leveling kit install, track bar bracket and retainer
 

I am installing a leveling kit on my Super Duty. I pulled the bolts out and the furthest bolt forward stripped out the nut from the retainer bracket inside the frame. I ordered the new part from Ford but I need to get the old one out.

I cut the old one in half as far as I could reach inside the access hole in the frame. I ground the remaining bolt down as far as I could while I was sticking through the hole in the frame. I STILL CANT GET IT OUT lol

The steering gear box bolts to that frame rail and the bolts that run through the frame are blocking the retainer from being able to come out. I thought I could pull them out but do they run through a metal sleeve? If so it wont help to pull the steering box out....any ideas?


http://i997.photobucket.com/albums/a...0057289420.jpg



this is pic of the frame rail. the red highlighted drawing is of the retainer plate inside of the frame. I cut it pretty much in half but the end of the bolt that I cut off (forward bolt) is still sticking up too high to get underneath the bolts for the steering box/

here is a better illustration


http://i997.photobucket.com/albums/a...0057770702.jpg

red is the outline of the retainer plate.
Yellow line is where I was able to cut it
Blue is the remaining bolt from the one I had to cut off because the nut on the retainer plate broke out.
Green is the bolt that runs through the frame, and the one that the blue stud gets stuck under. I would just pull the bolt out but I think it runs through a sleeve and that would still be in the way.

If anyone has a cross section of the front frame that would be great also so I can see if those sleeves are removable

I was finally able to get the piece out! Took forever but its ready for the new bracket tomorrow. Now I just have to figure out how to pull the axle over to get it lined up with the track bar bracket.



Once again the nut closest to the front of the frame was the on that broke off on me. The nut stripped off the bracket inside the frame rail so the front bolt was just spinning when I tried to pull it out.

I cut the front bolt end off that sticks down through the frame and track bar bracket, removed the second bolt and pulled the entire bracket out as far as I could through the window in the frame.
I cut the bracket in half to try and make it easier to wiggle the front bolt/nut out. I finally was able to break the front nut completely off the bracket and pull them out separate.
Basically I beat the crap out of the old bracket to get it to finally break apart inside the frame. I also ground off as much of the cut off front bolt as I could to make it smaller when i tried to pull it out. Then pried on it to finally get it to break. I bought a new bracket and new bolts to replace the old one.

You can also take a torch or even a welder and try to burn the bracket into pieces. Then use a magnet to pull the pieces out.

If just your first bolt is stripped out you can always just bend the bracket over or cut it off and use a new bolt and nut. That will only work on the bolt closest to the rear of the truck as you can fit a wrench in their to hold the nut while you tighten it.

I have done it 2 ways. In my instructions for my ICON adjustable track bar it states to drive the truck forward and backward (in a straight line) 10-20 feet. I have also used a come along and a drift punch to get everything aligned on a truck that was not driveable.

thanks man! Ill try driving it and see if that helps. I never heard about that before :-X22

Still cant get the axle moved over enough to line up the track bar. After driving it back and forth it moved over but still needed to come over like half an inch. I tried using a 8000 pound ratchet load puller and that didnt do it either. I have no clue how to get it to come over any farther. I even have a dropped track bar bracket and it still doesnt reach.

If the kit did not provide you with a relocation bracket (and it kind of sounds like it did) for the track bar then you will probably need to go out and get and adjustable track bar. With that - even if they did you may want to pick up an adjustable just to resolve your current issue. If you go with the adjustable you can remove the relocation bracket and bolt up in the stock locations/mounts unless you went extreme with your lift, then you may need both and adjustable bar and a relocation bracket. Be sure to check the year - the link below discusses the 05 up. There is a different part for the 99 - 04s. AND if the 99 350 is the truck you are working on AND if Ford did the same thing on the 350s that they did on the 250s, that year they had an early and a late version, and to install the ICON adjustable on the early you have to get a 3/4" dril bit and drill out the mounts to install. That is what I had to do and it worked out great!

Ford - 2005 - 2007 Super Duty - ICON Vehicle Dynamics

IMO, if you are having to pull it too much I would go with an adjustable bar. My stock bar broke and I didn't have to do as much as you are doing to get it aligned when I lifted my truck.

There are also less expensive options than the ICON bar. I'm not sure what they are...I have the ICON bar on my truck.

thanks for all the info guys. Last night I put a 8000lb load puller on it and still couldnt get it to come over. It only needs about a half inch and it will be there. I read another thread on here about how one of our members turned the wheel all the way to the left and it lined right up. So after work ill fire it up and see if that works. If not im slowly driving it to a local mechanic and he is going to put it up on a lift and see if he can do it. :-X16

Here are pics of how the track sat before the leveling kit and as it does now.

looks awesome, I just wish I could drive it already! haha

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<a href="http://s997.photobucket.com/albums/af98/josiah700/?action=view&amp;current=photobucket-26188-1340206416543.jpg" target="_blank"><img src="http://i997.photobucket.com/albums/af98/josiah700/photobucket-26188-1340206416543.jpg" border="0" alt="2012-06-15_18-56-35_138"></a>
<br/><br/><a href="http://s997.photobucket.com/albums/af98/josiah700/?action=view&amp;current=photobucket-2496-1340206417074.jpg" target="_blank"><img src="http://i997.photobucket.com/albums/af98/josiah700/photobucket-2496-1340206417074.jpg" border="0" alt="2012-06-19_19-59-33_401"></a><br/><br/>

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When I did the leveling kit on mine, the bar wouldn't line up and I simply turned the steering wheel until it did. Or even better, have someone else turn the wheel while you're underneath the truck and wait for it to line up. Simple as that!

Nice, ill try it tonight. Did you do that while the truck was sitting on its tires and everything bolted up?

Looks good jshalala! :-X22

When you take it to get it aligned be sure to let them know what mods you added and have them check the centering of the truck.

I am a stubborn guy so I bought a graduated punch pin and drove it through the bracket eye. Brought it almost perfect together. (turning the wheel brought it over alot, but not enough) I was able to get the bolt started and ALMOST all the way through lol but it is still a little crooked so its hanging up on the back side of the bracket. I was going to use my load puller on it again for that last centimeter but the wife dragged me out of the garage and out to dinner so I'll try it again tonight lol

http://i997.photobucket.com/albums/a...0292614539.jpg