Tuff Country 14810 - GM 88-98 K1500 / K2500 6lug 4 - Manual (Page 5)

Save the stock hardware for later re-installation. Using a
bungee cord, carefully tie
the stock brake caliper up and
out of the way in the fender well. Special Note: Take
special care not to kink or over extend the stock
brake line. Also, remove the stock rotor and set the
stock rotor aside for later reinstallation.
15. Working on the driver side, remove the stock nut that
connects the stock axle to the stock hub assembly. Save
the stock nut for later re-installation.
See Illustration # 3
16. Working on the driver side, disconnect the stock ABS
lines from each other. Also, disconnect the stock ABS
line from any other mounting points.
17. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
upper control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation. Loosen
the stock nut that connects the stock upper control arm
ball joint to the stock steering knuckle. Do not remove
the stock nut completely. Carefully break the stock
taper on the stock upper control arm ball joint. Special
Note: Take special care not to rip or tear the stock
ball joint dust boot.
18. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
lower control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation. Loosen
the stock nut that connects the stock lower control arm
ball joint to the stock steering knuckle. Do not remove
the stock nut completely. Carefully break the stock
taper on the stock lower control arm ball joint. Special
Note: Take special care not to rip or tear the stock
ball joint dust boot.
19. Working on the driver side, move back to the stock
nuts holding the stock upper control arm ball joint and the
stock lower control arm ball joint to the stock steering
knuckle and remove completely. Save the stock
hardware for later re-installation.
20. Working on the driver side, carefully remove the stock
hub assembly and the stock steering knuckle from the
stock location. During the removal of the stock hub
assembly and the stock steering knuckle carefully slide
the stock CV axle out of the stock hub assembly and the
stock steering knuckle during removal. Special Note: If
the stock CV does not slide out of the stock hub
assembly and the stock steering knuckle, use a
suitable removal tool to remove the stock CV axle
from the stock hub assembly. Special Note: Take
special care not to damage the stock threads on the
stock axle.
21. Working on the driver side stock hub assembly,
carefully remove the (3) stock bolts that connect the
stock hub assembly to the stock steering knuckle. Save
the stock hardware and stock hub assembly for later re-
installation. A new steering knuckle will be used, so the
stock steering knuckle may be discarded.
22. Locate the new driver side steering knuckle. Using
the stock hardware that was removed from step # 21,
secure the new driver side steering knuckle to the stock
hub assembly. Torque to 92 ft lbs. Special Note: Make
sure to use thread locker or lock tite.
23. Set the new driver side steering knuckle and hub
assembly a side for later re-installation.
24. Working on the driver side, scribe a mark on the CV
plate and another directly across to the stock differential,
this will allow you to re-install the stock CV back into the
stock location at a later step.
See Illustration # 4
25. Working on the driver side, unbolt and remove the (6)
stock bolts holding the inner CV axle to the stock
differential. The stock hardware may be discarded. Set
the stock CV axle a side for later re-installation.
26. Working on the driver side, remove the stock front
and rear hardware that connects the stock lower control
arm to the stock front and rear location. Save the stock
hardware for later re-installation. Set the stock lower
control arm a side for later re-installation.
27. Repeat step’s 13 - 26 on the passenger side.
28. Working on the driver side, locate the stock lower
bracket that wraps around the rear lower half of the stock
front differential. Remove the stock bolt that connects the
lower portion of the stock front differential to the stock
bracket. Save the stock hardware for later re-installation.
Using the stock mounting point on the rear lower control
arm as a reference point, measure 3” towards the inside
of the vehicle and scribe a line on the stock bracket that
wraps around the rear portion of the stock front
differential. Using a hacksaw or suitable cutting tool,
carefully cut along the line that was scribe earlier in this
step. Special Note: Tuff Country recommends not
using a cutting torch when performing step # 28.
Clean and dress up any exposed metal.
See Illustration # 5
29. Locate the stock wiring harness that connects the
4WD control panel to the stock front differential.
Disconnect the stock 4WD wiring harness from the stock
front differential. Tie the stock 4WD wiring harness up
and out of the way. Special Note: Take special care not
to kink wiring.
30. Place a pair of hydraulic floor jacks under the stock
front differential, and carefully raise up on both hydraulic
floor jacks at the same time, until they come into contact
with the stock front differential.