Fabtech FTS22177 Service manual

Fabtech Motorsports | 4331 Eucalyptus Ave. Chino, CA 91710
Tech Line: 909-597-7800 | Fax: [phone] | Web: www.fabtechmotorsports.com
INSTALLATION INSTRUCTIONS
2015 FORD F150 4WD
FTS22177 - 4” BASIC SYSTEM
FTS22178 - 4” PERFORMANCE SYSTEM
FT22176i

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FTS22176 COMPONENT BOX 1
1 FT30377BK SKID PLATE
1 FT30592BK FRONT CROSSMEMBER 4”
1 FT30593BK REAR CROSSMEMBER 4”
2 FT30491 DIFF DROP BRACKET UPPER
1 FT30621 SWAY BAR DROP BRACKET (DRIVER)
1 FT30622 SWAY BAR DROP BRACKET (PASSENGER)
1 FT30625 HARDWARE KIT
1 FT30567 DIFF DROP BRACKET CENTER 4”
1 FT30606BK DRIVER FENDER COVER
1 FT30607BK PASSENGER FENDER COVER
FTS22177 COMPONENT BOX 2 - BASIC SYSTEM
2 FT292 ALIGNMENT CAM KIT
1 FT30618 HARDWARE SUBASSEMBLY
4 FT350U UBOLTS
2 FTBK22 BLOCK 2.25”
1 FT30617D SPINDLE (DRIVER)
1 FT30617P SPINDLE (PASSENGER)
2 FTS30503 4” COILOVER
FT30618 HARDWARE SUB-ASSEMBLY
1 FT22176i INSTRUCTIONS
1 FT30619BK REAR CROSSMEMBER DIFF PLATE
2 FT30496 FRONT BRAKE LINE BRACKET
1 FT70033 REAR BRAKE LINE BRACKET
1 FT90115 BUSHING KIT
1 FTAS12 STICKER FT BLUE 10X4
1 FTAS16 DRIVER WARNING DECAL
1 FTREGCARD REGISTRATION CARD
1 FT30610 5/16” X 4” HOSE
K2193 4” BASIC W/ REAR PERFORMANCE SHOCKS
1 FTS22176 COMPONENT BOX 1
1 FTS22177 COMPONENT BOX 2
2 FTS7266 REAR PERFORMANCE SHOCKS
K2193DL 4” PERFORMANCE W/ DIRT LOGIC SHOCKS
1 FTS22176 COMPONENT BOX 1
1 FTS22178 COMPONENT BOX 2
1 FTS22183 2.5” DIRT LOGIC COILOVERS N/R (PAIR)
2 FTS810292 2.25” DIRT LOGIC NON RESI
K2193M 4” BASIC W/ REAR STEALTH SHOCKS
1 FTS22176 COMPONENT BOX 1
1 FTS22177 COMPONENT BOX 2
2 FTS6063 REAR STEALTH SHOCKS
K2196DL 4” PERFORMANCE W/ DIRT LOGIC RR SHOCKS
1 FTS22176 COMPONENT BOX 1
1 FTS22178 COMPONENT BOX 2
1 FTS22185 2.5” DIRT LOGIC COILOVERS W/RESI (PAIR)
2 FTS810292 2.25” DIRT LOGIC NON RESI
FTS22178 COMPONENT BOX 2 - PERFORMANCE SYSTEM
2 FT292 ALIGNMENT CAM KIT
1 FT30618 HARDWARE SUBASSEMBLY
4 FT350U UBOLTS
2 FTBK22 BLOCK 2.25”
1 FT30617D SPINDLE (DRIVER)
1 FT30617P SPINDLE (PASSENGER)
FT30625 - HARDWARE KIT LOCATION
BAG 1
4 5/16 SAE WASHER G5 ZINC BRAKE LINE
2 5/16-18 STOVER NUT G5 Z1
2 5/16-18 X 1 HEX BOLT G8 ZINC
8 7/16 SAE WASHER G5 ZINC SWAY BAR EXT
4 7/16-14 C-LOCK NUT ZINC
4 7/16-14 X 1-1/4 HEX BOLT G8 ZNC
4 1/2-13 X 3” HEX BOLT G8 ZNC LOWER SHOCK
8 1/2 SAE WASHER G8 ZINC
4 1/2-13 C-LOCK NUT ZINC
BAG 2
1 1/2-13 X 1-3/4 HEX BOLT G8 ZINC CENTER DIFF
4 1/2-13 X 4” HEX BOLT G8 ZNC DIFF MOUNT
16 1/2 SAE WASHER G5 ZINC DIFF MOUNT/ SKID
8 1/2-13 C-LOCK NUT ZINC
3 1/2-13 X 1-1/4 HEX BOLT G8 ZNC SKID PLATE
3 M10-1.5 X 45MM HEX BOLT CENTER DIFF
3 10MM SPLIT WASHER
3 M10 FLAT WASHER ZINC
1 M18-2.5 X 150MM HEX BOLT REAR CROSSMEMBER
2 M18 FLAT WASHER
1 M18-2.5
2 3/8-16 X 1” HEX BOLT CROSSMEMBER PLATE
4 3/8” SAE FLAT WASHER
2 3/8-16 C-LOCK NUT
BAG 3
2 5/16 SAE WASHER G5 ZINC REAR BRAKE LINE
1 5/16-18 STOVER NUT
1 5/16-18 X 1 HEX BOLT
8 9/16” SAE WASHER UBOLTS
8 9/16-18 NYLOCK NUT
8 #8 X 1/2” SELF TAP SCREW INNER FENDER PLATE
2 THREAD LOCKING COMPOUND 1 MIL

