Owner`s manual | Ford 839 Automobile User Manual

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.
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
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.
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.
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
bed bolts) apply Loctite®, reinstall bolt and
tighten to vehicle manufacturer torque
specifications.
24. Connect the steering shaft to the steering
extension. It will only go on one way. Be sure
that the steering shaft and the steering wheel
have not turned from their original location.
Install the stock steering bolt in the steering
shaft. Be sure that the bolt engages the slot on
the steering extension.
25. Bolt the transfer-case-lever extension
bracket to the transfer-case-lever using two
5/16" x 1 1/4" bolts, four 5/16" SAE washers,
and two 5/16" nylock nuts, and reinstall the
shift lever to the transfer-case shift linkage
using the stock hardware. Check the shift
lever operation. Be sure that it engages
properly in all 4-wheel drive ranges. Install the
mounting bolt and tighten it securely. Mount
the inner shift boot to the floorboard. Tighten
the mounting screws securely. Mount the
outer shift boot to the inner housing. Tighten
the mounting screws securely. Check the shift
lever operation once more.
26. Mount the parking-brake cable relocatingbracket to the parking brake cable hole in the
cab mount using a 5/16" x 1" bolts, two 5/16"
USS washers and one 5/16" nylock nut. Route
the front parking brake cable through the
largest hole in the relocating bracket.
Reconnect the front cable to the rear cable at
the clip. Adjust the parking brake cable to
factory specifications. Set parking brake to
help prevent the vehicle from rolling.
27. Replace the carpeting to its original
location. Reinstall both kick panels and both
doorjamb scuff plates. On supercab models,
replace the rear seat at this time. Mount the
seat on the studs protruding from the
floorboard. Install the bolts into the floorboard.
Install the nuts onto the studs. Tighten all
mounting hardware securely.
28. The fan shroud needs to have two
notches cut into the bottom. The notch for the
drain is 4" high and 3 1/2" wide. The notch for
the lower radiator hose is 4" high and 7" wide.
The shroud should be placed on the radiator
to mark the locations for the notches. The
shroud should resemble the picture. Pace the
fan shroud over the fan, then reinstall the
radiator in the vehicle. Reconnect both
radiator hoses. Reinstall the top mounting
bolts and cover. Be sure that all hose clamps
and lines are tightened properly and that the
drain is completely closed. Refill the radiator. It
will need to be topped off when the vehicle is
started. Using the stock bolts mount the two
upper fan shroud lowering brackets to the
radiator where the fan shroud was originally
mounted. Do not tighten. Mount the fan shroud
to the studs protruding from the fan shroud
brackets. Install a 1/4" washer and nylock nut
on each stud. Do not tighten. Check the fan to
fan-shroud clearance. Be sure that the gap is
the same all the way around the fan. Tighten
the upper mounting hardware and secure the
bottom of the shroud to the core support using
the supplied zip ties. Replace the air intake
duct to the top of the throttle body. Reconnect
the duct to the air filter housing. Close the
clamp at the air filter housing. Tighten the
clamp at the throttle body. Reinstall the cover
over the throttle body. Tighten the mounting
bolts securely.
29. Lengthen the fuel filler hose. Mark the
hose just below the bend so the two pieces
can be properly aligned after the extension
has been installed. Cut the filler pipe into two
pieces. Remove all burs and shavings from
the pieces of the hose. Install the round fuel
filler extension between the two pieces of the
filler hose. Install a #28 hose clamp at each
end of the filler extension. Tighten both hose
clamps securely. Remove the fuel vent hose.
Install the longer vent hose provided with the
kit. Install a #10 hose clamp on the new vent
hose and tighten securely. Reinstall the fuel
filler assembly on the vehicle. Install the fuel
filler hose to the fuel tank using the stock hose
clamp. Install the vent hose to the fuel tank
using the remaining #10 hose clamp. Mount
the filler neck to the body using the stock
screws. Be sure that the filler hose engages
properly at all areas. Tighten all fuel filler
hardware securely. Reinstall the fuel filler cap.
30. Install the front bumper. The bumper will
need to be notched along the bottom edge to
clear the front spring hanger. Use the drawing
to properly locate the notches. The drawing
shows the passenger side cutout, the drivers
side cutouts are a mirror image of the drawing.
Using eight 7/16" x 1" bolt, eight 3/8” washers,
eight 7/16" washers and eight 7/16" nylock
nuts, bolt the relocation brackets to the
bumper. Do not tighten. Using four 7/16" x 1
1/2" bolt, eight 7/16" washers and four 7/16"
nylock nuts, bolt the bumper to the frame.
