Ford - Explorer - Parts Catalogue - 1991 - 1994

Installation manual 4” radius arm relocation bracket kit 1983 - 1997 Ford Ranger 4WD 1991 - 1994 Ford Explorer 4WD Part # 20774 Part # 20774 1983 - 1997 Ford Ranger 4WD 1991 - 1994 Ford Explorer 4WD 4” radius arm relocation kit Part # Description R403 R404 20774NB 20774INST DS radius arm relocation bracket PS radius arm relocation bracket Hardware bag Instruction manual Rear view mirror hanger Warning decal MIRRORHANGER WARNINGDECAL sj05092011rev.01 Important customer information: Qty. 1 1 1 2 1 1 Congratulations on your selection to purchase a Tuff Country EZ-Ride Suspension System. We at Tuff Country EZ-Ride Suspension are proud to offer a high quality product at the industries most competitive pricing. Thank you for your confidence in us and our product. If you desire to return your vehicle to stock, it is the customers responsibility to save all stock hardware and components. The Tuff Country EZ-Ride Suspension product safety label that is included in your kit box must be installed inside the cab in plain view of all occupants. Please see the end of the installation manual for a picture of the hard parts that are included in this suspension system. Tuff Country EZ-Ride Suspension highly recommends that a qualified or a certified mechanic performs this installation. It is the responsibility of the customer/installer to wear safety glasses at all times when performing this installation. It is the customers/installers responsibility to read and understand all steps before installation begins. If you have any questions or concerns, please contact our technical department @ (801) 280-2777. Also, the OEM manual should be used as a reference guide. This vehicles reaction and handling characteristics may differ from standard cars and/or trucks. Modifications to improve and/or enhance off road performance may raise the intended center of gravity. Extreme caution must be utilized when encountering driving conditions which may cause vehicle imbalance or loss of control. DRIVE SAFELY! Avoid abrupt maneuvers: such as sudden sharp turns which could cause a roll over, resulting in serious injury or death. It is the customers responsibility to make sure that a re-torque is performed on all hardware associated with this suspension system after the first 100 miles of installation. It is also the customers responsibility to do a complete re-torque after every 3000 miles or after every off road use. After the original installation, Tuff Country EZ-Ride Suspension also recommends having the alignment checked every 6 months to ensure proper tracking, proper wear on tires and front end components. Tuff Country EZ-Ride Suspension takes no responsibility for abuse, improper installation or improper suspension maintenance. Limited lifetime warranty Notice to all Tuff Country EZ-Ride Suspension customers: It is your responsibility to keep your original sales receipt! If failure should occur on any Tuff Country EZ-Ride Suspension component, your original sales receipt must accompany the warranted unit to receive warranty. Warranty will be void if the customer can not provide the original sales receipt. Do not install a body lift in conjunction with a suspension system. If a body lift is used in conjunction with any Tuff Country EZ-Ride Suspension product, your Tuff Country EZ-Ride Suspension WARRANTY WILL BE VOID. Tuff Country Inc. (“Tuff Country” ) suspension products are warranted to be free from defects in material and workmanship for life if purchased, installed and maintained on a non-commercial vehicle; otherwise, for a period of twelve (12) months, from the date of purchase and installation on a commercial vehicle, or twelve thousand (12,000) miles (which ever occurs first). Tuff Country does not warrant or make any representations concerning Tuff Country Products when not installed and used strictly in accordance with the manufacturer’s instructions for such installation and operation and accordance with good installation and maintenance practices of the automotive industry. This warranty does not apply to the cosmetic finish of Tuff Country products nor to Tuff Country products which have been altered, improperly installed, maintained, used or repaired, or damaged by accident, negligence, misuse or racing. (“Racing is used in its broadest sense, and, for example, without regards to formalities in relation to prizes, competition, etc.) This warranty is void if the product is removed from the original vehicle and re-installed on that or any other vehicle. This warranty is exclusive and is in lieu of any implied warranty of merchantability, fitness for a particular purpose or other warranty of quality, whether express or implied, except the warranty of title. All implied warranties are limited to the duration of this warranty. The remedies set forth in this warranty are exclusive. This warranty excludes all labor charges or other incidental of consequential damages. Any part or product returned for warranty claim must be returned through the dealer of the distributor from whom it was purchased. Tuff Country reserves the right to examine all parts returned to it for warranty claim to determine whether or not any such part has failed because of defect in material or workmanship. The obligation