part # 52434/b/52434mxr 2005-2006 4wd f250-350 coil over ... · mx6069r mx-6 shock absorber 2 - -...

52434 /52434MXR Revised 10.30.07

PRO COMP SUSPENSION

Suspension Systems that Work!

2360 Boswell Road Chula Vista, CA 91914 Phone 619.216.1444 Fax 619.216.1474 E-Mail [email protected]

This document contains very important information that includes warranty information and instructions for resolving problems you may encounter. Please keep it in the vehicle as a permanent record.

Part # 52434/B/52434MXR

2005-2006 Ford Super Duty

4WD F250-350 Diesel Stage 2 Dual Coil Over Lift Kit

52434 /52434MXR Revised 10.30.07

Box 1 of 10-PN 52434MXR-1

Part # Description Qty. Illus. Page

2

90-6271 HARDWARE PACK: End Caps 1 - - 15-11213 1 1/2" END CAP 4 4a,4b 9 90-2562 COIL OVER LOWER MOUNT 2 11 15 90-2564 COIL OVER HOOP-Drvr 1 4a 9 90-2565 COIL OVER HOOP-Pass 1 4b 9 90-6464 HARDWARE PACK: Coil Over hoop 1 - - 70-0501251800 1/2" X 1 1/4" GR. 8 HEX BOLT 4 6,11 11,15 70-0501751800 1/2" X 1 3/4" GR. 8 HEX BOLT 3 4a,4b 9 72-050100816 1/2" STOVER NUT 6 4a,4b,7,12 9,12,16 73-0500830 1/2" SAE WASHER 13 4a,4b,7,12 9,12,16 90-6466 HARDWARE PACK: Lower Coil Over Mount 1 - - .140C600HCS1Y 14mm-2.0 X 60mm 10.9 HEX BOLT 2 11 15 .140NWHDY 14mm FLAT WASHER 2 11 15 62FNHI5Z 5/8" HARDENED NUT 4 11 15

90-3053 DRIVESHAFT SHIM 1 18 23 90-6337 HARDWARE PACK: Bump Stop 1 - - 97-165 10mm X 165mm CENTER PIN 2 17 22 95-150F 1 1/2” BLOCK 2 17 22 13-90180 U-BOLT 4 17 22 20-65471 HARDWARE PACK: 5/8" NUTS 1 17 22 90-3215 REAR SHOCK BRACKET - Drvr 1 - - 90-3216 REAR SHOCK BRACKET - Pass 1 - - 90-5054 TRACK BAR DROP BRACKET 1 1,12,16 7,12,19 90-3401 BUMP STOP DROP- Drvr 1 6 11 90-3402 BUMP STOP DROP-Pass 1 6 11 90-3416 SWAY BAR DROP- Drvr 1 14a,14b 17 90-3418 SWAY BAR DROP- Pass 1 14a,14b 17 90-6470 HARDWARE PACK: Sway Bar End Link 1 - - 91-2566 SWAY BAR END LINK 2 13 16 P-1036 SLEEVE 2 13 16 600000 BUSHING 2 13 16 600020 BUSHING 2 13 16 90-6340 HARDWARE PACK: Sway Bar 1 - - 70-0431001800 7/16” X 1 1/4” HEX BOLT GR. 8 4 14a,14b 17 72-043100816 7/16” STOVER NUT 4 14a,14b 17 73-0400830 7/16” SAE FLAT WASHER 8 14a,14b 17


52434 /52434MXR Revised 10.30.07

Part # Description Qty. Illus. Page 90-6467 HARDWARE PACK: ABS/Brake line/Vacuum Brackets 1 - - 25C50HCS8Y 1/4"-20 X 1/2" GR. 8 HEX BOLT 4 11 15 25NLOC8Y 1/4" LOCK WASHER 4 9,11 13,15 25C75HCS8Y 1/4"-20 X 3/4" GR. 8 HEX BOLT 4 9 13 25NWHDY/SAE 1/4" FLAT WASHER 8 9,11 13,15 25CNNE8Y 1/4"-20 NYLOC NUT 4 9,11 13,15 90-6468 HARDWARE PACK: Sway Bar End Link 1 - - 70-0563001800 9/16" X 3" HEX BOLT GR. 8 2 13 16 72-056100816 9/16” STOVER NUT 2 13 16 73-05600830 9/16" SAE FLAT WASHER 4 13 16 90-6469 HARDWARE PACK: ABS Line 1 - - 90-3240 ADEL CLAMP 4 11 15 90-1582 NUT PLATE 1 4b 9 90-6460 HARDWARE PACK: Sway Bar 2 - - 90-3427 SHOCK ADAPTER 1 13 16 54314 SHOCK SLEEVE 1/2” X 5/8” X 1” 1 13 16 90-6396 HARDWARE PACK 1 - - 73-05000100512 1/2" SAE FLAT WASHER 2 13 16 70-0502751500 1/2" X 2 3/4" USS GR. 5 HEX BOLT 1 13 16 72-05000100512 1/2" USS GR. 5 NYLOCK NUT 1 13 16 72-06200100512 5/8" USS GR. 5 NYLOCK NUT 1 13 16 73-06200032 5/8" SAE FLAT WASHER 1 13 16 90-3010 COIL OVER WRENCH: Large 1 - - 90-3011 COIL OVER WRENCH: Small 1 - - FD-700 PITMAN ARM 1 1 7 90-6399 HARDWARE PACK: Radius Arms 1 - - .180CNUCZ 18mm-2.5 STOVER NUT 1 10 14 .180NWHDZ 18mm HARDENED FLAT WASHER 1 10 14 90-3198 STABLIZER BRACKET 1 14a,14b 17 90-6369 HARDWARE PACK: Track Bar Drop 1 - - 70-0563001800 9/16" X 3" HEX BOLT GR.8 3 13 16 72-056100816 9/16" STOVER NUT 3 13 16 73-05600830 9/16" FLAT WASHER SAE GR. 8 6 13 16 90-6315 HARDWARE PACK: Sway Bar 2 - - 70-0431751800 7/16” X 1 3/4” HEX BOLT GR. 8 4 14a,14b 17 72-043100816 7/16” STOVER NUT 4 14a,14b 17 73-04300830 7/16” HARDENED FLAT WASHER 8 14a,14b 17 90-6340 HARDWARE PACK: Sway Bar 2 - - 70-0431001800 7/16” X 1 1/4” HEX BOLT GR. 8 4 14a,14b 17 72-043100816 7/16” STOVER NUT 4 14a,14b 17 73-0400830 7/16” SAE FLAT WASHER 8 14a,14b 17 96-5002 PITMAN ARM TOOL 1 2 8 90-6595 HARDWARE PACK: Pitman Arm Tool 1 - - Thread locker 1 - - 0431251800 7/16" X 1 1/4" GR. 8 HEX BOLT 1 2 8 04300030 7/16" FLAT WASHER 1 2 8 04300100512 7/16" NYLOC NUT 2 2 8

