Owners manual

ManualsBrandsPro Comp Suspension ManualsAutomotiveK4102B Stage I Lift Kit Fits 90-96 F-150

INSTALLATION

INSTRUCTIONS

PARTS LIST:

ITEM# DESCRIPTION QTY.

ILLUST.

90-1005 Radius Arm Drop Brkt. (Drvr.) 1 2

90-1006 Radius Arm Drop Brkt. (Pass.) 1 2

90-1203 Driver I-Beam Pivot Drop Brkt 1 4

90-1202 Passenger I-Beam Pivot Drop Brkt 1 3

90-1197 Stiffener Plate 1 3

90-6072 Hardware Pack Containing:

70-0563501800 9/16” x 3 1/2” USS Gr. 8 Hex Bolt 1 3-4

70-0501501800 1/2” x 1 1/2” USS Gr. 8 Hex Bolt 8 3-4

70-0431251800 7/16” x 1 1/4” USS Gr. 8 Hex Bolt 10 2

70-0431001800 7/16” USS Gr. 8 Hex Bolt 6 3-4

73-05600034 9/16” SAE Hardened Flat Washer 2 3-4

73-05000034 1/2” SAE Hardened Flat Washer 16 3-4

73-04300034 7/16” SAE Hardened Flat Washer 34 2-3-4

72-05600100816 9/16” USS Gr. C Toplock Nut 1 3-4

72-05000100816 1/2” USS Gr. C Toplock Nut 8 3-4

72-04300100816 7/16” USS Gr. C Toplock Nut 14 2-3-4

Loctite (Retaining Compound) 1

90-6372 Hardware Pack Containing:

70-031100800 5/16” x 1” USS Gr. 8 Hex Bolt 2 5

72-03100100512 5/16” USS Nyloc Nut 2 5

73-03100032 5/16” USS Flat Washer 4 5

91-2144 Bumpstop Spacer 2 5

90-6029 Brake Line Support Kit

The following parts are used in conjunction with this kit. They are packaged and must be ordered sep-

arately.

ITEM# DESCRIPTION QTY.

24412 Bronco/Standard Cab Coil Spring (4” Lift) pair 1

24413 Extra Cab Coil Spring (4”Lift) pair 1

Part # 52180B

82’-96’ Ford F150 & Bronco IFS

Stage I Suspension System

Revised: 12/2/2005

Pro Comp Suspension, Inc. Chula Vista, CA USA

Ph: (619) 216-1444 • Fax: (619) 216-1474 • E-Mail: tech@explorerprocomp.com • Website: www.explorerprocomp.com

Summary of content (13 pages)