Adjust the bumper to body clearance using the
dimensions recorded earlier. Tighten all
bumper mounting hardware securely.
Reconnect any wires that were previously
disconnected from the front bumper. Replace
the rubber air flap to its original location.
31. Install the rear bumper. Mount the
relocating brackets to the rear bumper using
the stock hardware. Mount the bumper
relocating brackets to the frame using four
7/16" x 1 1/2" bolts, 7/16" washers and 7/16"
nylock nuts. Tighten all rear bumper mounting
hardware securely. Reconnect the license
plate lights to the rear bumper
32. Place the warning sticker on the vehicle
dash in plain sight of all vehicle occupants.
CAUTION
All fasteners should be retorqued after 500
miles and after off road use. All body lift
components should be visually inspected and
fasteners retorqued during routine vehicle
servicing.
33. Double-check the vehicle. Reinstall the air
bag fuse. Reconnect both battery cables. Be
sure to connect the positive cable first, then
the negative cable. Check all wires, hoses,
cables, etc. to be sure that there is ample
slack. Double check the fan to fan-shroud
clearance. Be sure that the fan cannot make
contact with the shroud. Check the radiator
hoses to be sure that they are not contacting
any moving parts (such as the fan or lower
pulley assembly). Be sure that all hardware
has been tightened properly. Check the entire
engine compartment for anything that looks
unusual. If the radiator was removed earlier
remove the radiator cap so the radiator can be
refilled once the vehicle has reached normal
operating temperature. Start the vehicle.
Check the steering. Turn the wheel all the way
to the left and all the way to the right. Be sure
that there is no binding. Check the clutch
operation. Check the manual transmission
shift lever operation. Be sure that it engages in
all gears. Check the automatic transmission
shift lever operation. Check the 4-wheel drive
shift lever operation. Once the engine has
reached normal operating temperature, top off
the coolant level and install the radiator cap.
Be sure that the overflow tank is filled to the
proper level. Check the transmission fluid
level. Be sure that the fluid is filled to the
proper level. Test-drive the vehicle in all gears
and 4 wheel drive ranges. Check all mounting
hardware in 500 miles and as part of your
regular maintenance schedule.
CAUTION
Performance
Accessories
does
not
recommend any particular wheel and tire
combinations for use with its body lifts and can
not assume responsibility for the customers
choice of wheels and tires. Your owner's
manual can be referenced for recommended
tire sizes and warnings related to the use of
oversized tires.
Larger wheel and tire
combinations increase stress and wear on
steering and suspension components, which
leads to increased maintenance and higher
risk for component failure. Larger wheel and
tire combinations also alter speedometer
calibration, braking effectiveness, center of
gravity, and handling characteristics. Consult
with an experienced local off road shop to find
what wheel and tire combinations work best
with your vehicle.
NOTE
The vehicle owner must retain all warranty
information, instruction sheets, and other
documents regarding the installation of this
product. Information contained in the
instructions and on the warranty card will be
required for any warranty claims. The vehicle
owner needs to understand the modifications
that have been made to his vehicle and how
they affect the handling and performance of
the vehicle. Failure to provide the customer
with this information can result in damage to
the vehicle and possible personal injury.
Revision 2, July 12, 1999
1999 Ford Super Duty
Kit # 893
Parts List
KIT
16 3x3 blocks
4 3x2 overload blocks
2 Front bumper brackets
2 Rear bumper brackets
1 4wd shifter extension bracket
1 1 1/2" x 5" fuel-filler extension
1 3/4" x 18" fuel vent hose
1 Warning to driver sticker
1 Logo label
1 10ml bottle Loctite 262
1 Bolt pack BP893
4 12mm x 200mm bolts
4 12mm x 180mm bolts
4 12mm x 160 mm bolts
4 12mm x 140mm bolts
16 Thick 1/2" USS washers
1 se 3000 steering extension
1 3/8" x 1 1/4" socket head bolt
1 Parking brake bracket
1 5/16” x 1” bolt
2 5/16” washers
1 5/16” nylock nut
1 Hardware Pack HP893
Bolts
8 7/16" x 1 1/2" bolts
6 5/16" x 1" bolts
2 1/4" x 1" bolts
Washers
16 7/16" USS washers
8 5/16" SAE washers
6 1/4" washers
Nuts
8 7/16" nylock nuts
2 5/16" nylock nuts
4 1/4" nylock nuts
Misc.
2 bent fan shroud brackets
2 #10 hose clamps
2 #28 hose clamps
2 cable ties
SE 3000 Steering extension
3x2 overload blocks
Front bumper bracket
Rear bumper bracket
Fan shroud cut-outs
Parking brake bracket
Bumper cutouts
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