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
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.
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.
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.
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) 636-
0979 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
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
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
