Sky s OFFROAD DESIGN 92-97 F350/F250 2wd to 4wd Swap Complete Kits Instruction Manual

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Sky s OFFROAD DESIGN 92-97 F350/F250 2wd to 4wd Swap Complete Kits

Notice to Dealer / Consumer

Important: Read all instructions before attempting any work on the vehicle.

Disclaimer Notice: Installing this suspension system on any vehicle implies that you are in agreement with the following term and conditions with respect to that vehicle, the vehicle owner, and any or all occupants of said vehicle at any time:

• Sky Manufacturing is not responsible and cannot be held responsible for any conditions of said vehicle, including but not lim-ited to the following: 1) Any and all adverse behavior, premature failure, or breakage caused by oversized tires and wheels, im-proper installation, failure to follow instructions, or any general negligence caused by installer or owner of said vehicle. 2) Any breakage or premature failure caused by racing or driver negligence. 3) Any incident determined to be caused by an increase height in said vehicle’s center of gravity. 4) Any incident determined to be caused by improper installation. 5) Any incident deter-mined to be caused by a failure of materials.
• Sky Manufacturing is to be held harmless by the installer of this suspension component, owner of said vehicle, and any par-ties related directly or indirectly to said vehicle or owner of said vehicle. Sky Manufacturing is to be held harmless by all parties mentioned during the course of any and all circumstances or incidence resulting from the installation of this suspension compo-nent.
  It is not the intention of Sky Manufacturing that said vehicle be modified for use on public highways sanctioned by the Depart-ment of Transportation, or any state or local governing body. Vehicle owner accepts sole responsibility for ensuring that said ve-hicle is not in violation of local, state, or federal laws or vehicle code. Please check local vehicle laws and regulations before modifying your vehicle.

By installing this kit or having this kit installed on your vehicle, you are implying that you agree to the above terms and conditions. Please do not install this system if you do not agree.

WARNING

Vehicles modified for Off-road use may handle differently and vehicle may roll-over.
Vehicles modified for off-road use are generally do not improve in cornering or maneuverability on the highway, therefore it is imperative to familiarize yourself and all operators with the specific driving characteristics of the vehicle. Failure to operate in a safe and conservative manner may cause you, your passengers, and/or third parties to suffer serious injury or even death if con-trol is lost.

Always wear your seatbelt and shoulder harness. Seatbelts not only help to protect occupants from injury but also keep the driv-er behind the wheel and in control when operating in rough terrain. Always remain on trails and observe conservation techniques while operating your vehicle.

There are no specific directions to install this product due to the number of combinations of springs, axles, lifts etc. possible. Professional installation is recommended. This kit requires knowledge of suspension design, fabrication and welding skills.
If you lack those, do not attempt to install this kit!

INSTALLATION INSTRUCTIONS

• Step 1
  • Safely lift and support the truck. The closer you get the front frame rails to level now, the easier it will be to install this kit properly.
• Step 2
  • Remove the 2wd front suspension and clean up the frame. Note: As you can see these trucks were not built to a high level of precision. This truck was not wrecked, the two pieces of frame rail were nearly 1/4” off and they just welded it up. This will not affect the install.
• Step 3
  • Locate these two oblong holes on the frame as pictured
  • Use either the paper template available on the product page under the installation tab along with these instructions or the metal template available with this kit to mark the holes.
  • Note: We will follow along the process with the paper template. The metal template simplifies this process.
• Step 4 A
  • With the paper template you will mark just the 9/16” hole that would be the factory 4wd shackle hole. Center punch this hole and drill a pilot hole before drilling it out to size.
• Step 4 B
  • Using the optional metal template center punch and pilot drill all four holes.
  • Repeat this process on both sides.
• Step 5
  • If you are using the metal templates you can drill all the necessary holes at this point. Then skip to step 9.
  • If you are using the paper templates you will drill out 9/16” hole and bolt the FORD-4WDC-001 frame box kit to the outside of the frame rail.
• Step 6
  • Level the frame and zero your angle gauge.
• Step 7
  • Pivot the box kit on the bolt to adjust the angle to match that of the frame.
• Step 8
  • With the box kit properly aligned to the frame use a 1/2” transfer punch to locate the remaining holes.
• Step 9
  • With all the holes correctly in the frame clean the surfaces inside and out. The frame box kits will be welded in, so be sure to prep the surface inside the frame rails well.
• Step 10
  • Bolt the frame box kits in place with the supplied hardware. To ensure proper fitment. If any holes do not line up, die grind as needed to ensure they do.
• Step 11
  • Using a cutoff wheel cut through the tack welds holding the frame spacers on the hanger. These are for the 4WD frame and are not needed here.
• Step 12
  • Test fit the hanger to the frame to be sure all holes are properly aligned on the frame. Meas-ure for square and adjust if needed. Tack the frame box kits in place with the hanger bolted in to ensure everything stays square.
• Step 13
  • Weld frame box kits in, we like a nice bead across the top and bottom.
• Step 14
  • From here you can switch to the FSR instruc-tions for the kit you purchased for further de-tails, however there will be one significant difference:
  • Instead of measuring from the factory spring hanger at the rear of the spring to locate the new spring hanger up front, you will be measuring back from the new spring hanger to locate your shackle hanger (Our HD replacement FSSH or a stock hanger removed from a donor frame)
  • From here the rest of the install will be the same as it would be on a 4×4.
    Once you have it all installed and mocked up, pull it apart and paint all bare metal surfaces.

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