ZONE OFFROAD F1220 Jeep Audio Electronics Installation Guide

ZONE OFFROAD F1220 Jeep Audio Electronics

Product Information

Specifications:

• Product Name: F1220 Installation Instructions 2021 Ford Bronco 2 Door/4 Door 2 Strut Spacer Lift Kit
• Installation Time: Estimated 2-3 hours
• Difficulty Level: Easy (rated 1 out of 5)

Product Usage Instructions

Pre-Installation:
Before installing the F1220 Installation Instructions 2021 Ford Bronco 2 Door / 4 Door 2 Strut Spacer Lift Kit, make sure to read and understand all instructions and warnings provided in the user manual. Ensure that you have all the necessary tools for the installation process.

Trimming Strut Studs:
It is essential to trim the factory studs on the top of the struts to be flush or below the top surface of the strut spacer part numbers 05113 and 05115. Failure to trim these studs can result in broken strut top spacers. Refer to the attached instruction sheet for detailed information on how to trim the strut studs.

Professional Installation:
Zone Offroad Products recommends having this lift kit installed by a professional technician. The installation process requires professional knowledge of disassembly/reassembly procedures and post-installation checks. Minimum tool requirements include assorted metric and standard wrenches, a hammer, a hydraulic floor jack, and a set of jack stands. Refer to the Special Tools Required section for additional tools needed.

Off-Road Performance:
Some Zone Suspension Products are designed to improve off-road performance. It’s important to note that modifying your vehicle for off-road use may result in different handling compared to a factory-equipped vehicle. Extreme care must be taken to prevent loss of control or vehicle rollover. Always drive your modified vehicle at reduced speeds and wear your seat belt for your safety.

Tire/Wheel Fitment:
When selecting tire/wheel combinations larger than the original equipment (OE) size, consider the additional stress it may induce on the suspension, steering, and related components. Larger rim and tire combinations may increase leverage on these parts. Post-suspension system vehicles may also experience drive-line vibrations, which may require tuning and replacement of certain components.

FAQ (Frequently Asked Questions):

• Q: Can I install the F1220 Lift Kit myself?
  A: While it is possible to install the lift kit yourself, Zone Offroad Products recommends professional installation by a technician who knows disassembly/reassembly procedures and post-installation checks.

• Q: Where can I find additional information about this product?
  A: Visit www.zoneoffroad.com for additional information, including the latest instructions, videos, photos, and more. You can also contact Zone tech support directly at 888.998.ZONE or send an email to [email protected] for a quick response.

• Q: What should I do if I experience drive line vibrations after installing the lift kit?
  A: Post-suspension system vehicles may experience drive line vibrations. In such cases, it is recommended to tune the angles, replace the slider on the shaft if necessary, lengthen or true the shafts, and replace any worn-out U-joints.

ATTENTION
OE STRUT STUD CUTTING WARNING

• The factory studs on the top of the struts MUST be trimmed to be flush or below the top surface of the strut spacer part numbers 05113 and 05115.
• Failure to trim these studs will result in broken strut top spacers.
• Details about the strut stud trimming can be found in the attached instruction sheet.

Read and understand all instructions and warnings before installation of the product and operation of the vehicle.
Zone Offroad Products recommends this system be installed by a professional technician. In addition to these instructions, professional knowledge of disassembly/reassembly procedures and post-installation checks must be known. Minimum tool requirements include the following: Assorted metric and standard wrenches, a hammer, a hydraulic floor jack, and a set of jack stands. See the “Special Tools Required” section for additional tools needed to complete this installation properly and safely.

PRODUCT SAFETY WARNING

Certain Zone Suspension Products are intended to improve off-road performance. Modifying your vehicle for off-road use may result in the vehicle handling differently than a factory-equipped vehicle. Extreme care must be used to prevent loss of control or vehicle rollover. Failure to drive your modified vehicle safely may result in serious injury or death. Zone Offroad Products does not recommend the combined use of suspension lifts, body lifts, or other lifting devices.

You should never operate your modified vehicle under the influence of alcohol or drugs. Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions. Always wear your seat belt.

