Tuff Country 12903 - GM 88-06 K1500 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:__________________________
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, scribe a mark on the lower
control arm and one directly across to the torsion bar. This
will ensure that the torsion bar gets installed properly back
into the OE location.
3. Working on the driver side and using a proper torsion bar
removal tool. Carefully remove the torsion bar bolt and
block. Set the torsion bar bolt and block aside. Remove the
stock torsion bar unloading tool from the stock cross mem-
ber. Special note: Tuff Country EZ-RIde Suspension
requires that a proper torsion bar unloading tool be
used when performing this installation. If you do not
have one, please contact your local GM dealer to pur-
chase one from them.
5. Working on the driver side, tap the torsion bar forward
until the torsion bar key can be removed. Remove and dis-
card the torsion bar key.
6. Locate the new torsion bar key. Working on the driver
side, install the new key into the OE location. Tap the tor-
sion bar back into the torsion bar cross member until it
seats properly into the new torsion bar key. Special note:
Make sure that the marks that were scribed earlier on
the lower control arm and the torsion bar line up with
each other.
7. Using the torsion bar unloading tool, adjust the new tor-
sion bar key up high enough so that the torsion bar block
and bolt can be re-installed.
8. Locate the torsion bar bolt and block and install into the
OE location. Adjust the bolt so that there is at least a 1/4”
of thread past the torsion bar block. After the completion of
the installation, if more height is needed, adjust the 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.
9. 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 # 2 - 9 on the passenger side.
12. Carefully lower the vehicle to the ground.