Tuff-country 24850 - Ford 91-94 Explorer 4 box kit User Manual

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Part # 24850
1991 - 1994 Ford Explorer 4WD
4” suspension system
Part
# Description
Qty.
R401 Front axle pivot relocation bracket 1
R402 Rear axle pivot relocation brackets 1
R403 DS radius arm relocation bracket 1
R404 PS radius arm relocation bracket 1
R405 Rear axle pivot support bracket 1
F405 Front sway bar relocation bracket 2
TCI-R31HD Rear add-a-leaf 2
TCI-R37 Rear add-a-leaf 2
CB38 Hardware bag 1
5U-9231R 1/2” x 3 1/4” x 9 3/4” round u-bolt 4
5U-144R 1/2” x 2 3/4” x 9 7/8” round u-bolt 4
12NW Hardware bag 1
R4NB Hardware bag 1
FBLNB2 Hardware bag 1
CAM1NB Hardware bag 1
BP20 Clevis shock mount 2
24850INST Instruction manual 2
MIRRORHANGER
Rear view mirror hanger 1
WARNINGDECAL Warning decal 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 pric-
ing. Thank you for your confidence in us and our prod-
uct.
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 pic-
ture of the hard parts that are included in this suspen-
sion system.
Installation manual
4” suspension system
1991 - 1994
Ford Explorer 4WD
Part # 24850
sj05102011rev.01
Important customer information:
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 instal-
lation.
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 per-
formance 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 suspen-
sion maintenance.
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Summary of Contents

Page 1 - Installation manual

Part # 248501991 - 1994 Ford Explorer 4WD4” suspension systemPart# DescriptionQty.R401 Front axle pivot relocation bracket 1R402 Rear axle pivot reloc

Page 2

33. Locate (2) 5/16” x 1” bolt, (4) 1/4” USS flat washers and(2) 5/16” unitorque nuts from hardware bag FBLNB2.Working on the driver side, secure the

Page 3

Rear end installation:38. To begin installation, carefully block the front tires andwheels so that the vehicle can not roll forward. Safely lift there

Page 4

line relocation brackets. 51. Working on the driver side, remove the stock e-clip thatis holding the stock brake line to the stock location. Thestock

Page 5

R404 / Qty. 1Passenger side radius armrelocation bracketR402 / Qty. 1Rear axle pivot relocationbracket / (small)R401 / Qty. 1Front axle pivot relocati

Page 6

Limited lifetime warranty Notice to all Tuff Country EZ-Ride Suspensioncustomers: It is your responsibility to keep youroriginal sales receipt! If fai

Page 7

Special note: Before installation begins, it is thecustomers/installers responsibility to make sure that allparts are on hand. If any parts are missin

Page 8

3. Working on the driver side, remove the stock sway barfrom the frame mounting location. Save the hardware.Repeat procedure on the passenger side.4.

Page 9

9. Working on the driver side stock radius arm bracket,remove the stock hardware or the stock rivets that connectthe bracket to the frame rail. The st

Page 10

14. Locate the new rear twin eye beam axle pivot relocationbracket and new support bracket. Also, locate (5) 7/16” x 11/2” bolts, (1) 1/2” x 1 1/2” bo

Page 11

Special note: Part # 24850 does not include the front coilsprings. Part # 24861 is the part # for the front coilsprings and needs to be ordered as a s

Page 12

21. Locate the stock cotter pin and castle nut that connectedthe stock tie rod to the stock pitman arm. Install the stock tierod to the newly installe

Page 13

26. Locate the stock sway bar and the stock sway bar lowerhardware. Working on the driver side, install the stock swaybar end link into the stock loca

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