Special Tools Required

• Strut Compressor
• Air Hammer (Recommended)
• 35mm Axle Nut Socket
• 27mm Socket
• OTC 204-592 Ball Joint Separator (Recommended)
• Tie Rod End Separator (Recommended)

Tire/Wheel Fitment

• 275/70 w/ stock 18″ Outer Banks Wheels

• 275/80 w/ stock 17″ Black Diamond Wheels

• 315/70 w/ stock 17″ Sasquatch Wheels

• 285/70 w/ stock 17″ Badlands Wheels

• 35″ x 11.2″ on 6″ to 5″ BS, 9″ wide wheels

• 35″ x 12.50″ on 5-1/2″ to 5″ BS, 9″ wide wheels
  See more information at the end of the instructions.

• BS = Backspacing

All tire/wheel fitment is with intrusion beams removed.

PRE-INSTALLATION NOTES

1. Special literature required: OE Service Manual for model/year of the vehicle. Refer to the manual for proper disassembly/reassembly procedures of OE and related components.
2. Adhere to recommendations when replacement fasteners, retainers, and keepers are called out in the OE manual.
3. Larger rim and tire combinations may increase leverage on suspension, steering, and related components. When selecting combinations larger than OE, consider the additional stress you could be inducing on the OE and related components.
4. Post-suspension system vehicles may experience drive line vibrations. Angles may require tuning, the slider on the shaft may require replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced.
5. Secure and properly block vehicles before installation of Zone Offroad Products. Always wear safety glasses when using power tools.
6. If the installation is to be performed without a hoist, Zone Offroad Products recommends rear alterations first.
7. Due to payload options and initial ride height variances, the amount of lift is a base figure. Final ride height dimensions may vary in accordance to the original vehicle attitude. Always measure the attitude before beginning installation.

F1220 Kit Contents

Qty/Part

• 2 Front Upper Strut Spacer
• 2 Rear Upper Strut Spacer
• 1 Bolt Pack 368
  • 24 10mm-1.50 Prevailing Torque Nut, Clear Zinc
  • 24 10mm Washer, Clear Zinc
  • 6 10mm-1.50 x 45mm Bolt, Clear Zinc
  • 6 10mm-1.50 x 50mm Bolt, Clear Zinc

IMPORTANT
It is required that ride height measurements be taken before and after installation. Measure from the WHEEL AXLE CENTER up to the FENDER LIP of the wheel opening. Do this for all 4 wheels. Record measurements below.**

• BEFORE:
  LF__ RF__ LR__ RR__

• AFTER:
  LF__ RF__ LR__ RR__

These ride heights will be required if you have any ride height concerns after installation. Please be prepared to provide these to Technical Support.

INSTALLATION INSTRUCTIONS

PRE-INSTALLATION NOTES

1. This kit is designed to lift the front of the vehicle 2″ and rear 1″. Can ONLY be used with black body (base model) struts.
2. CANNOT be used with Sasquatch Suspension Package vehicles.
3. CANNOT be used with Badlands Suspension Package vehicles.
4. CV axle nut may need to be loosened and tightened on the ground with the weight the vehicle.
5. Does not fit Bronco Sport models.

FRONT DISASSEMBLY

1. Park the vehicle on a clean, flat surface and block the rear wheels for safety.

2. Raise the front of the vehicle and support with jack stands at the frame rails.

3. Remove the front wheels.

4. Disconnect the driver’s and passenger’s side front sway bar links from the lower control arm. Figure 1A Another option is to remove the 2 bolts and 2 nuts attaching the sway bar to the frame on the driver and passenger while still leaving the sway bar links attached to the lower control arm Figure 2B. Allow the sway bar to rest out of the way for the front-end disassembly. A thread locker will be required if disassembled from the mounts to the frame.
   Step 4 Note:
   Do not use power tools to remove the stabilizer bar link nut to the lower control arm. Damage to the stabilizer bar link ball joint or boot may occur

5. Disconnect the front brake line and ABS line from the steering knuckle. Figure 2

6. Disconnect the front brake line from the frame. Figure 3

7. Remove the steering tie rod end nut from the tie rod end at the steering knuckle. Use a tie rod end remover to dislodge the tie rod end from the knuckle. Be careful not to damage the boot. Figure 4 Remove the tie rod end from the knuckle.