PAGE 1
Revised: 12/2/2005 Pro Comp Suspension, Inc. Chula Vista, CA USA Ph: (619) 216-1444 • Fax: (619) 216-1474 • E-Mail: tech@explorerprocomp.com • Website: www.explorerprocomp.
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4612 24613 319510 or 321510 326500 13130 532 7325 or 7330 FD400 Bronco/Standard Cab Coil Spring (6” Lift) pair Extra Cab Coil Spring (6” Lift) pair Front Shock Absorber (4” Lift) 1 1 2 Front Shock Absorber (6” Lift) Rear Shock Absorber Rear Add-A-Leaf Kit Adjustable Camber/Caster Bushing (4WD) 2-3/4” Stainless Brake Hose Kit (3 pc.) 90’-96’ 2 2 1 1 1 Stainless Brake Hose Kit (3 pc.) 82’-89’ Pitman Arm 1 1 PRIOR TO INSTALLATION: Check the VEHICLE FRAME for any damage or severe corrosion.
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Foot pound torque readings are listed on the Torque Specifications Chart at the end of the instructions unless specifically stated in an instruction. Apply loctite retaining compound on all bolts during installation. A drop on the exposed threads of a bolt before installing the nut will provide an adequate bond. Unless otherwise specified, all bolts should be installed with a flat washer at both ends. Loctite, then torqued to specifications. DO NOT USE AN IMPACT WRENCH TO TIGHTEN ANY OF THE BOLTS.
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INSTALLATION: 1) Block the rear wheels of the vehicle in front and behind the tires. Raise the front of the vehicle with a floor jack and support the frame with jackstands. Remove the front wheels and shock absorbers. 2) Separate the relay rod from the pitman arm. If your vehicle is equipped with a front anti-sway bar, remove the brackets that hold it to the frame. 3) Mark the front driveshaft and the front differential yoke so that the driveshaft can be reconnected in its original position.
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ILLUSTRATION 1 LE “J” CLIP IC H EXISTING F COIL TOWER T VE O N O FR COIL SPRING SHOCK EXISTING EXISTING RADIUS ARM EXISTING I-BEAM EXISTING EXISTING Remove the rivets as follows: A) Center punch rivet head B) Drill 1/4” pilot hole in center of rivet approximately 1/4” deep C) Drill rivet head off using a 7/16” bit, being careful not to drill into frame. D) Drive rivet out with a hammer and punch. 10) Remove the brackets that held the radius arms to the frame.
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ILLUSTRATION 2 RADIUS ARM DROP BRACKET 90-1005 (DRVR.) 90-1006 (PASS.) FRAME FLAT WASHER, 7/16” HEX BOLT, 7/16” x 1-1/4” LG.
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ILLUSTRATION 3 DRILL 1/2” DIAMETER HOLE FLAT WASHER, 1/2” TOP LOCK NUT, 1/2”-13 H IC LE HEX BOLT, 7/16” x 1” LG. F VE FLAT WASHER, 7/16” FR O N T O CROSSMEMBER DRILL 7/16” DIAMETER HOLE DRILL 1/2” DIAMETER HOLE STIFFENER PLATE, 90-1197 TOP LOCK NUT, 7/16”-14 FLAT WASHER, 7/16” EXISTING DRILL 7/16” DIAMETER HOLE HEX BOLT, 1/2” x 1-1/2” LG. FLAT WASHER, 1/2” EXISTING TOP LOCK NUT, 1/2”-13 FLAT WASHER, 1/2” HEX BOLT, 7/16” x 1” LG. FLAT WASHER, 7/16” EXISTING HEX BOLT, 1/2” x 1-1/2” LG.
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14) Install the driver side pivot drop bracket (90-1203). Locate the drop bracket onto the crossmember as shown in ILLUSTRATION 4 using holes and hardware, but do not tighten. 15) Still referring to ILLUSTRATION 4, mark the two (2) two holes that are needed with a centerpunch. Remove the drop bracket and drill the necessary size holes. File any raised edges. Clean the mounting surface and install the bracket with the specified hardware provided, using loctite and torque per the Torque Specification Chart.
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19) Using the floor jack, raise and position one of the beams into the new bracket. Insert the existing pivot bolt through the bracket and beam and install the nut. Refer back to ILLUSTRATION 3. Do not tighten yet. Repeat this procedure on the other beam. 20) Check again, to make sure that all the radius arm bushings and spacers are installed as in ILLUSTRATION 2. Apply loctite and torque the radius arm nuts and the beam pivot bolts per the Torque Specification Chart.
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ILLUSTRATION 6 DRIVER SIDE SWAY BAR MOUNT REMOVE USING TEMPLATE TRATION 6. Remove the crossmembers from the anti-sway bar and trim using a saber saw or die grinder. File any sharp edges and reinstall crossmembers. 26) Reinstall the anti-sway bar and reconnect the relay rod to the pitman arm. Install the shock absorbers using the supplied 1/2” hardware through the radius arm hole (see ILLUSTRATION 1). Reinstall the wheels. RECHECK ALL NUTS AND BOLTS TO BE SURE THEY ARE PROPERLY TORQUED. Lower the vehicle.
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3) Remove the axle u-bolts. Remove the spring eye bolts and/or shackles and remove the springs from the vehicle. 4) Hold the spring assembly securely together with “C” clamps. Remove any spring leaf alignment clamps. Remove the spring center bolt. A hammer and drift punch may be used to drive it out if necessary. 5) Carefully remove “C” clamps and lay the unassembled spring aside. NOTE: The add-a-leaf will be placed in the spring assembly progressively according to length.
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1/2” Bolts...................................... 5/16” Bolts.................................... 7/16” Bolts.................................... 9/16” Bolts.................................... Radius Arm - Frame Bracket................ Spring Retainer - Upper Spring Seat..... Radius Arm - Axle Beam (Stud & Bolt).. Lower Spring Retainer - Radius Arm.... Pitman Arm - Steering Gear Nut........... 70 ft./lbs. 13 ft./lbs. 58 ft./lbs. 115 ft./lbs. 80-120 ft./lbs. 13-19 ft./lbs. 180-220 ft./lbs. 30-70 ft./lbs.
PAGE 13
Notice to Owner operator, Dealer and Installer: Vehicles that have been enhanced for off-road performance often have unique handling characteristics due to the higher center of gravity and larger tires. This vehicle may handle, react and stop differently than many passenger cars or unmodified vehicles, both on and off–road. You must drive your vehicle safely! Extreme care should always be taken to prevent vehicle rollover or loss of control, which can result in serious injury or even death.