52434 /52434MXR Revised 10.30.07

Part # Description Qty. Illus. Page Box 3 of 10-PN 52434MXR-3

90-3403 COIL BUCKET- Drvr 1 - - 90-3411 COIL BUCKET- Pass 1 5 11 90-6455 HARDWARE PACK: Coil Over Shock 1 - - 70-0504751800 1/2" X 4 3/4" GR. 8 HEX BOLT 4 12 16 72-050100816 1/2" STOVER NUT 4 12 16 73-0500830 1/2" SAE WASHER 8 12 16 90-6465 HARDWARE PACK: Bucket/Bump Stop 1 - - 70-0431251800 7/16” X 1 1/4” HEX BOLT GR. 8 12 5 11 70-0431751800 7/16” X 1 3/4” HEX BOLT GR. 8 5 6 11 72-043100816 7/16” STOVER NUT 17 5,6 11 73-0400830 7/16” SAE FLAT WASHER 34 5,6 11 90-6472 HARDWARE PACK: SD HOOP BRACE 1 90-3420 OUTER HOOP BRACE 4 7,12 12,16 90-3425 VACUUM MOUNT TAB 2 11 15 90-2055 SWAY BAR SPACER 4 14a,14b 17 90-6463 HARDWARE PACK: Mono Ball Spacer 1 - - 90-2433 MONO BALL SPACER-10 8 12 16

629000R COIL OVER W/ RESERVOIRS 1 11,12 15,16 15-11015 RESERVOIR ISOLATER BUSHING 2 11,12 15,16 CLAMP-3250 STAINLESS 9/16" CLAMP 2 11,12 15,16


Box 9 of 10-PN 52434MXR-9 629000R COIL OVER W/ RESERVOIRS 1 11,12 15,16 15-11015 RESERVOIR ISOLATER BUSHING 2 11,12 15,16 CLAMP-3250 STAINLESS 9/16" CLAMP 2 11,12 15,16

90-2506 RADIUS ARM– Passenger 1 - - 90-2509 SWAY BAR DROP SUPPORT TUBE 1 14a,14b 17

90-2502 RADIUS ARM– Driver 1 10 14







52434 /52434MXR Revised 10.30.07

5

Please Note: ⇒ Front suspension and head light realignment is necessary! ⇒ Speedometer and ABS recalibration will be necessary if larger tires (10% more than stock diameter) are in-

stalled. ⇒ IT IS ADVISABLE THAT YOU HAVE HELP AVAILABLE WHEN INSTALLING THIS KIT.

SOME COMPONENTS ARE HEAVY AND AWKWARD. AN ADDITIONAL SET OF HANDS IS GOOD INSURANCE AGAINST INJURY!

♦ This installation requires a professional mechanic! ♦ We recommend that you have access to a factory service manual to assist in the disassembly and reassembly of

your vehicle. It contains a wealth of detailed information. ♦ Prior to installation, carefully inspect the vehicle’s steering and driveline systems paying close attention to the tie

rod ends, ball joints, wheel bearing preload, pitman and idler arms. Additionally, check steering-to-frame and suspension-to-frame attaching points for stress cracks. The overall vehicle must be in excellent working condi-tion. Repair or replace all worn or damaged parts!

♦ Read the instructions carefully and study the illustrations before attempting installation! You may save yourself a lot of extra work.

♦ Check the parts and hardware against the parts list to assure that your kit is complete. Separating parts according to the areas where they will be used and placing the hardware with the brackets before you begin will save instal-lation time.

♦ Check the special equipment list and ensure the availability of these tools. ♦ Secure and properly block vehicle prior to beginning installation. ♦ ALWAYS wear safety glasses when using power tools or working under the vehicle! ♦ Use caution when cutting is required under the vehicle. The factory undercoating is flammable. Take appropriate

precautions. Have a fire extinguisher close at hand. ♦ Foot pound torque readings are listed on the Torque Specifications chart at the end of the instructions. These are

to be used unless specifically directed otherwise. Apply thread lock retaining compound where specified.

♦ Please note that while every effort is made to ensure that the installation of your Pro Comp lift kit is a positive experience, variations in construction and assembly in the vehicle manufacturing process will virtually ensure that some parts may seem difficult to install. Additionally, the cur-rent trend in manufacturing of vehicles results in a frame that is highly flexible and may shift slightly on disassembly prior to installation. The use of pry bars and tapered punches for align-ment is considered normal and usually does not indicate a faulty product. However, if you are uncertain about some aspect of the installation process, please feel free to call our tech support department at the number listed on the cover page. We do not recommend that you modify the Pro Comp parts in any way as this will void any warranty expressed or implied by the Pro Comp Suspension company.

Introduction:

MX6069R MX-6 SHOCK ABSORBER 2 - - 63012 RESERVOIR ISOLATER BUSHING 2" X 2" 2 - -

Part # Description Qty. Illus. Page Box 10 of 10-PN 52434MXR-10

22415 REAR LEAF SPRINGS 2 17 22

The following parts are used in conjunction with this kit and must be purchased separately.