8. Remove the upper ball joint nut and thread back on a couple of turns by hand. Use a ball joint separator tool to dislodge the upper ball joint from the knuckle (204-592 tool recommended). Be careful not to damage the boot. Figure 5 Remove the nut and remove the ball joint from the knuckle. Allow the knuckle to rest back away from the front strut.

9. Optional: Remove the CV retaining nut. Figure 6

10. Optional: Use an air hammer to dislodge the CV shaft from the hub Figure 7. This step is optional but will make it easier to remove the strut from the vehicle.
    Step 10 Note:

    • Be careful not to hit the threads on the CV shaft
    • A punch and hammer can also be used to dislodge the CV shaft from the hub.

11. Support the lower control arm with an appropriate jack. Remove the lower strut mount nuts at the lower control arm. OPTIONAL: This can be done to make the strut easier to remove. Use an air hammer to dislodge and remove the strut studs in the lower strut mounts Figure 8.

    • Step 11 Note:
      A punch and hammer can also be used to dislodge the studs from the lower strut mount.

    • Step 11 Note:
      Be sure to support the lower control arm/knuckle assembly when removing the strut.

12. Remove the three upper strut mounting nuts at the frame. Figure 9 DO NOT remove the center strut rod nut.

13. Using the jack, lower the lower control arm/knuckle assembly and remove the strut from the vehicle Figure 10.

    • Step 13 Note:
      Be sure to support the lower control arm/knuckle assembly when removing the strut.

    • Step 14 Note:
      Coil Spring is under extreme pressure. Improper removal/installation of coil springs could result in serious injury or death. Use only a high-quality spring compressor and carefully read and follow the manufacturer’s instructions.
      STRUT SPACER INSTALLATION

14. Remove the pin in the strut top hat.

15. Due to lower bar pin angle in the strut, the top plate of the strut assembly must be rotated 180 degrees. Place alignment marks on the upper strut mount, isolator, spring, strut body and lower coil seat for reference when the strut is assembled. Compress the coil spring slightly and rotate the upper plate 180 degrees. Figure 11A & B. This will allow the lower bar pin to reassemble in the lower control arm smoothly.

16. Install the shorter 10mm bolts through the hex holes on the bottom of the front strut spacer (05047). The front strut spacer will have a slight taper to it. Attach strut spacer on top of the factory strut with high side of the taper towards the outside of the vehicle. Tighten to the top plate using the provided 10mm washer and OE strut nuts to 35 ft-lbs as shown in Figure 12C. DO NOT EXCEED 35 ft-lbs when tightening the spacer to the strut.

    • Step 16 Note:
    • Hardware for the strut spacers is in Bolt Pack 368.
    • The “Made in the USA” / 05047 is on the high/thick side of the taper and will face outwards towards the tire when installed.

17. Reinstall the strut assembly into the upper frame mount by aligning the studs in the new spacer with the original mounting holes and aligning the lower studs with the mounting holes in the lower control arm Figure 13A. It is important to note that the outer winding of the coil spring must face the outside (tire side) of the vehicle Figure 13C & D. This is to ensure proper “bowing” of the coil spring. Verify the coil spring position and adjust accordingly using a strut compressor.

    • Driver Side: The lower end tip faces the front of the vehicle. Figure 13B

    • Passenger Side: The lower end tip faces the rear of the vehicle. Figure 13B
      Step 17 Note:

    • Hardware for the strut spacers is in Bolt Pack 368.

    • The thick part of the spacer will be pointing towards the outside of the vehicle as shown in Figure 12D.

    • The studs will be just at the surface for the frame mount when installing the strut into the vehicle. A magnet can be used to pull the studs up. This is done to make installation easier when the lower barpin studs are not removed.

    • Step 18 Note:
      Hardware for the strut spacers is in Bolt Pack 368.

18. Loosely fasten the strut to the upper frame mount with the provided 10mm nuts and 10mm washers.

19. Loosely fasten the strut to the lower control arm replacing the nuts onto the studs. If the studs were removed earlier for ease of removal of the strut, replace the studs and nuts.