For technical assistance call: 909-597-7800 or e-mail: [email protected]
Read this before you begin installation-
Check all parts to the parts list above before beginning installation. If any parts are missing contact Fabtech at 909-597-7800
and a replacement part will be sent to you immediately.
Read all instructions thoroughly from start to finish before beginning the installation. If these instructions are not properly
followed severe frame, driveline and / or suspension damage may occur.
Check your local city and state laws prior to the installation of this system for legality. Do not install if not legal in your area.
Prior to the installation of this suspension system perform a front end alignment and record. Do not install this system if the
vehicle alignment is not within factory specifications. Check for frame and suspension damage prior to installation.
The installation of this suspension system should be performed by two professional mechanics.
Use the provided thread locking compound on all hardware.
Do not combine this suspension system with any other lift device or parts.
This suspension must be installed with Fabtech shock absorbers.
WARNING- Installation of this system will alter the center of gravity of the vehicle and may increase roll over as compared
to stock.
On EcoBoost 3.5L and 2.7L models, discard all air shields.
OEM Wheels and tires cannot be used after the installation of this kit. Larger tires cannot be installed on the OEM wheels.
Verify differential fluid is at manufacture’s recommended level prior to kit installation. Installation of the kit will reposition the
differential and the fill plug hole may be in a different position. (For example, if the manufacture recommends 3 quarts of fluid,
make sure the diff has 3 quarts of fluid). Check your specific manual for correct amount of fluid.
Recommend Tires and Wheels:
Use 35/13.50R18 tires w/ 18x9 wheels w/ 5” BS w/ minor trimming
Use 35/13.50R20 tires w/ 20x9 wheels w/ 5” BS w/ minor trimming
Use 285/55R22 tires w/ 22x9.5 wheels w/ 5” BS w/ minor trimming
- PRE-INSTALLATION NOTES -
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Required Tools (Not Included)
Floor Jack, Jack Stands, Torque Wrench
Assorted Metric and S.A.E sockets, and Allen wrenches
Die Grinder w/Cut-off Wheel
1-1/2” Barrel Sand Wheel, 1/2” Barrel Sand Wheel
- TOOL LIST -