52434 /52434MXR Revised 10.30.07

⇒ Read the instructions and study the illustrations before attempting the installation. ⇒ Separating the parts according to the areas where they will be used and placing the hardware with

the brackets before you begin will save installation time. ⇒ Check the parts and hardware against the parts list to assure that your kit is complete. ⇒ ALWAYS wear safety glasses when using power tools or working beneath your vehicle. ⇒ A pitman arm removal tool and tie rod separating tool are required to perform the installation. See

the special tools at the top of this page. ⇒ Always use NEW cotter pins on re-assembly! (These items are NOT supplied)

Before You Begin:

6

Important!

Due to differences in manufacturing, dimensions and inflated measurements, tire and wheel combinations should be test fit prior to installation. Tire and wheel choice is cru-cial in assuring proper fit, performance, and the safety of your Pro Comp equipped vehi-cle. For this application, we recommend a wheel not to exceed 10” in width with a maximum backspacing of 5 3/4” must be used. Additionally, a quality tire of radial de-sign, not exceeding 37” tall X 13.50” wide is also recommended. Violation of these rec-ommendations will not be endorsed as acceptable by Pro Comp Suspension and will void any and all warranties either written or implied.

Optional Equipment Available from your Pro Comp Distributor!Optional Equipment Available from your Pro Comp Distributor! 22415 REAR LEAF SPRINGS

52480 CARRIER BEARING SHIM KIT, 599 ALIGNMENT CAM KIT,

50191 U-BOLT KIT, 72400: TRACTION BARS,

72099: TRACTION BAR MOUNTING KIT 219567: DUAL STEERING STABILIZER

99-400: 4 DEGREE REAR AXLE SHIM KIT Also, check out our outstanding selection of Pro Comp tires

to compliment your new installation!

NOTE: If you experience launch shutter and are not installing a Pro Comp traction bar kit, 4 degree rear axle shim kit (99-400) may be required to help remedy the problem.

Special Tools: Pitman Puller Snap-On PN CJ1119B Tie Rod Separator Ford PN T64P-3590-F

52434 /52434MXR Revised 10.30.07

1. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or asphalt). Block the rear tires and set the emergency brake.

2. Measure and record the distance from the center of each wheel to the top of its fender opening. Record below.

3. Place the vehicle in neutral. Place your floor jack under the front axle and raise the vehicle. Place jack stands under the frame rails and lower the frame onto the stands. Remove the jack and place the vehicle back in gear, set the emergency brake, and place blocks both in front and behind the rear wheels.

4. Remove the track bar bolt from the driver side frame mount. Save this hardware for re-use.

5. Remove cast track bar mount on driver side of frame. Save the bolts and pal nuts. Hardware will be reused.

6. Unbolt the sway bar from the sway bar end links and the frame mounts. Remove the sway bar from the vehicle.

7. If the vehicle is equipped with a factory steering stabilizer unbolt it from the frame mounting bracket and remove the factory bracket from the frame.

8. Remove the cotter pin and nut from drag link. Save the nut for reinstallation. Use a tie rod separator to separate drag link from Pitman arm.

9. Remove the sector Pitman arm retaining nut and save for reinstallation. Use a Pit-man arm puller to remove the OE pitman arm. The threads of the sector shaft and the Pitman arm retaining nut must be cleaned of all factory dry adhesive.

IMPORTANT!: THE ENTIRE INSTALLA-TION PROCESS MUST BE DONE WITH HAND TOOLS TO ENSURE PROPER IN-

STALLATION. DO NOT USE IMPACT TOOLS.

10. Install new pitman arm on sector shaft. Oil the sector shaft threads to ensure a proper torque reading. Install Pitman arm retaining nut and tighten until snug. See ILLUSTRATION 1.

11. Insert the key and unlock the steering wheel.

12. Install the Pitman arm torque tool (90-5002) to the Pitman arm using one of the previously removed OE 14mm track bar bracket outer retaining bolt and nut plate. See ILLUSTRATION 2.

13. Secure the torque tool (90-5002) to the existing hole in the frame crossmember using the supplied 7/16” X 1 1/4” bolt and hardware. See ILLUSTRATION 2. NOTE: The steering wheel may need to be turned in order for the hole in the torque tool and the frame crossmember

7

Front Installation:

LR: RR:

RF: LF:

FD-700 Pitman Arm

Cotter Pin

90-5054 Track Bar Drop Bracket

Sector Shaft Nut

Illustration 1 Pitman Arm Install

Drag Link

52434 /52434MXR Revised 10.30.07

8

to line up. Once the bolts are tightened the torque tool will align it’s self prop-erly. NOTE: The use of the torque tool is to keep the Pitman arm from moving right or left, but allow for movement up the sector shaft. If you do not have this tool, a length of chain or a flat bar with two holes is a suitable replacement.

14. Torque the Pitman arm retaining nut to 375 ft./lbs.

15. With the torque tool (90-5002) still in place remove the pitman arm retaining nut. The threads of the sector shaft and the Pitman arm retaining nut MUST be cleaned using brake cleaner or another suitable method to remove the previously applied oil.

16. Use the entire supplied thread locking compound to thoroughly cover the entire surface of the threads on the Pitman arm retaining nut.

17. Reinstall the Pitman arm retaining nut to the sector shaft and torque to 350 ft./lbs. NOTE: Whether re-using the exist-ing pitman arm retaining nut or replac-ing with a new nut, the supplied locking compound must be used.

18. Unbolt and remove the Pitman arm torque tool (90-5002) from the vehicle.

NOTE: Save this Pitman arm torque tool to add to your toolbox for any future Pitman arm installations. 19. Unbolt the front brake line bracket from

the lower spring perch and from the upper spring bucket.

20. Unbolt and unclip the ABS wiring con-nected to the radius arm and fender well. Save hardware for reuse.

21. Remove the factory front bump stop from the bump stop mounting cup. Pliers and a back and forth rocking motion will assist in removal of the bump stop. Save for reinstallation.