20. Tighten the upper frame mount nuts to 35 ft-lbs. DO NOT EXCEED 35 ft-lbs when tightening the spacer to the strut.

21. Tighten the two lower strut studs/nuts to 66 ft lbs. If the lower strut studs were removed, ensure that the stud is fully seated into the lower bar pin on the strut after torquing.
    FRONT INSTALLATION

22. With the strut installed, reconnect the knuckle to the upper ball joint. Replace with factory hardware Figure 14A. While connecting the upper ball joint, be sure that the CV shaft properly aligns into the hub Figure 14B. Torque the upper ball joint nut to 46 ft lbs.

    • Step 23 Note:
      CV axle nut may need to be torqued on the ground with the weight of the vehicle.

23. Be sure the CV is properly seated in the hub and replace it with the factory CV axle nut. Torque the CV axle nut to 221 ft-lbs.

24. Reconnect the brake line bracket and ABS line to the steering knuckle and frame with the factory bolts. Torque hardware to 159 in-lbs.

25. Attach the steering tie rod end to the steering knuckle and replace it with factory nuts. Torque to 46 ft-lbs.

26. Complete installation of strut spacers on both sides of the vehicle.
    FINAL FRONT INSTALLATION

27. With both sides complete, reconnect the sway bar links to the lower control arm and replace them with factory hardware. Torque to 111 ft-lbs. If the sway bar was removed from the mounts to the frame, replace the 2 factory bolts and 2 factory nuts to the mounts in the frame. A thread locker must be used on the bolts if removed from the mounts to the frame.

28. Check all brake/ABS lines for proper routing and clearances.

29. Install the wheels and lower the vehicle to the ground. Torque lug nuts to 100 ft-lbs in a crossing pattern.

    • Step 27 Note:
      Do not use power tools to remove/install the stabilizer bar link nut to the lower control arm. Damage to the stabilizer bar link ball joint or boot may occur

REAR DISASSEMBLY

1. Block the front wheels for safety.

2. Optional: Disconnect the track bar from the rear axle mount. Save hardware.

3. Raise the rear of the vehicle and support it with jack stands under the frame rails just ahead of the lower control arm mounts.

4. Support the axle with a hydraulic jack.

5. Remove the wheels.
   Complete this portion of the installation on one side at a time

6. Remove the screws and screw clips attaching the rear inner fenders to the vehicle Figure 15A & B. Remove the inner fender from the vehicle. This will allow access to the rear upper strut mounts.

7. Make sure the rear axle is supported. Remove the three upper strut mounting nuts at the frame. Figure 15 DO NOT remove the center strut rod nut. Discard the nuts.

8. Remove the lower strut mount bolt from the axle end. Figure 17

9. Remove the strut assembly from the vehicle Figure 18.
   REAR INSTALLATION

10. The rear studs will need to be trimmed for the strut spacer to be installed. The studs must be 1″ tall from the mounting surface Figure 19.

    • Step 10 Note:
      IMPORTANT!
      FAILURE TO FOLLOW THE STUD TRIMMING STEP WILL RESULT IN STRUT SPACER DAMAGE.

11. Install the longer 10mm bolts through the hex holes on the bottom of the rear strut spacer (05115) Figure 20A. Attach the strut spacer on top of the factory strut Figure 20B. Tighten to the top plate using the provided 10mm washers and OE strut nuts to 35 ft-lbs as shown in Figure 20C. DO NOT EXCEED 35 ft-lbs when tightening the spacer to the strut.
    Step 11 Note:

    • Make sure the OE studs do not stick past the top of the strut spacer.
    • Hardware for the strut spacers is in Bolt Pack 368.
    • The rear strut spacers are not tapered and can be installed any direction on the strut.

12. Reinstall the strut to the vehicle, noting that the strut will be installed 180 deg opposite as it was removed.

13. Use the provided 10mm nuts and 10mm washer to attach the strut to the frame mount Figure 21.

    • Step 13 Note:
      Hardware for the strut spacers is in Bolt Pack 368.

14. Attach the strut to the axle using an OE lower strut mount bolt and nut Figure 22.
    Post-Installation Warnings

15. Check all fasteners for proper torque. Check to ensure adequate clearance between all rotating, mobile, fixed, and heated members. Verify clearance between exhaust and brake lines, fuel lines, fuel tank, floor boards and wiring harness. Check the steering gear for clearance. Test and inspect the brake system.

