

    NOTEIf parts are missing from kit, be prepared to provide thefollowing information:

    1. Name of purchase location2. Bar Code on side of box3. Date above bar code4. Date inside box cover5. Inspector # from inside box cover

    WARNINGCompressed coil springs can expand quickly andcause serious personal injury. Use extreme cautionwhen working with compressed springs.

    Positive Cable

    Negative Cable

    Prepare to install kit

    A. Front of Vehicle.

    1. Front Wheels

    a. Remove two center wheel caps from two frontwheels.

    b. Loosen five lug nuts each from two front wheels.

    c. Position hydraulic jack under center of axleframe crossmember. Slowly lift front tires offground three to five inches.

    d. Position jack stands under frame just in front oftransmission support cross member. Lowerframe onto jack stands. Do not remove hydraulicjack and maintain some pressure on vehicle.

    e. Remove five lug nuts each from two frontwheels. Remove wheels from vehicle.

    Lug Nuts

    Center Wheel Cap

    Hydraulic Jack

    Jack Stands

  • 3 04-09 Ford F150 Leveling Kit - Kit FL221

    2. Strut Assembly

    a. Passenger side: Remove nut and sway bar linkfrom lower A-arm.

    b. Loosen but do not remove nut from steeringknuckle and upper ball joint. Do not remove nutcompletely.

    c. Using a hammer, hit steering knuckle at ball jointlocation causing steering knuckle to come loosefrom tie rod.

    d. Remove ball joint nut and tie steering knuckleaside with two kit zip ties.

    NOTEIt is only necessary to remove the sway bar link on thepassenger side.

    Nut

    Sway Bar Link

    Lower A-Arm

    Upper Ball Joint NutSteering Knuckle

    Hit Steering Knuckle Here

    Steering Knuckle

    Zip Tie

    e. Remove nut and bolt from strut assembly andlower A-arm.

    f. Remove three nuts and strut assembly from struttower frame mount.

    g. Remove strut assembly from vehicle.

    Lower Strut Assembly

    Nut and Bolt

    Strut Tower Frame Mount

    Nuts

  • 4 04-09 Ford F150 Leveling Kit - Kit FL221

    Install Kit1. Strut Assembly

    a. Mark bolt plate, spring, and strut assembly fromtop to bottom as shown.

    2. Coil Spring.

    a. Compress coil spring far enough to allow move-ment/twisting of bolt plate. Coil Spring Compres-sor is required to perform this step

    b. Remove nut, washer, bolt plate, bushing, andstrut from compressed coil spring.

    NOTEA coil spring compressor is required for the followingsteps. Note position of coil spring for installation laterin these instructions.

    WARNINGCompressed coil springs can expand quickly andcause serious personal injury. Use extreme cautionwhen working with compressed springs. DO NOTattempt to remove the spring from the strut assem-bly without a Coil Spring Compressor.

    Mark Along Strut As-sembly Strut Assembly

    Coil spring CompressorBolt Plate

    Bushing

    Bump Stop Strut

    c. With bolt plate on a hard flat surface, knock outthree bolts.

    3. Leveling Kit Spacers

    a. Position three kit bolts, (10mm x 40mm) in boltplate.

    b. Position kit urethane bushing on spring, align-ing spring end with recess in bushing. Markbushing using mark from spring as a guide.

    c. Install bolt plate, with three kit bolts, kit ure-thane bushing, and compressed spring onstrut. Align marks on all components.

    d. Install washer and nut on strut assembly.

    e. Remove spring compressors from spring allow-ing spring to seat in urethane bushing. Ensuremarks remain aligned on strut, spring, bushing,and bolt plate.

    Bolts

    Bolt Plate

    Bolts

    Bolt Plate

    Spring

    Bushing

    Strut

  • 5 04-09 Ford F150 Leveling Kit - Kit FL221

    f. Position kit aluminum spacer on bolt plate.

    g. Install strut assembly in upper strut tower framemount placing three kit lock washers and kitnuts on bolts.

    h. Using a floor jack and block of wood underlower A-arm, lift A-arm high enough to slidelower strut assembly into mounting bracket.Install factory bolt and nut in lower strut assym-bly.

    i. Remove zip tie strap while holding spindle.

    NOTEPerformance Automotive Group recommends usingLoctite supplied in the kit for all mounting hardware.

    Bolts

    Bushing

    Aluminum Spacer

    Bolt Plate

    Strut Tower Frame Mount

    Nuts and Lock Wash-ers

    Lower Strut Assembly

    Nut and Bolt

    j. Pull down on upper control arm sliding upper balljoint into steering knuckle. Install upper ball jointnut.

    k. Driver side: Perform installation of driver sideleveling kit following the same procedure as thepassenger side.

    l. Install sway bar link and nut in passenger sidelower A-arm.

    m. Check all mounting nuts and bolts for tightnessprior to next step.

    4. Front Wheels

    a. Install two front wheels with five lug nuts each.

    b. Using a hydraulic jack, slowly lift front of vehicleso that front tires are three to five inches off ofground. Remove jack stands from frame. Lowervehicle to ground and tighten ten lug nuts to 95ft.-lbs.

    NOTEKeeping pressure on lower A-arm, with the jack, willhelp in the installation of the ball joint.

    NOTEPerformance Automotive Group recommends usingLoctite supplied in the kit for all mounting hardware.

    Upper Ball Joint NutSteering Knuckle

    Upper Con-trol Arm

    Upper Ball Joint

    Lug Nuts

    Center Wheel Cap

  • 6 04-09 Ford F150 Leveling Kit - Kit FL221

    c. Install two center wheel caps on two frontwheels.

    5. Battery Cables

    a. Connect positive cable first, then negative cableto battery.

    Finish the kit.1. Check Vehicle.

    a. Check all mounting hardware to ensure it isproperly tightened.

    b. Start vehicle and check the steering in both