1/8” and 7/16” drill bits

OE Coil Bucket

Front OE Rivet Heads

1/8” and 7/16” drill bits

Illustration 3 Rivet Removal

Lower OE Rivet Heads

OE 14mm Track Bar Retaining Bolt

Frame Crossmember Existing Hole

90-5002 Torque Tool

Frame Crossmember

7/16” X 1 1/4” Bolt

90-5002 Torque Tool

Pitman Arm

OE 14mm Nut Plate

Illustration 2 Pitman Arm Torque Tool

Pitman Arm

52434 /52434MXR Revised 10.30.07

90-2564 Shock Hoop – Drvr

OE Steering Box Bolt

15-11213 End Cap (2)

1/2” X 1 3/4” Bolt

Illustration 4a Coil Over Hoop Install

Driver Side

90-2565 Shock Hoop – Pass

15-11213 End Cap (2)

1/2” X 1 3/4” Bolt

90-1582 Nut Plate

1/2” X 1 3/4” Bolt

Illustration 4b Coil Over Hoop Install

Passenger Side

Drill Rear Mounting Hole to 1/2”

Drill Rear Mounting Hole to 1/2”

Mounting Hole Must Be Drilled

9

52434 /52434MXR Revised 10.30.07

22. Unbolt the bump stop mounting cups from the frame. Save for reinstallation.

23. On the driver side, unclip the axle vent line from inside the frame.

24. On the passenger side unclip the axle hub vacuum line from inside of the axle bump stop plate.

25. Raise the front axle enough to relieve ten-sion on the shock hardware and remove the shocks from the vehicle.

26. Lower the front axle enough to remove the coil springs from the front spring bucket. The coil springs and isolators will not be reused.

27. Support the front axle with jack stands and place a floor jack under the rear of the front differential housing.

28. Working on one side of the vehicle at a time.

29. Hit the face of the rivet heads with a ham-mer holding the factory coil spring bucket to the frame to flatten for drilling.

30. Center punch the flattened faces of the rivet heads (front and lower) and drill an 1/8” pilot hole in each rivet. See ILLUS-TRATION 3.

31. Drill out the 1/8” pilot holes to 7/16”. CAUTION! Be very careful not to drill through any wiring or lines that may be attached to the frame. 32. Knock the heads of the rivets off using a

chisel and push the rivet body out of it’s hole through the back of the frame.

33. Remove the factory coil spring bucket from the vehicle. The factory coil bucket will not be reused.

34. Repeat on the remaining side of the vehi-cle.

35. Driver side hoop installation, remove the front lower mounting bolt from the frame that connects the steering box to the

frame. See ILLUSTRATION 4a. 36. Drill out the existing rear mounting hole

to 1/2”as shown in ILLUSTRATION 4a. CAUTION! Be very careful not to drill through any wiring or lines that may be attached to the frame. 37. Insert the shock hoop (90-2564) with the

short arm of the hoop to the rear of the truck. Secure the front of the hoop using the previously removed steering box bolt. See ILLUSTRATION 4a.

NOTE: Use thread locker on the steering box bolt and start it by hand to en-sure it goes in properly. 38.Bolt the hoop rear mounting tube to the

frame using the supplied 1/2” X 1 3/4” bolt and hardware in the rear mounting hole. Leave hardware loose at this time. See ILLUSTRATION 4a.

39.Passenger side hoop installation, install the passenger side coil bucket (90-3411) to the frame temporarily using only (3) bolts. Install (2) bolts through the front and (1) center bolt from the bottom. Tighten the bottom bolt first. See ILLUSTRATIONS 5,6.

40.Bolt the (2) outer hoop mounting tabs (90-3420) to the hoop (90-2565) using the 1/2” X 1 1/4” bolts and hardware. See ILLUS-TRATION 7.

41.Raise the shock hoop (90-2565) with the short arm of the hoop to the rear of the truck into position and bolt the outer mounting tabs (90-3420) to the coil bucket using the supplied 1/2” X 4 3/4” bolts and hardware. See ILLUSTRATION 4b & 7.

42.Make sure the hoop mounting tubes are level and sitting flush against the frame. Center punch and drill the front 1/2” mounting hole.

43.Drill out the existing rear mounting hole to 1/2”. See ILLUSTRATION 4b.

52434 /52434MXR Revised 10.30.07

11

Illustration 5 Coil Over Bucket Install

7/16” X 1 1/4” Bolts Frame

Coil Bucket 90-3403 drvr and 90-3411 pass

Previously Drilled Out Rivet Holes

7/16” Hardware

11

Illustration 6 Bump Stop Assembly

Passenger Side Driver Side

Frame Frame

OE Bump Stop and Mounting Cup

7/16” X 1 3/4” Bolts

90-3401 Bump Stop Drop

90-3402 Bump Stop Drop

(3) 7/16” Hardware

(2) 7/16” Hardware

(3)7/16” X 1 3/4” Bolts

OE Bump Stop and Mounting Cup

52434 /52434MXR Revised 10.30.07

CAUTION! Be very careful not to drill through any wiring or lines that may be attached to the frame. 44. Bolt the rear hoop mounting tube to the

frame using the supplied 1/2” X 1 3/4” bolts and hardware. See ILLUSTRA-TION 4b.

45. Unbolt the outer mounting tabs from the hoop.

NOTE: Be careful not to let the hoop fall once it is unbolted from the mounting tabs. 46.Unbolt and remove the coil bucket from

the vehicle. 47. Bolt the front hoop mounting tube to the

frame using the supplied 1/2” X 1 3/4” bolts, hardware and nut plate (90-1582). Leave hardware loose at this time. See ILLUSTRATION 4b.

48.Working on one side of the vehicle at a time.

49.Raise the new Pro Comp coil bucket (90-3403 drvr and 90-3411 pass) into place by lining up the rivet holes with the holes in the new coil bucket. See ILLUSTRA-TION 5.