of Tuff Country under this warranty shall be limited to repairing, replacing or crediting, at its option, any part or product found to be so defective. Regardless of whether any part is repaired, replaced or credited under this warranty, shipping and/or transportation charges on the return of such product must be prepaid by the customer under this warranty. Important information that needs to be read before installation begins: Tuff Country EZ-Ride Suspension packages (2) sets of instruction sheets with this box kit. (1) is for the installer and (1) is for the customer. The (1) for the customer has some post installation procedure literature and it is the installers responsibility to make sure that the customer receives a copy of the installation manual along with the literature. Before installation begins, Tuff Country EZ-Ride Suspension highly recommends that the installer performs a test drive on the vehicle. During the test drive, check to see if there are any uncommon sounds or vibrations. If uncommon sounds or vibrations occur on the test drive, uncommon sounds or vibrations will be enhanced once the suspension system has been installed. Tuff Country EZ-Ride Suspension highly recommends notifying the customer prior to installation to inform the customer of these issues if they exist. Make sure to use thread locker or loctite on all new and stock hardware associated with the installation of this suspension system. Special note: Before installation begins, it is the customers/installers responsibility to make sure that all parts are on hand. If any parts are missing, please feel free to call one of our customer service representatives @ (801) 280-2777. Hardware bag R4NB includes: Description Quantity 12112B (1/2” x 1 1/2” bolt) 12UN (1/2” unitorque nut) 716WA (7/16” USS flat washer) 16 16 32 Recommended tools selection: Cut off wheel Torque wrench Standard socket set Standard wrench set Metric socket set Metric wrench set Tape measure Hydraulic floor jacks Air chisel Please follow instructions carefully: 1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the vehicle with a pair of jack stands. Place a jack stand on both the driver and the passenger side. Special note: Place the jack stands on the body mounts. Next, remove the front wheels and tires from both sides. 2. Place a pair of hydraulic floor jacks under the driver and passenger side stock radius arms. Carefully raise up on the hydraulic floor jacks until they come into contact with the 5. Locate the new driver and passenger side radius arm relocation brackets. Also, locate (16) 1/2” x 1 1/2” bolts, (32) stock radius arms. 7/16” USS flat washers and (16) 1/2” unitorque nuts from 3. Working on the driver side stock radius arm bracket, hardware bag 20774NB. Working on the diver side, secure remove the stock hardware or the stock rivets that connect the new radius arm relocation bracket to the stock radius the bracket to the frame rail. The stock hardware and rivets arm bracket using the new 1/2” x 1 1/2” bolts and hardware. may be discard. Repeat procedure on the passenger side. Do not tighten at this point. Now secure the new radius Special note: Using a die grinder and making a cross cut arm relocation bracket to the stock frame rail using the new on the rivets then using a air chisel will help make the new 1/2” x 1 1/2” bolts and hardware. Move back to all 1/2” hardware and add some tread locker or loctite and torque to removal of the rivets easier. 65 ft lbs. Repeat procedure on the passenger side. 4. Working on the driver side, carefully drill out the frame and the stock radius arm bracket holes to 1/2”. Repeat procedure on the passenger side. 6. If you have not already done so, remove all the hydraulic floor jacks from under the vehicle. Check and double check to make sure that all steps have been performed properly and check again. Install the tires and wheels and carefully lower the vehicle to the ground. Installation completed! Special note: After the completion of the installation, Tuff Country EZ-Ride Suspension recommends taking the vehicle to an alignment shop and having a proper front end alignment performed. Tuff Country EZ-Ride Suspension recommends that a complete re-torque is done on all bolts associated with this suspension system. It is the customers responsibility to make sure that a re-torque is performed on all hardware associated with this suspension system after the first 100 miles of installation. It is also the customers responsibility to do a complete re-torque after every 3000 miles or after every off road use. Neglect of following these steps could cause brackets to come loose and cause serious damage to the suspension system and to the vehicle. Tuff Country EZ-Ride Suspension packages (2) sets of instruction sheets with this box kit. (1) is for the installer and (1) is for the customer. The (1) for the customer has some post installation procedure literature and it is the installers responsibility to make sure that the customer receives a copy of the installation manual along with the literature. If you have any questions or concerns, please feel free to contact Tuff Country or your local Tuff Country dealer. R403 / Qty. 1 Driver side radius arm relocation bracket R404 / Qty. 1 Passenger side radius arm relocation bracket