6. Remove the brake caliper and place it next to the frame.
Do not overstretch the brake hose when doing so. Retain
the hardware for reinstallation. Remove the brake rotor
and save. Disconnect the vacuum lines attached to the
rear of the hub assembly. Allow the vacuum lines to hang
freely. Remove the electronic stability control (ESC) sensor
from the top of the hub. Cover the sensor to keep it free
from dirt and debris. SEE FIGURE 3
7. Carefully remove the dust cap covering the hub assembly
nut. Remove the C.V. bearing nut and save the nut and
dust cap. Remove the dust shield and save for re-
installation. SEE FIGURE 4
8. Remove the upper and lower ball joint nuts. 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 remove the knuckle with the hub. Use extra
care not to over extend the C.V. axle shaft when removing
the knuckle. SEE FIGURES 5-6
- INSTRUCTIONS -
FRONT SUSPENSION
1. Disconnect the negative terminal on the battery. 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. Remove and discard the factory splash guard under the
differential.
3. Locate the sway bar end links and disconnect from the
factory lower control arms, save the hardware. Locate
the sway bar frame mounts and disconnect them from
the frame, remove the sway bar from the truck. Save the
hardware and sway bar.
4. Working from the driver side of the vehicle disconnect
the brake line and ABS line from the factory knuckle. SEE
FIGURE 1
5. Disconnect the tie rod ends from the steering knuckle
by striking the knuckle to dislodge the tie rod end. SEE
FIGURE 2
FIGURE 2 - STEP 5
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FIGURE 1 - STEP 4
FIGURE 3 - STEP 6
FIGURE 4 - STEP 7

9. Locate the lower shock mount bar pin nuts and remove.
Loosen and remove the control arm at the crossmembers
and save for re-installation. SEE FIGURES 7-8
10. Locate the three upper coilover nuts and remove. Save
the hardware. Remove the shock assembly from the
vehicle and mark “Driver” for assembly to install later with
Fabtech shock extensions. NOTE: If installing Dirt Logic
coilovers the factory coilover and hardware will not be
re-used. SEE FIGURE 9
11. Repeat steps 4 through 10 on the passenger side of the
truck.
12. Remove the factory rear crossmember from the vehicle
and discard. NOTE: Due to varinces in vehicles, the
bolt attaching the crossmember and the frame on the
drivers side may need to be cut off. SEE FIGURE 10-11
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FIGURE 5 - STEP 8
FIGURE 6 - STEP 8
FIGURE 7 - STEP 9
FIGURE 8 - STEP 9
FIGURE 9 - STEP 10
FIGURE 10 - STEP 12

15. Locate the driver side rear lower control arm pocket. Mark
the frame 1-3/8’’ from the control arm pivot hole and 90
degrees to the bottom of the pocket where the cross
member was mounted. Using a die grinder, cut all the
way around the pocket. Discard removed portion of the
pocket. SEE FIGURES 14-15
16. Still working on the driver side rear lower control arm
pocket, locate the tab on the pocket towards the rear of
the vehicle. You will need to cut and sand a radius in the
rear side of the pocket in order to clear the differential
housing. SEE FIGURE 16
13. Remove the front drive shaft bolts where they attach to
the front differential. Support the end of the driveshaft
before removing the front differential. SEE FIGURE 12
14. Supporting the differential, remove the 3 differential mount
bolts and save for re-installation. Remove the differential
from the vehicle. SEE FIGURE 13
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FIGURE 12 - STEP 13
FIGURE 11 - STEP 12
FIGURE 13 - STEP 14
FIGURE 15 - STEP 15
FIGURE 14 - STEP 15
FIGURE 16 - STEP 16
2.15”

17. Locate the front tab on the same mount. You will need
to sand a 1/2” on the inside to clear the differential. SEE
FIGURE 17
18. Locate the two Fabtech upper differential mounts
(FT30491). These upper differential mounts will be placed
into the factory upper differential mounts using the factory
upper differential mount hardware. Leave the hardware
loose in preparation for the differential installation.
SEE FIGURES 18
19. Locate the factory front differential and install into the
Fabtech upper differential mounts using two ½’’-13 x 4’’
hex cap bolts, washers and lock nuts. Leave all hardware
loose in preparation of the installation of the remaining
differential mounts. SEE FIGURE 19
20. Locate the Fabtech rear crossmember (FT30593BK)
and rear diff plate (FT30619BK). Install the rear diff plate
(FT30619BK) on the (FT30593BK) rear crossmember
using the 3/8” hardware. Leave loose. Next, mount
the crossmember using the factory control arm pivot
hardware. SEE FIGURES 20-22
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FIGURE 17 - STEP 17
FIGURE 18 - STEP 18
FIGURE 19 - STEP 19
FIGURE 20 - STEP 20
FIGURE 21 - STEP 20

