Ford Truck Installation Instructions

This kit is designed to add adjustability to the factory supplied system to compensate for torsion bar sag and fatigue.

Applications Include:

• Full Site Ford 150 4x4 Series
• Trucks with Torsion Bars
• SUV's with Torsion Bars
• 1997 - 2003

FX Cams are designed to add additional height adjustment to your vehicle. Under no circumstance should the truck be adjusted beyond the factory height measurement.

The shock absorber is the suspension height limiter and only stock length stock length shock absorbers are recommended without modification whatsoever.

Adjusting vehicle suspension beyond the maximum factory height can cause binding of crucial steering and suspension components.

These instructions and warnings are not to be substituted for the factory service manual. Torsion bars are preloaded in the vehicle. Only experienced suspension technicians with working knowledge of the system and the properly designed tools and Safety Equipment should attempt installation of this part.

Installation of this product and all the adjustments should be performed by a licensed certified technician using the correct tools and procedures. Adjusting the suspension beyond the factory recommended height can cause binding and accelerated wear of critical steering and suspension parts. Under no circumstances shall Suspension Maxx Inc. be held liable for any damaged parts or loss of use do to incorrect installation or adjustments. The purchaser of this product assumes all liability.

Calibration is required before installation.

Pat. Pending

• To calibrate match A or B stamped on the internal hub with the appropriate numbered outer position.
• Apply Anti-seize on gear tooth area to ease future disassembly
• Install hub retainer clip (one clip supplied)
• Reinstall FX Cam in vehicle
• Remove hub retainer clip
• Adjust suspension ride height within specified range
• Wheel alignment required after installation

Notice.Wheel Alignment required after installation.

Ford Truck Torsion Bar Tool

Caution: To prevent personal injury.

Wear eye protection that meets ANSI787.1 and OSHA requirements.

The torsion bar is under pressure, creating a potentially dangerous situation. Completely release pressure before servicing the torsion bar.

Removal
Caution: The left and right side torsion bars are not interchangeable! The bares are identified and stamped R or L, for right and left. The bars do not have a front or rear end and can be installed with either end facing forward.
Caution: If the vehicle is equipped with a air suspension system, electrical power supply system must be turned off prior to hoisting, jacking or towing vehicle. This can be done by disconnecting battery or turning air suspension switch to OFF position. Switch is located in right hand kick panel.

1. Raise and support the vehicle with the front suspension hanging.


2. Remove torsion bar adjuster bolt. Install torsion bar installer/remover (T95T-5310-AR) and adapter (T96T-5310-A) onto torsion bar. See Fig. 4. Tighten installer/remover until adjuster lifts off adjuster nut. Remove the adjustor nut. Remove remover/installer. Remove torsion bar adjuster.

3. Remove torsion bar and anchor. Remove anchor from torsion bar. See Fig 5.

4. Remove all foreign material from torsion bar mounting in anchor and suspension arm.


5. Inspect adjustment bolt, bearing and swivel for damage.

Installation Caution: The left and right side torsion bars are not interchangeable. The bars are identified and stamped R or L for right or left. The bars do not have a front or rear ed and can be installed with either end facing forward.

1. Insert torsion bar ends into FX Cam and suspension arm.


2. Position the FX Cam in the frame crossmember


3. Install torsion bar installer/remover (T95T-5310-AR) and adapter (T96T-5310-A) onto torsion bar. See Fig. 4. Tighten installer/remover to load torsion bar. Coat adjusting bolt with a dry adhesive whenever it is backed off or removed. Install torsion bar adjuster nut and bolt.


4. Remove install/remove tool see Fig.4


5. Tight all fasteners to specification, lower vehicle and adjust right height.

Ride Height Adjustment Procedures: Caution: User had tools when adjusting right height. DO NOT use power tools.

Note: On vehicle with 4 wheel air suspension system, see ride height adjustment under adjustments in appropriate electronic article.

1. On vehicles with front air suspension systems, air shock absorbers must be vented prior to adjusting riding height. To vent shock absorbers, connect new generation star (NGS) tester to data link connector (DLC) located under steering column. Select air suspension control mode under active commands modes menu. Select vent frnt to deflate front air shocks.


2. Hold 30 seconds to allow complete system venting. Do NOT disconnect NGS Tester. Keep NGS tester in same mode to keep system at dagnotic mode at time of right height measurement. If NGS tester is disconnected, system will go to operational mode and based on signal inputs will level vehicle to specified height.


3. Raise vehicle on hoist with frictionless plates to support front wheels. Jounce vehicle to normalize static right height. Measure distance between center of lower control arm front bolt and ground (STEP 1) in illustration. Measure distance between bottom of steering knuckle and ground (STEP 2 in illustration) Subtract smaller measurement from larger measurement. This is riding height measurement.


4. Riding height measurement should be as specified. See Riding Height Specifications table. If riding height is not as specified, tighten or loosen bar adjusting bolt at each side required. Ensure to check ride height at each side after each adjustment.


5. After mechanical ride heights have been adjusted, using NGS Tester select save calibration values under active command mode menu to calibrate control module. Scroll Through warning message and save front (turn from OFF to ON). Do not save rear ride height. Rear ride heights are precalibrated values already stored in the control module.

Application Expedition & Navigator      Without Air Suspension           Original Components (First Measured)           Original Components (After Repair)           New Components      With Air Suspension (Vehicle In Kneel Position)           Original Components (First Measured)           Original Components (After Repair)           New Components F150      Original Components      New Components

In. (mm) 4.02-5.20 (102-132) 4.21-4.44 (107-113) 4.80-5.04 (122-128) 2.36-3.42 (60-87) 3.00-3.23 (76-82) 3.00-3.32 (76-82) 3.89-5.11 (99-130) 5.00-5.23 (127-133)