Tuff Country 12904 - GM 01-10 K2500HD/K3500HD torsion bar keys - Manual (Page 3)

Please follow instructions carefully:
Before installation begins, measure from the center of
the hub, to the bottom of the fender well, and record
measurements below.
Pre-installation measurements:
Driver side front:_______________________________
Passenger side front:___________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post installation measurements:
Driver side front:______________________________
Passenger side front:__________________________
Torsion bar key installation:
1. To begin installation, block the rear tires of the vehicle so
that the vehicle is stable and can’t roll backwards. Safely lift
the front of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and pas-
senger side.
2. Working on the driver side, remove the stock shock from
the stock lower mounting location and save the stock hard-
ware. Now remove the stock lower shock bracket from the
stock lower control arm. Save the stock hardware. The
stock shock bracket may be discarded. Repeat procedure
on the passenger side.
3. Working on the driver side and using a proper torsion bar
removal tool. Special note: Tuff Country EZ-RIde
Suspension requires that a proper torsion bar unload-
ing tool be used when performing this installation. If
you do not have one, please contact your local GM
dealer to purchase one from them. Carefully remove the
stock torsion bar bolt and block. Set the stock torsion bar
bolt and block aside. Remove the stock torsion bar unload-
ing tool from the stock cross member.
4. Working on the driver side, tap the stock torsion bar for-
ward until the stock torsion bar key can be removed.
Remove and discard the stock torsion bar key.
5. Locate the new torsion bar key and install into the stock
location. Tap the stock torsion bar back into the torsion bar
cross member until it seats properly into the new torsion
bar key. Using the torsion bar unloading tool, adjust the
new torsion bar key up high enough so that the stock tor-
sion bar block and bolt can be re-installed.
6. Locate the stock torsion bar bolt and block and install
into the stock location. Adjust the stock bolt so that there is
at least a 1/4” of thread past the stock torsion bar block.
After the completion of the installation, if more height is
needed, adjust the stock bolt to achieve the proper height.
Special note: For each 1/4” of adjustment on the stock
bolt equals 1” of height.
Special note: If the stock torsion bar bolt is over
adjusted, ride quality issues will occur and over adjust-
ing the bolt is not recommended.
7. Working on the driver side, measure from the stock
bump stop to the stock lower control arm. This measure-
ment should not exceed 1/2”. If you have more than a 1/2”,
the stock torsion bar bolt will need to be lowered until our
measurement is less than a 1/2”.
Repeat step # 3 - 7 on the passenger side.
8. Locate the new lower shock relocation bracket and the
stock hardware. Working on the driver side, install the new
lower shock bracket to the stock lower control arm and
secure using the stock hardware. Make sure to use
thread locker or lock tite and torque to 45 ft lbs. Repeat
procedure on the passenger side.
9. Locate the stock lower shock mounting hardware.
Working on the driver side, install the stock shock to the
newly installed lower shock relocation bracket and secure
using the stock hardware. Make sure to use thread lock-
er or lock tite and torque to 65 ft lbs. Repeat procedure
on the passenger side.
10. Carefully lower the vehicle to the ground.
Congratulations, installation complete!
Special note: After the completion of the installation, Tuff
Country EZ-Ride Suspension recommends taking the vehicle
to an alignment shop and having a proper front end align-
ment performed.
Tuff Country EZ-Ride Suspension recommends that a com-
plete re-torque is done on all bolts associated with this sus-
pension system. It is the customers responsibility to make
sure that a re-torque is performed on all hardware associat-
ed with this suspension system after the first 100 miles of
installation. It is also the customers responsibility to do a
complete re-torque after every 3000 miles or after every off
road use. Neglect of following these steps could cause
brackets to come loose and cause serious damage to the
suspension system and to the vehicle.
Tuff Country EZ-Ride Suspension packages (2) sets of
instruction sheets with this box kit. (1) is for the installer and
(1) is for the customer. The (1) for the customer has some
post installation procedure literature and it is the installers
responsibility to make sure that the customer receives a
copy of the installation manual along with the literature.
If you have any questions or concerns, please feel free to
contact Tuff Country or your local Tuff Country dealer.