16. Perform a steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating, mobile, or heated members. Inspect rear brake hoses at full extension for adequate slack. Failure to perform hose check/ replacement may result in component failure.

17. Perform headlight check and adjustment.

18. Re-torque all fasteners after 500 miles. Always inspect fasteners and components during routine servicing.

19. Tighten the upper frame mount nuts to 35 ft-lbs. DO NOT EXCEED 35 ft-lbs when tightening the spacer to the strut.

20. Leave the lower strut bolt/nut loose. Since this is a rubber bushing this will be tightened with the weight of the vehicle on the ground.
    FINAL REAR INSTALLATION

21. Reinstall the rear inner fender liners using the clips and screws previously removed. Torque any hardware for the inner fender liner to 18 in-lbs.

22. Check all brake/ABS lines for proper routing and clearances.

23. Install the wheels and lower the vehicle to the ground. Torque lug nuts to 100 ft-lbs in a crossing pattern.

24. Bounce the rear suspension to settle it. Tighten the two lower strut bolts/nuts to 350 ft-lbs

25. If removed, replace the track bar bolt and nut and tighten to 159 ft-lbs.
    Recommend Alignment Specifications

    • CASTER
      3.18˚ ± 0.60˚

    • CAMBER
      +0.20˚ ± 0.50˚

    • TOE
      +0.10˚ ± 0.15˚

WHEEL/TIRE FITMENT NOTES

Fitment Note:

• All Wheel/Tire fitment information is with the front and rear intrusion beams removed same as how a Sasquatch model has them removed.
• Tire diameter and width will vary based on tire brands and wheels used. The tire side profile will also affect clearance to the stock UCA and sway bar.

1. Although 37″ x 12.50″ will work at ride height, the tires will still contact the front body mount (Figures A & B) and possibly the rear inner fender (Figure C) through wheel travel and steering lock to lock. If running this size tire and using the full suspension travel, these areas must be addressed.
2. A maximum of 35″ x 12.50″ tire on a 17×8.5, 17×9, 18×8, 18×9, or 20×9 on 5.5″ to 5″ backspacing will clear through wheel travel and is recommended for best performance and minimal rubbing Figure D.
3. A 275/70R18 is recommended on 18″ Outer Banks wheels or other wheels with similar backspacing (6.375″ BS). Wider tires may rub the sway bar.
4. A 275/80R17 is recommended on 17″ Black Diamond wheels or other wheels with similar backspacing (6.5″ BS). Wider tires may rub the sway bar.
5. A 285/70R17 is recommended on 17″ Badlands wheels or other wheels with similar backspacing (6.75″ BS). Wider tires may rub the sway bar.
6. A 315/70R17 is recommended on 17″ Sasquatch wheels or other wheels with similar backspacing (6″ BS).
7. A maximum of 35″ x 11.20″ (285mm width tire) tire on a 17×8.5, 17×9, 18×8, 18×9, or 20×9 on 6″ backspacing will clear through wheel travel and is recommended for best performance and minimal rubbing. Wider tires/more aggressive sidewall tires than 285mm width (295-315mm widths) will rub the sway bar and/or UCA on a 6″ backspace wheel.
   • 20″: 285/65R20, 285/60R20
   • 18″: 285/75R18, 285/70R18
   • 17″: 285/75R17, 285/70R17
8. 35″ x 12.50″ tire on a stock 17″ Badlands, 17″ Black Diamond, or 18″ Outer Banks wheel will NOT clear through wheel travel and will rub on the stock UCA when turning Figure E and the sway bar. Any other stock wheel or aftermarket wheel with 6.75″ to 6″ backspacing will have similar rub issues on a 35″ x 12.50″ tire.

TECHNICAL SUPPORT

• www.zoneoffroad.com may have additional information about this product including the latest instructions, videos, photos, etc.
• Send an e-mail to [email protected] detailing your issue for a quick response.
• 888.998.ZONE Call to speak directly with Zone tech support.
• Difficulty Level easy 1 2 3 4 5 Difficult
• Estimated installation: 2-3 hours

References

• Lift Kits, Body Lifts, Leveling Kits for Jeeps, GM, Dodge, Ford Trucks – Zone Offroad

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