Ford - F 350 - Workshop Manual - 1980 - 1997

1980-1997 Ford F250 / F350 4WD 4”- 6” Suspension Lift Installation Instructions www.skyjacker.com Required Tool List: * Safety Glasses * Metric / Standard Wrenches & sockets * Assorted Drill Bits * Floor Jack * Jack Stands * Measuring Tape * Torque Wrench Before beginning the installation, thoroughly & completely read these instructions & the enclosed driver’s WARNING NOTICE. Affix the WARNING decal in the passenger compartment in clear view of all occupants. Please refer to the Parts List to insure that all parts & hardware are received prior to the disassembly of the vehicle. If any parts are found to be missing, contact SKYJACKER® Customer Service at 318-388-0816 to obtain the needed items. If you have any questions or reservations about installing this product, call SKYJACKER® Technical Assistance at 318-388-0816. Make sure you park the vehicle on a level concrete or asphalt surface. Many times a vehicle is not level (side-to-side) from the factory & is usually not noticed until a lift kit has been installed, which makes the difference more visible. Using a measuring tape, measure the front & rear (both sides) from the ground up to the center of the fender opening above the axle. Record this information below for future reference. Driver Side Front: Passenger Side Front: Driver Side Rear: Passenger Side Rear: IMPORTANT NOTES: • This lift is determined from the amount of lift to the front of the vehicle, while only lifting the rear to a position level with the front. • If larger tires (10% more than the stock diameter) are installed, speedometer recalibration will be necessary. Contact your local Ford dealer or an authorized dealer for details. • After installation a qualified alignment facility is required to align the vehicle to factory specifications. IF250 REV1 11-11 Pg 1 Twin I Beam Component Boxes: F840T: ITEM# LHB75-5 RHB75-6 58X338X13U 916X318X912U RB20 HB-F8TM Kit Box Breakdown: DESCRIPTION LEFT HINGE BRACKET F250 RIGHT HINGE BRACKET F250 5/8 X 3 3/8 X 13 U-BOLT ROUND 9/16 X 3 1/8 X 9 1/2 U-BOLT 2" REAR BLOCK HARDWARE BAG FOR F840-60 T & M QTY 1 1 4 4 2 1 Box Kit # F840TS will not include rear blocks and the rear U-bolts will be Part # 58X338X11U Box Kit # F860T will include (2) 4.5” Rear Blocks Part # RB45. The rear U-bolts will be Part # 58X338X1412U Box Kit # F860TS will not include rear blocks & the rear U-bolts will be Part # 58X338X11U Hardware Bag Breakdown: HB-F8TM ITEM# DESCRIPTION 12FTN 1/2-20 FINE N/I LOCK NUT 12SAEW 1/2 SAE WASHER 12X112FTB 1/2 X 1 1/2 FINE THRD BOLT 58FTN 5/8-18 NYLON INSERT LOCKNUT 916FTN 9/16-18 NYLON INSERT LOCKNUT SP2037 F250 SPRING BUSHING SSF25080 SPRING SLEEVE F250 80-UP IF250 QTY 8 8 8 8 8 8 4 Pg 2 Straight Axle Component Boxes: F840M: ITEM# 58X338X13U 916X318X912U RB20 TB35-B HB-F8TM Kit Box Breakdown: DESCRIPTION 5/8 X 3 3/8 X 13 U-BOLT ROUND 9/16 X 3 1/8 X 9 1/2 U-BOLT 2" REAR BLOCK TRACK BAR EXTENSION BRACKET F350 HARDWARE BAG FOR F840-60 T & M QTY 4 4 2 1 1 Box Kit # F840MS will not include rear blocks & the rear U-bolts will be Part # 58X338X13U Box Kit # F860M will include (2) 3.5” Rear Blocks Part # RB35. The rear U-bolts will be Part # 58X338X1412U Box Kit # F860MS will not include rear blocks & the rear U-bolts will be Part # 58X338X13U Hardware Bag Breakdown: HB-F8TM ITEM# DESCRIPTION 12FTN 1/2-20 FINE N/I LOCK NUT 12SAEW 1/2 SAE WASHER 12X112FTB 1/2 X 1 1/2 FINE THRD BOLT 58FTN 5/8-18 NYLON INSERT LOCKNUT 916FTN 9/16-18 NYLON INSERT LOCKNUT SP2037 F250 SPRING BUSHING SSF25080 SPRING SLEEVE F250 80-UP IF250 QTY 8 8 8 8 8 8 4 Pg 3 FRONT INSTALLATION: 1. The SOFTRIDE® front springs carry an offset center pin. The spring will be installed with the short end towards the front. 2. Open the hardware bag & apply a thin coat of lithium-based grease around the polyurethane bushings & insert into each eye of the new front springs then apply a thin coat on the outside of the bushings. Insert one "thin wall" sleeve (will be the front eye of spring) & one "thick wall" sleeve in each spring. Photo # 1 3. Raise the front of the vehicle & support securely with jack stands under the frame behind the front springs & block the rear tires. Remove the tires, shocks, & u-bolts (Caution: Once the u-bolts are removed, the front axle will be free to move, so support securely on a floor jack). Unbolt each end of the front leaf springs & remove from both sides. 1980 - 1997 F250 models & 80-85 IFS F350 models continue with Step # 4. 1986 - 1997 F350 models skip to Step # 6, All others skip to Step # 7. 