NOTE: The plastic inner fender will need to be trimmed to allow the coil buckets to fit properly. Use the new coil bucket as a guide for cutting. CAUTION! Be very careful not to cut any wiring that may be attached to the inner fender. Be Sure that the A/C lines have at least a 1/2” of clearance from the backside of the coil bucket mounting bolts. 50.Secure the coil bucket to the frame using

the supplied (5) 7/16” x 1 1/4” bolts in the rivet holes. Do not torque these bolts at

12

OE Bolts


OE Pal Nut

OE Pal Nut

OE Bolts

Illustration 8 Track Bar Bracket Install

(3) 9/16” X 3” Gr. 8 Bolts

Illustration 7 Hoop Support Tab Install

1/2” X 1 1/4” Bolts

Coil Bucket 90-3403 drvr and 90-3411 pass

90-3420 Hoop Mount Tab

90-3420 Hoop Mount Tab

52434 /52434MXR Revised 10.30.07

13

this time. 51.Use the lower mounting holes in the coil

bucket as a drill guide and drill new mounting holes in the frame using a 7/16” drill bit

NOTE:(2) lower holes on the passen-ger side and (1) lower hole on the driver side will need to be drilled out. 52.Drill out the existing hole in the OE bump

stop mounting cup to 7/16”. NOTE: Grind off the locating tab from the mounting cup. 53.Use the supplied 7/16” X 1 1/4” bolt and

hardware to bolt the bump stop mounting cup to the bump stop drop bracket.

54. Reinstall the previously removed OE bump stop into the mounting cup on the new bump stop drop. See ILLUSTRA-TION 6.

55. Install the bump stop drop assembly (90-3401 drvr and 90-3402 pass) to the lower

plate of the coil bucket. Line up the holes and secure with the remaining 7/16” X 1 3/4” bolts and hardware. See ILLUS-TRATION 6.

NOTE: ON THE DRIVER SIDE BUMPSTOP DROP ONLY! Do not install a bolt in the forward lower mounting hole. The OE track bar bolt will be installed there during the track bar installation. 56. Torque all the 7/16” coil bucket and

bump stop drop mounting hardware ac-cording to the chart on page 25.

57. Bolt the (2) outer hoop mounting tabs to the hoop using the 1/2” X 1 1/4” bolts and hardware. See ILLUSTRATION 7.


59. Install track bar drop bracket (90-5054)using (3) 9/16” X 3” and (2) OE bolts. Use thread locker on the bolts. Torque OE the bolts to 129 ft./lbs. and the 9/16” bolts to 110 ft./lbs. See ILLUSTRATION 8.

60. Bolt the factory brake line bracket to the hole on the front edge of the new coil bucket using the supplied 1/4” X 3/4” bolt and hardware. Be sure that the tab fits properly in the upper hole. See IL-LUSTRATION 9.

NOTE: Carefully pull down and bend the metal brake line down to create enough slack to accommodate the new lower mounting position. Be sure to tuck the lines back up under the frame. NOTE: On the driver side make sure that the metal brake line does not come in contact with the steering shaft, rag joint or any moving parts or non-moving parts. 61. Unbolt and remove the passenger side

radius arm from the vehicle by taking out the (3) OE mounting bolts from the front axle and the rear frame mounting pocket.

Illustration 9 ABS Bracket Install

OE Brake Line Bracket

Coil Bucket

1/4” Hardware

Frame

1/4” X 3/4” Bolt

52434 /52434MXR Revised 10.30.07

Inside View Outside View

Driver Side Pro Comp Radius Arm

Final Assembly

Illustration 10 Driver Side Pro Comp Radius Arm Assembly

OE Bolts

Frame Mounting Pocket

Axle Mount

Front Axle

Radius Arm (90-2502)

OE Bolts

OE Nut

OE Nut

18mm Nut and Washer

14

52434 /52434MXR Revised 10.30.07

15

62. On the driver side remove the rear radius arm to frame mounting bolt.

63. Using the floor jack carefully pivot the rear of the differential housing down. This will allow for easier installation of the new passenger side radius arm.

64. On the passenger side, install the new Pro Comp radius arm (90-2506) using the (3) previously removed OE bolts. Leave the bolts loose. See ILLUSTRATION 10.

65. Remove the driver side radius arm from the vehicle.

66. Install the driver side Pro Comp radius arm (90-2502) using the (3) previously removed OE bolts, (2) OE nuts and the supplied (1) 18mm nut and (1) hardened washer.

NOTE: Use thread locker on the OE bolts, nuts and new 18mm nut. 67. Torque the front axle mount bolts to 222

Vacuum Line Tab

Axle

90-2562 Lower Coil Over Mount

Illustration 11 Lower Coil Over Mount

Install

Brake Line Bracket

Brake Line Bracket Drill Picture

90-3425 Vacuum Line Tab

5/8” Mounting Nut

1/4” Bolt and Hardware

1/4” Drill Bit

Adel Clamp

629000R Coil Over Shock

14mm X 60mm Bolt

5/8” Nut

1/4” X 1/2” Bolt and Lock Washer

ABS Line

Adel Clamp

Brake Line

Brake Line Bracket Locating tab

Inside Flat Edge of 5/8” Mounting Nut

1/4” X 1/2” Bolt and Lock Washer

52434 /52434MXR Revised 10.30.07

16

ft./lbs. Do not torque the rear mounting bolt until vehicle is on the ground. See ILLUSTRATION 10.

68. Unbolt the center bolt from the lower coil

spring mount block and remove it from the vehicle.

69. Insert the new dual coil over lower mount (90-2562), vacuum line extension tab and secure with the supplied 14mm X 60mm bolt. See ILLUSTRATION 11. Apply thread locking compound to the bolt and torque according to the chart on page 25.

70. Using the supplied Adel clamp, secure the vacuum line to the extension tab (90-3425). Slip the tab in between the ends of the Adel clamp and tighten using the sup-plied 1/4” X 3/4” bolt and hardware. See ILLUSTRATION 11.

71. Insert the mono ball spacers (90-2433) from pack (90-6463) in the tops of the (4)coil over shocks as shown in ILLUSTRA-TION 12.

NOTE: The spacers are a tight fit. A press might be needed to fit the spacers into the mono balls.

