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1997-03 Ford 4WD F150, Super Crew & Expedition 6″ Performance Suspension System

August 17th, 2009 · No Comments

1. Disconnect the negative terminal on the battery. With the vehicle on level ground set the emergency brake and block the rear tires. Jack up the front end of the truck and support the frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE! Remove the front tires.
2. Locate the torsion bar adjusting cams and threaded bolts. Measure exposed threads of torsion bar adjusting bolts and record for reinstallation. Mark torsion bars indicating driver and passenger. Using a torsion bar removal tool unload the torsion bars and remove the crossmember and bars. Retain the hardware for reinstallation. NOTE- Do not attempt to unload or remove torsion bars without the proper torsion bar tool. Torsion Bars are under extreme spring load.
3. Working from the driver side of the vehicle disconnect the tie rod ends from the steering knuckle by striking the knuckle to dislodge the tie rod end. Use care not to damage the tie rod end when removing.
4. Remove brake caliper and place next to frame. Do not overstretch bake hose when doing so. Retain hardware for reinstallation SEE PHOTO BELOW
5. Remove brake rotor, axle nut dust cover, cotter pin and axle nut. Remove ABS line and retaining clip from steering knuckle. Remove dust shield and discard.
6. Remove the upper and lower ball joint nuts and cotter pins. Disconnect the upper and lower ball joints from the steering knuckle by striking the knuckle with a large hammer next to each ball joint on the knuckle to dislodge the ball joints. Use care not to hit the ball joints when removing. Retain hardware and discard knuckle.
7. Working off the vehicle remove hub assembly from steering knuckle, retain hardware and parts for reinstallation
8. Taking care remove the stock wheel seal from the stock steering knuckle noting the direction of the seal lip. Reinstall this factory seal in to the new steering knuckle FT30006D for driver side and FT30006P for passenger side with lip in same direction.

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