4. Remove the drag link from the pitman arm & lower the assembly down. With a floor jack under the front differential & another floor jack under the passenger side axle housing, remove the two OEM axle hinge brackets from the cross member. Remove the axle beam bolt & discard the OEM brackets. Photo # 2 5. Install the new Skyjacker drop brackets with the supplied hardware (the larger bracket is for the passenger / right side axle beam). DO NOT TIGHTEN AT THIS TIME. (See Photo # 1 & # 2) 6. Monobeam Models: Remove the OEM track bar bracket from the cross member. Bolt the new Skyjacker extension bracket to the cross member & bolt the OEM bracket to the bottom of the new extension bracket using the supplied hardware. (See Photo # 3) Photo # 3 7. Install new springs with the short end towards the front bumper. (NOTE: DO NOT tighten spring eye bolts at this time). Using the floor jack, raise the front axle up to the leaf springs. Be sure the tie bolts align & fit down into the holes in the axle housing. Install & evenly tighten the new Skyjacker u-bolts. 8. On IFS models, swing axle beams up to the new brackets & install the OEM hinge bolts (use the top hole for 4" kits & the bottom hole on 6" kits). (See Photo # 4) Tighten all the upper bolts on the new drop brackets & then tighten the lower hinge bolts. Note: You MUST weld each new drop bracket to its cross member. (See Photo # 5 & # 6) This is to help keep the cross member from cracking due to additional stress applied. IF250 Photo # 4 Pg 4 9. Install the new Skyjacker shocks & tires, then lower the vehicle to the ground. Tighten the spring eye bolts now that the vehicle weight is on the springs. Refer to the pitman arm instructions at this time. Rear Installation: 1. Raise the rear of the vehicle & support securely with jack stands & block the front wheels. Remove the tires, shocks, & u-bolts. (Caution: The rear axle will now be free to move, so support securely with a floor jack.) "SYSTEMS" with rear springs, continue with Step # 2, otherwise skip to Step # 3 or # 4. Photo # 5 2. Systems With Rear Leaf Springs: Unbolt & remove the OEM rear springs & bolt up the new Skyjacker rear springs with the long end of the spring towards the rear bumper. (NOTE: On springs with a bottom degree shim, the thick end of the shim must also be towards the rear bumper.) If the rear sits higher than the front, the OEM rear block may be removed to lower rear down, if desired. 3. Kits With Rear Blocks: Install the new Skyjacker blocks, tall end toward the rear bumper, between the springs & the OEM blocks. This means the new block will be installed on top of the OEM block. Photo # 6 4. Kits With Rear Add-A-Leafs: Place C-clamps around the rear leaf spring pack within approximately 6" of each side of the tie bolt & remove the tie bolt from the spring pack. Install the new Skyjacker add-a-leaf between the spring pack & OEM bottom overload leaf. Insert the new tie bolt from the bottom going through the OEM overload, the new add-a-leaf, & the spring pack. Tighten the nut & remove the C-clamps from the spring pack. 5. Using a floor jack, raise the axle to the rear springs. Be sure the spring tie bolts & block pins all align in the proper holes. Install the new Skyjacker u-bolts & shocks. Install the tires & lower the vehicle to the ground. Torque specificAtions Metric system Inch System Bolt Size 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Grade 5 15 FT LB 30 FT LB 45 FT LB 65 FT LB 95 FT LB 135 FT LB 185 FT LB Grade 8 20 FT LB 35 FT LB 60 FT LB 90 FT LB 130 FT LB 175 FT LB 280 FT LB Bolt Size 6MM 8MM 10MM 12MM 14MM 16MM 18MM Class 8.8 5 FT LB 18 FT LB 32 FT LB 55 FT LB 85 FT LB 130 FT LB 170 FT LB Class 10.9 9 FT LB 23 FT LB 45 FT LB 75 FT LB 120 FT LB 165 FT LB 240 FT LB *The above specifications are not to be used when bolt is being installed with a bushing. IF250 Pg 5 NOTES: * On models equipped with a rear carrier bearing, it will be required to lower the carrier bearing after the installation of this lift. (Order Skyjacker Part # CBL3401) * All IFS Fords require a front end alignment after suspension changes are made. Your local front end alignment shop can do this. Toe-In & Camber / Caster adjustment is required. If needed, adjustable camber / caster bushings are available. (Order Skyjacker Part #1032H qty 2 required) * Have the front end alignment checked periodically by a professional for your safety & longer tire life. * Check drive shafts to be sure there is proper length. Check brake line length; it may be necessary to re-route the OEM lines or replace them with new longer DOT approved stainless steel lines available from Skyjacker. * It may be necessary to re-center the steering wheel so there are equal turns left & right by adjusting the turn buckles on the drag link / tie rod assembly. * Check clearance between the tires & leaf springs. If there is possibility of contact, adjust the steering stops to prevent contact. * Retorque ALL nuts, bolts, & especially the u-bolts after the first 100 miles, again after another 100 miles, & then check periodically thereafter. ACCESSORIES: • SOFTRIDE® Rear Springs • SOFTRIDE® Hydro & Nitro Shocks • Triple or Dual Front Shock Kit • HD OEM Replacement Steering Stabilizer • Single Steering Stabilizer • Dual Steering Stabilizer • Extended Stainless Steel Brake Lines - DOT Approved • Extended Sway Bar End Links • Carrier Bearing Lowering Kit SEAT BELTS SAVE LIVES. PLEASE WEAR YOUR SEAT BELT. IF250 Pg 6