Illustration 12 Coil Over Upper Install

1/2” X 4 3/4” Bolt

1/2” X 4 3/4” Bolt

1/2” Hardware

90-2433 Upper Mount Spacers

Reservoir

Reservoir

90-3420 Hoop Mount Tab 90-3420 Hoop

Mount Tab

629000R Coil Over Shock

Illustration 13 Sway Bar End Link

Assembly

Sway Bar

90-2566 Sway Bar End Link

90-3427 End Link Adapter

9/16” X 3” Bolt

1/2” X 2 3/4” Bolt

52434 /52434MXR Revised 10.30.07

17

Sway Bar

Illustration 14a Sway Bar Drop Assembly

Drill out the smaller sway bar mount hole to 7/16”

7/16” X 1 1/4” Bolt

7/16” X 1 3/4” Bolt

90-3416 drvr and 90-3418 pass Sway Bar Drop Bracket

90-2509 Sway Bar Drop Brace

Drill out the smaller sway bar mount hole to 7/16”

90-2055 Spacer

7/16” X 1 3/4” Bolt

90-2055 Spacer

7/16” X 1 1/4” Bolt

Finished Assembly Driver Side

7/16” X 1 1/4” Bolt

7/16” X 1 1/4” Bolt

7/16” X 1 1/4” Bolt

Illustration 14b Passenger Side Steering Stabilizer Bracket Sway

Bar Drop Brace Tab

Steering Stabilizer Bracket 90-3198

7/16” X 1 1/4” Bolt

90-3418 Sway Bar Drop Bracket OE Stabilizer

Hardware

7/16” X 1 1/4” Bolt

Factory Steering Stabilizer

7/16” X 1 3/4” Bolt

7/16” X 1 3/4” Bolt

52434 /52434MXR Revised 10.30.07

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72. Install the rear coil over shock assembly (629000R) onto the rear lower mount stud. Secure using the supplied hardened 5/8” fine thread nut. See ILLUSTRA-TION 11.

NOTE: Use thread locker on the 5/8” fine thread nut and start it by hand to ensure it does not cross thread. 73. Secure the top of the rear coil over shock

assembly to the coil bucket using the outer hoop mounting tab (90-3420) and the supplied 1/2” X 4 3/4” bolt. See IL-LUSTRATION 12.

74. Install the front coil over shock assembly (629000R) onto the front lower mount stud. Secure using the supplied hardened 5/8” fine thread nut. See ILLUSTRA-TION 11.

NOTE: Use thread locker on the 5/8” fine thread nut and start it by hand to

ensure it does not cross thread. 75. Secure the top of the front coil over

shock assembly to the coil bucket using the outer hoop mounting tab (90-3420) and the supplied 1/2” X 4 3/4” bolt. See ILLUSTRATION 12.

76. Secure the shock reservoirs to the shock hoop using the supplied clamps and plas-tic reservoir isolators. See ILLUSTRA-TION 12.

NOTE: Make sure the fitting and the braided line have adequate space and do not contact anything. Make sure there are no kinks in the lines. 77. Repeat on the remaining side of the vehi-

cle. 78. On both sides, torque all the hoop mount-

ing hardware according to the torque chart on page 25. See ILLUSTRATION 4b.

NOTE: On the driver side, be sure to re-torque all (3) steering box bolts to 111 ft./lbs. 79. Install (15-11213)- 1 1/2" end caps in the

ends of the shock hoops. See ILLUS-TRATION 4a & 4b.

80. Assemble the sway bar end links (90-2566) using the bushings and sleeves from hardware pack (90-6413). See IL-LUSTRATION 12.

NOTE: Each end link gets (1) 54314 sleeve & (1) bushing 5/8” (600000) on the bottom and (1) 1036 sleeve & (1) bushing 3/4” (600020) on top. 81. Bolt the lower adapter bracket (90-3427)

to the short end sway bar end link using the supplied 1/2” X 2 3/4” bolts and hard-ware.

82. Bolt the sway bar end link adapter to the OE sway bar end link hole in the front axle. Secure with the 5/8” hardware.

Illustration 15 Final Install

52434 /52434MXR Revised 10.30.07

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NOTE: The angled end of the sway bar end link should be facing in towards the center of the vehicle. 83. Remove the sway bar and factory clips

from the frame on both sides of the vehi-cle. Note the orientation of the sway bar for reinstallation.

84. Install sway bar drop brackets (90-3416 drvr and 90-3418 pass). Assemble all components shown before you begin to tighten any hardware. Use the (4) 7/16” X 1 3/4” bolts, hardware and spacers (4) (90-2055) to secure the drop brackets to the frame. See ILLUSTRATION 14a.

85. On the driver side, bolt the sway bar sup-port tube (90-2509), above the lower ra-diator hose and cooler lines, to the drop bracket (90-3416) with (2) 7/16” X 1 1/4” and hardware.

86. On the passenger side, bolt the sway bar support tube (90-2509) and steering stabi-lizer bracket (90-3198) to the sway bar

drop bracket (90-3418) using the (2) 7/16” X 1 3/4”, (1) 7/16” X 1 1/4” and hardware. Use (1) 7/16” X 1 1/4” and hardware to bolt the steering stabilizer bracket to the tab on the sway bar support tube. See ILLUSTRATION 14b.

87. Bolt the factory sway bar to the drop brackets using the (4) 7/16” X 1 1/4” bolts and hardware. See ILLUSTRA-TION 14a.

NOTE: The smaller hole on each factory sway bar mount needs to be drilled out to 7/16” to accommodate the supplied 7/16” bolts. 88. Secure the top of the sway bar end link to

the sway bar using the supplied 9/16” X 3” bolts and hardware.

89. Torque all sway bar hardware according to the chart on page 25.

90. Install draglink end into pitman arm and torque draglink nut to 148 ft./lbs. Rein-stall cotter pin.

91. Install the steering stabilizer stem to the new pro comp bracket (90-3198) using the previously removed OE hardware. See ILLUSTRATION 14b.

92. On the driver side, re clip the axle vent line on the frame providing adequate slack for the line at full droop.

93. On the passenger side, reposition the clip on the axle hub vacuum line to provide adequate slack to re-clip the line to the existing hole on the outside of the bump stop plate.

NOTE: Be sure that the newly re-routed vent line does not interfere with the travel of the bump stop. 94. The OE front brake line bracket will need

to have a 1/4” mounting hole drilled into the end near the locating tab. Place the locating tab of the bracket against the in-side flat edge of the 5/8” rear lower coil

Track Bar

OE Pal Nut

OE Bolt


Illustration 16 Track bar Install

52434 /52434MXR Revised 10.30.07

20

over mounting nut. Mark the face of the bracket for drilling. See ILLUSTRA-TION 11 for reference.

