Tuff Country 12909 - Hummer 01-09 H2 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 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.
3. 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.
4. Locate the new torsion bar key. Special note: The driv-
er side torsion bar key is the one that has part # KEY-
WAY-03 molded into it and the passenger side torsion
bar key is the one that has part # KEYWAY-02 molded
into it. Working on the driver side, install the new torsion
bar key into the stock location. Tap the stock torsion bar
back into the torsion bar cross member until it seats prop-
erly 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 torsion bar block and bolt can be
re-installed.
5. 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.
6. 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 - 6 on the passenger side.
7. 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 alignment performed.
Tuff Country EZ-Ride Suspension recommends that a
complete re-torque is done on all bolts associated with
this suspension system. It is the customers responsi-
bility to make sure that a re-torque is performed on all
hardware associated with this suspension system after
the first 100 miles of installation. It is also the cus-
tomers 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 cus-
tomer has some post installation procedure literature
and it is the installers responsibility to make sure that
the customer receives a copy of the installation manu-
al along with the literature.
If you have any questions or concerns, please feel free
to contact Tuff Country or your local Tuff Country
dealer.