52421B /52421BMX Revised 10.30.07 2360 Boswell Road Chula Vista, CA 91914 Phone 619.216.1444 Fax 619.216.1474 E-Mail tech@explorerprocomp.com PRO COMP SUSPENSION Suspension Systems that Work! Part # 52421B/52421BMX 2005-2006 Ford Super Duty 4WD F250-350 Stage 1 Lift Kit 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.
52421B /52421BMX Revised 10.30.07 Box 1 of 3-PN 52421B/52421BMX-1 Part # Description Qty. Illus.
52421B /52421BMX Revised 10.30.07 Part # Description Qty. Illus. Page 90-3198 STEERING STABILIZER BRACKET 1 8a,8b 13 90-6390 70-0436501800 73-04300034 72-04300100816 HARDWARE PACK: Bump Stop 7/16” X 6 1/2” USS GR. 8 HEX BOLT 7/16” SAE FLAT WASHER 7/16” USS GR.8 STOVER NUT 1 2 4 2 9 9 9 14 14 14 90-3053 CARRIER BEARING SPACER 1 12 18 90-6337 97-165 72-01015008812 HARDWARE PACK CONTAINING: 10MM X 165MM SUPER DUTY CENTER PIN 10MM-1.
52421B /52421BMX Revised 10.30.07 Special Tools: Pitman Puller Tie Rod Separator Snap-On PN Ford PN CJ1119B T64P-3590-F The following parts are used in conjunction with this kit and must be purchased separately.
2421B /52421BMX Revised 10.30.07 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 crucial in assuring proper fit, performance, and the safety of your Pro Comp equipped vehicle. 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 design, not exceeding 37” tall X 13.
52421B /52421BMX Revised 10.30.07 Front Installation: 1. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or asphalt) and block the rear tires. 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. LF: RF: LR: RR: 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.
52421B /52421BMX Revised 10.30.07 Frame Crossmember Illustration 2 Existing Hole 90-5002 Torque Tool Pitman Arm Torque Tool Pitman Arm OE 14mm Track Bar Retaining Bolt Pitman Arm 90-5002 Torque Tool OE 14mm Nut Plate 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 to line up.
52421B /52421BMX Revised 10.30.07 Illustration 4 Front Radius Arm Drop Bracket Assembly 3/4” X 1 1/2” Gr. 8 Bolt Frame Pocket 3/4” X 1 1/2” Gr. 8 Bolt 3/4” X 5” Gr. 8 Bolt The Notched Bracket Goes on the Bottom 3/4” Stover Nut and Washers 90-3166 Radius Arm Drop Bracket 90-3167 Radius Arm Drop Bracket 90-2507 Spacer Tube OE the bolts to 129 ft. lbs. and the 9/16” bolts to 110 ft. lbs. See ILLUSTRATION 3. 20. Unbolt the front brake line bracket and ABS clips from the lower coil block.
52421B /52421BMX Revised 10.30.07 Illustration 5 Front Radius Arm Drop Drill Picture Drill Out (2) Center Holes Using Assembled Drop Bracket as a Template 7/16” Hardware Transfer Case Skid Plate Transfer Case Skid Plate 7/16” Drill Bit 3/4” X 5” Gr. 8 Bolt 3/4” X1 1/2” Gr. 8 Bolt 3/4” X 1 1/2” Gr.
52421B /52421BMX Revised 10.30.07 3/4” X 5” bolt in the rear hole. Do not torque at this time. See ILLUSTRATION 4. 29. From the rear, slide the previously removed transfer case skid plate in between the frame and the rear of the radius arm drop bracket. Insert (2) 7/16” X 1 1/2” bolts through the outside holes in the rear of the drop bracket and skid plate. Tighten these bolts and use the radius arm bracket holes as a drill template to drill out the (2) inside holes in the factory skid plate and frame.
52421B /52421BMX Revised 10.30.07 Illustration 7 Pro Comp Spring Coil Spacer Assembly 14mm. X 100mm. 10.9 Bolt Front of Vehicle Factory Lower Coil Mount 90-3168 Coil Spacer Side Plate 6mm. 90-3158 Coil Spacer Side Plate 8mm. 6mm. X 16mm. Bolts and (2) Adel Clamps 8mm. X 20mm.
52421B /52421BMX Revised 10.30.07 plied brake line clamps (171006ERL) in the top 2 holes. See ILLUSTRATION 7. 43. On the bottom rear holes secure using the supplied (2) 5/16” X 1” hex head bolts and hardware. See ILLUSTRATION 7. 44. Torque all spring block hardware. 45. Repeat on the remaining side of the vehicle. out to 7/16” to accommodate the supplied 7/16” bolts. 51. Torque all 7/16” sway bar hardware to 50 ft. lbs. 52. Remove the factory front bump stop from the bump stop mounting cup.
52421B /52421BMX Revised 10.30.
52421B /52421BMX Revised 10.30.07 Illustration 9 Bump Stop Drop Assembly 7/16” Bolt and Washer Existing Bump Stop Hole. Drill Out To 7/16” 90-2511 Bump Stop Drop 60. Install the steering stabilizer stem to the new pro comp bracket (90-3198) using the previously removed OE hardware. See ILLUSTRATION 8b. 7/16” Washer NOTE: If installing a PRO COMP double shock hoop kit skip the following step. 7/16” X 6 1/2“ Bolt 61. Re-attach the sway bar to the sway bar end links and torque to 111 ft. lbs.
52421B /52421BMX Revised 10.30.07 NOTE: Make sure the tab on the brake line bracket fits into the Allen head of the previously installed inner Allen head bolt. 67. Reinstall the front wheels and lower the vehicle to the ground. Torque to manufacturers specifications. 68. Torque the OE rear Radius arm bolts to 222 ft. lbs. 69. Reinstall the track bar into the Pro Comp track bar bracket (90-5054) and torque to 406 ft. lbs. See ILLUSTRATION 10.
52421B /52421BMX Revised 10.30.07 Rear Installation: 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.
52421B /52421BMX Revised 10.30.07 Illustration 11 20-65471 Hi-Nuts 10mm Center Bolt Nut Pro Comp Rear spring Assembly Center Hole may need to be drilled out to 3/4” Upper Spring Plate 22415 Leaf Spring 97–165 Center Bolt 4” Factory Block OR 13-90180 U-bolts or 13-90190 U-bolts 2 1/4” Factory Block 95-150F 1 1/2” Aluminum Lift Block Rear Spacer Options ∗ FOR VEHICLES EQUIPPED WITH THE FACTORY 4” BLOCK, INSTALL THE SPRING PACK (22415) AND FACTORY 4” BLOCK ONLY.
52421B /52421BMX Revised 10.30.07 14. Install your new Pro Comp shocks (PN 93 4008 or MX6018). Torque the upper mounting hardware to 46 ft. lbs. and the lower mounting hardware to 66 ft. lbs. Use thread locker on these bolts. NOTE: If installing 9000 series shocks, ON THE DRIVER SIDE ONLY remove the factory lower shock bracket and replace it with shock bracket (90-3242). Secure the bracket to the axle using the previously removed OE hardware.
52421B /52421BMX Revised 10.30.07 bolt thread length. If you do this you should leave approximately one inch of thread exposed after the U-bolts are torqued. NOTES: ⇒ On completion of the installation, have the suspension and headlights realigned. ⇒ After 100 miles recheck for proper torque on all newly installed hardware. ⇒ Recheck all hardware for tightness af- ter off road use.
52421B /52421BMX 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 passenger cars or unmodified vehicles, both on and off–road.