95. Center punch the previously made mark and drill out to 1/4”.

96. Secure the OE brake line bracket to the front end of the lower coil over mount stud using the supplied 1/4”-20 X 1/2” Bolt and lock washer. See ILLUSTRA-TION 11.

NOTE: The brake line bracket may need to be bent in slightly toward the coil over for additional clearance. 97. Bolt the ABS line to the rear of the lower

coil over mount stud using the supplied Adel clamp 1/4”-20 X 1/2” bolt and lock washer. See ILLUSTRATION 11.

98. Drill a new ABS line inner fender clip mounting hole, using a 15/64” bit, 3” lower in the inner fender to provide ade-quate slack for line and reattach the ABS line.

99. Flip the ABS wiring clips 180 degrees and fasten to the tabs on the backside of the radius arms using the OE bolts.

NOTE: Use silicone to seal the ABS line push clip to the hole on the top of the Radius arm. 100.Reinstall the front wheels and lower the

vehicle to the ground. Torque to manu-facturers specifications.

101.Torque the OE rear Radius arm bolts to 222 ft./lbs.

102.Reinstall the track bar into the Pro Comp track bar bracket (90-5054) using the OE bolt. Torque to 406 ft./lbs. See ILLUS-TRATION 16.

NOTE: You may find that having someone inside the vehicle and moving the steering wheel from side to side will aid in the alignment of the track rod. DO NOT

start the engine for this! You only have to move it enough to line the holes up on the track bar mount. 103.On both sides of the vehicle, check the

routing of the brake lines and the ABS wire harnesses. There must be no pinching, rubbing, or stretching of either component. At full droop, cycle the steering from lock to lock while observing the reaction of these components. Reposition them if needed.

NOTES: ⇒ The Pro Comp coil over shocks

have been preset to provide the proper ride height and shouldn’t require any adjustments. If any adjustments are deemed neces-sary make sure to do so with coil over shocks fully extended.

⇒ On completion of the installation, have the suspension and head-lights re-aligned.

⇒ After 100 miles recheck for proper torque on all newly in-stalled hardware.

⇒ Recheck all hardware for tight-ness after off road use.

52434 /52434MXR Revised 10.30.07

1. Block the front tires and raise the rear of the vehicle. Support the frame with jack stands forward of the rear springs.

2. Remove the wheels and tires. 3. Remove the shocks on both sides of the

vehicle. It may be necessary that you slightly raise the axle to unload the shocks for removal.

4. Unbolt the emergency brake line brackets from the upper spring plate on both sides of the vehicle. Save hardware for reuse.

5. Unclip the differential vent line from the frame.

6. If your vehicle is equipped with factory sway bar, unbolt it from the end links.

7. Support the rear axle with a floor jack and remove the U-bolts on the driver side. Slightly loosen the U-bolts on the passen-ger side.

8. Lower the rear axle and remove the fac-tory block and rear leaf spring from the driver side only at this time.

9. The heavy factory leaf on the bottom of the leaf pack and the upper overload spring must be removed and used on the new Pro Comp rear leaf spring. Use C-clamps to hold the leaves together. Make note of the direction of the arch and the offset of the centering hole (long end for-ward/back etc.). Remove the OE center bolts and separate the spring pack. See ILLUSTRATION 17.

10. Install the heavy leaf on the bottom of the new Pro Comp spring pack (PN 22415). Install the overload with the spacer at the top of the Pro Comp spring, use the new center bolt and lock nut from pack (90-6337) if needed, again use C-clamps to assist in the assembly. See ILLUSTRA-TION 17.

NOTE: Top spring plate center hole needs to be drilled out to 3/4” to clear nut from pack (90-6337) if the factory overload set up is not used. 11. Install the spring pack to the hangers us-

ing the factory hardware. Do not torque at this time.

NOTE: If installing traction bar kit 72099 install the rear mount at this time.

12. Reinstall the factory block and if noted above the 1 1/2” aluminum lift block (95-150F). Make sure the pin fits into the hole on the spring perch. Use your floor jack to raise the axle to the spring making sure the pin on the factory leaf spring as-sembly fits into the hole on the lift block. Secure the assembly with the 5/8” U-bolts (PN 13-90180) or (PN 13-90190 from U-bolt kit 50191 (sold separately) for vehicles not equipped with a fac-tory overload spring), hi-nuts (PN 20-65471) and washers supplied. Do not torque the hi-nuts at this time. See IL-LUSTRATION 17.

NOTE: Make sure the block sits flush on the axle perch.

PLEASE NOTE: ∗ FOR VEHICLES EQUIPPED

WITH THE FACTORY 4” BLOCK, INSTALL THE SPRING PACK (22415) AND FACTORY 4” BLOCK ONLY.

∗ FOR VEHICLES EQUIPPED WITH THE FACTORY 2 1/4” BLOCK, INSTALL THE SPRING PACK (22415), FACTORY 2 1/4” BLOCK AND THE SUPPLIED 1 1/2” ALUMINUM BLOCK.

See ILLUSTRATION 17.

Rear Installation:

52434 /52434MXR Revised 10.30.07

22

OR

Illustration 17 Pro Comp Rear Spring

Assembly

Upper Spring Plate

20-65471 Hi-Nuts

13-90180 U-bolts

2 1/4” Factory Block

95-150F 1 1/2” Aluminum Lift Block

4” Factory Block

22415 Leaf Spring

Rear Spacer Options ∗ FOR VEHICLES EQUIPPED WITH THE FACTORY 4” BLOCK, IN-

STALL THE SPRING PACK (22415) AND FACTORY 4” BLOCK ONLY. ∗ FOR VEHICLES EQUIPPED WITH THE FACTORY 2 1/4” BLOCK, IN-

STALL THE SPRING PACK (22415), FACTORY 2 1/4” BLOCK AND THE SUPPLIED 1 1/2” ALUMINUM BLOCK.

See Inset box after instruction 11.