24. Install a ½” -13 x 4” bolt, washers and nut through the
tabs on the rear crossmember and the bushing on the
center bracket. Leave loose at this time. SEE FIGURE 27
21. Locate the center differential bracket (FT30567). Install
two of the Fabtech (FT1020) bushings and one sleeve
(FT181) into the barrel on the differential bracket.
SEE FIGURE 23
22. On the front axle tube, remove the rear and lower bolts
to allow for the new center differential bracket to be
mounted.
23. Mount the differential bracket to the center of the
differential using three M10-1.5 x 45mm bolts, lock
washers, and at washers. Mount the front tab on the diff
to the center bracket using one ½”-13 x 2” bolt, nut and
washers. Leave loose at this time. SEE FIGURES 24-26
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FIGURE 22 - STEP 20
FIGURE 24 - STEP 23
FIGURE 25 - STEP 23
FIGURE 27 - STEP 24
FIGURE 23 - STEP 21
FIGURE 26 - STEP 23

25. Torque the M10-1.5 x 45mm bolts to 35 ft-lbs. Torque the
½”-13 x 2” bolt to 90 ft-lbs.
26. Reinstall the front drive shaft with the factory hardware
and torque to 35 ft-lbs. SEE FIGURE 28
27. Locate upper differential brackets and torque the factory
upper bolts to 90 ft-lbs and lower ½’’ bolts 127 ft-lbs.
Locate the center diff mount on the cross member and
torque the ½”-13 x 4” bolt to 90 ft-lbs.
28. Install the supplied 4” hose to the factory differential vent
tube and back on to the differential. SEE FIGURE 29
29. Locate the Fabtech front crossmember (FT30592BK).
Install the front crossmember into the factory front control
arm pockets using the factory hardware. Make sure the
skid plate tab on the crossmember is facing the Fabtech
rear crossmember. Leave the hardware loose at this time.
SEE FIGURE 30
30. Locate the Fabtech skid plate (FT30377BK). The skid
plate will span the distance between the front and rear
crossmembers directly under the front differential. Attach
the end of the skid plate with the single hole to the tab on
the back side of the front crossmember using one ½’’- 13
x 1-1/4” bolt, washers and a C-lock nut. Leave loose at
this time. Lift up the back side of the skid plate and install
it to the rear crossmember using two ½’’- 13 x 1-1/4”
bolts, washers and a C-lock nut. Torque only the 2 rear
bolts at this time to 127 ft-lbs. SEE FIGURE 31
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FIGURE 28 - STEP 26
FIGURE 29 - STEP 28
FIGURE 30 - STEP 29
FIGURE 31 - STEP 30

31. Locate the Alignment cam kit (FT292). Locate the
factory control arms. Install the lower control arms into
the Fabtech crossmembers using the hardware in the
cam kit (FT292). Torque the cam bolts at 200 ft-lbs after
alignment. Torque crossmember bolts to 240 ft-lbs. SEE
FIGURE 32
32. If installing Dirt Logic coilovers (FTS22183 or
FTS22185) do so at this time, using the instructions
provided in the shock box. Once finished, you may
skip to STEP 38.
If using FTS30503 coilover continue to STEP 33.
33. Locate the factory coilovers removed earlier.
34. Using a spring compressor, compress the factory spring
and remove the top coilover center nut and cap. Next
install the factory spring onto the new Fabtech coilover
using the new lower isolator and re-using the factory top
cap and hardware. SEE FIGURE 33
35. Repeat Step 34 on the passenger side.
36. Install the coil over into the frame bucket using the factory
hardware. Torque 59 ft-lbs. SEE FIGURE 34-35
37. Rotate the lower control arm up and mount to the lower
coilover bar pin using the supplied 1/2”-13 X 3” bolts and
hardware. Torque to 127 ft-lbs. SEE FIGURE 36
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FIGURE 32 - STEP 31
FIGURE 34 - STEP 36
FIGURE 35 - STEP 36
FIGURE 36 - STEP 37
FIGURE 33 - STEP 34
FT30503