97–165 Center Bolt

10mm Center Bolt Nut

Center Hole may need to be drilled out to 3/4”

52434 /52434MXR Revised 10.30.07

23


14. Remove the emergency brake bracket from the passenger side shock bracket. One at a time remove the factory rear shock brackets and install the new shock adapter brackets (90-3215 drvr and 90-3216 pass) to the rear axle. Reattach the emergency brake bracket to the passenger side bracket (90-3216) using the OE hardware. Make sure the bracket seats properly on the axle locator pin. Use the OE hardware and be sure to not over tighten the hardware.

15. Install your new Pro Comp shocks (MX6069R). Torque the upper mounting hardware to 46 ft./lbs. and the lower mounting hardware to 66 ft./lbs. Use thread locker on these bolts.

16. On driver side, carefully bend down the bracket that secures the emergency brake to the frame and re-fasten the emergency brake line bracket to the upper spring plate.

17. Support the rear driveshaft and remove the carrier bearing housing bolts. Insert rear driveshaft spacer (PN 90-3053) be-tween carrier bearing housing and frame mount. The open side will be facing the front and the notch goes on the top. Use the supplied 7/16” X 1 1/4” bolts and hardware from hardware pack (90-6340)to bolt spacer to frame mount. Use the remaining 7/16” X 1 3/4” bolts and hard-ware from hardware pack (90-6315) to secure the bearing housing to the spacer. Torque to 60 ft./lbs. See ILLUSTRA-TION 18.

NOTE: If vehicle came with a fac-tory carrier bearing spacer it may need to be removed depending on the amount of drive-line vibration experienced. Also additional shim kit PN 52480 can be purchased to alle-viate this problem.

18. Re-clip the rear axle differential vent line on the frame to provide adequate slack.

19. If vehicle came equipped with a rear sway bar, Re-attach the rear sway bar to the end links. Secure with the previously re-moved OE hardware.

20. Reinstall the wheels and tires and lower the vehicle to the ground. Torque lug nuts to manufacturers specifications.

21. Torque the spring mounts at this time. The front bolts are torqued to 250 ft./lbs. and the rear bolts are torqued to 185 ft./ lbs. Torque the 5/8” U-bolts to 120 ft./lbs.

22. Re-check the wheel lug torque on all four wheels at this time.

23. Re-check all hardware (both the front and the rear) for proper installation and torque!!

24. If you wish, you may trim the excess u-bolt thread length. If you do this you should leave approximately one inch of

Frame Mount

7/16” X 1 1/4”

7/16” Nut & Washer

Drive-shaft Shim 90-3053

7/16” X 1 3/4” Bolt

Illustration 18 Carrier Bearing Shim

Assembly

Factory Carrier Bearing Shim May Be Included Here

52434 /52434MXR Revised 10.30.07

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thread exposed after the U-bolts are torqued.

NOTES: ⇒ The Pro Comp coil over shocks

have been preset to provide the proper ride height and shouldn’t require any adjustments. If any adjustments are deemed neces-sary make sure to do so with coil over shocks fully extended.

⇒ On completion of the installation, have the suspension and head-lights re-aligned.

⇒ After 100 miles recheck for proper torque on all newly in-stalled hardware.

⇒ Recheck all hardware for tight-ness after off road use.

52434 /52434MXR Revised 10.30.07

52434 /52434MXR Revised 10.30.07

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 passen-ger 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. Al-ways avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking! Pro Comp re-minds you to fasten your seat belts at all times and reduce speed! We will gladly answer any questions concerning the design, function, maintenance and correct use of our products.

Please make sure your Dealer/Installer explains and delivers all warning notices, warranty

forms and instruction sheets included with Pro Comp product. Application listings in this catalog have been carefully fit checked for each model and year denoted. How-

ever, Pro Comp reserves the right to update as necessary, without notice, and will not be held responsible for mis-prints, changes or variations made by vehicle manufacturers. Please call when in question regarding new model year, vehicles not listed by specific body or chassis styles or vehicles not originally distributed in the USA.

Please note that certain mechanical aspects of any suspension lift product may accelerate or-

dinary wear of original equipment components. Further, installation of certain Pro Comp products may void the vehicle’s factory warranty as it pertains to certain covered parts; it is the consumer’s responsibility to check with their local dealer for warranty coverage before installation of the lift.

Warranty and Return policy: Pro Comp warranties its full line of products to be free from defects in workmanship and materials. Pro

Comp’s obligation under this warranty is limited to repair or replacement, at Pro Comp’s option, of the defective product. Any and all costs of removal, installation, freight or incidental or consequential damages are expressly excluded from this warranty. Pro Comp is not responsible for damages and / or warranty of other vehicle parts re-lated or non-related to the installation of Pro Comp product. A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will assume all risk and responsibility for potential damages in-curred as a result of their chosen modifications. Warranty coverage does not include consumer opinions regarding ride comfort, fitment and design. Warranty claims can be made directly with Pro Comp or at any factory author-ized Pro Comp dealer.

IMPORTANT! To validate the warranty on this purchase please be sure to mail in the warranty card. Claims not covered under warranty- • Parts subject to normal wear, this includes bushings, bump stops, ball joints, tie rod ends and heim joints • Discontinued products at Pro Comp’s discretion • Bent or dented product • Finish after 90 days • Leaf or coil springs used without proper bump stops • Light bulbs • Products with evident damage caused by abrasion or contact with other items • Damage caused as a result of not following recommendations or requirements called out in the installation manuals • Products used in applications other than listed in Pro Comp’s catalog • Components or accessories used in conjunction with other manufacturer’s systems • Tire & Wheel Warranty as per Pro Competition Tire Company policy • Warranty claims without “Proof of Purchase” • Pro Comp Pro Runner coil over shocks are considered a serviceable shock with a one-year warranty against leakage only. Rebuild service and replacement parts will be available and sold separately by Pro Comp. Contact Pro Comp for specific service charges. • Pro Comp accepts no responsibility for any altered product, improper installation, lack of or improper maintenance, or improper use of our products.

E-Mail: [email protected] Website: www.explorerprocomp.com Fax: (619) 216-1474 Ph: (619) 216-1444

HERE: __________________

WARRANTY REGISTRATION NUMBER

PLACE

part # 52434/b/52434mxr 2005-2006 4wd f250-350 coil over ... · mx6069r mx-6 shock absorber 2 - -...

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