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

31. Disconnect any other vent hoses and/or wiring that is
connected to the stock front differential.
32. Working on the driver side, remove the stock
hardware that connects the upper driver side tab of the
stock front differential to the stock location. Save the
stock hardware for later re-installation.
33. Working on the passenger side, remove the (2) stock
nuts that connect the passenger side of the stock front
differential to the stock location and save the stock
hardware for later re-installation.
34. Carefully lower down on both hydraulic floor jacks at
the same time allowing enough room to remove the stock
front differential completely from the vehicle. With some
help from a buddy, carefully lift and remove the stock
front differential off both of the hydraulic floor jacks and
set the stock front differential on a table or on the ground.
35. Working on the driver side of the stock front upper
differential tab, measure 2” from the stock mounting point
and scribe a mark on the stock front differential. Using a
sawzall, carefully cut the upper tab off of the stock front
differential and discard. Refer to illustration # 6 for
proper cut line.
See Illustration # 6
36. Locate the new driver side differential relocation
bracket, (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut, (2)
7/16” flat washers and (1) 7/16” lock washer from
hardware bag 14810NB2. Locate (4) 10 mm x 60 mm
bolts and (4) 10 mm lock washers from hardware bag
14810NB1. Also, locate (2) PB2408 poly bushings from
poly bag 14810PL and (1) S10082 crush sleeve from
sleeve bag 14810SL. Install the new poly bushings and
crush sleeve into the new driver side differential
relocation bracket. Special Note: Make sure to use a
lithium or moly base grease prior to inserting the new
bushings and sleeve into the new driver side
differential relocation bracket. This will increase the
life of the bushing as well as prevent squeaking.
Referring to illustration # 7, remove the (4) stock
differential mounting bolts that connect to two half’s of the
stock front differential together. The stock bolts may be
discarded. Secure the new driver side differential
relocation bracket to the stock front differential using the
new 10 mm x 60 mm bolts and lock washers. Special
Note: Get all (4) stock bolts started but do not tighten
at this point. Also, make sure to use thread locker or
lock tite. Secure the lower portion of the new driver side
differential relocation bracket to the stock front
differential, using the new 7/16” x 3” bolt and hardware.
Torque to 34 Ft. lbs. Go back to the (4) new 10 mm x
600 mm bolts that hold the new differential relocation
bracket to the stock front differential and torque to 34 ft
lbs. Special Note: Make sure not to over tighten the
stock and new hardware associated with the stock
front differential and the new driver side differential
relocation bracket. If these bolts are over tightened,
the stock front differential may crack. At this time,
Tuff Country EZ-Ride Suspension highly
recommends adding a minimum of 1 pint, but no
more that 1 1/2 pints, of proper front differential fluid
into the front differential. To achieve this, you may
have to fill the differential with it on its side or you
may have to insert the fluid through the vend tube
opening. On occasion, the customer may find
burping of fluid coming out of the front vent tube.
See Illustration # 7
37. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 33. Install the new passenger side differential drop
bracket into the stock location and secure using the stock
hardware. Do not tighten at this point. Special Note:
Make sure to use thread locker or lock tite.
See Illustration # 8
38. With some help from a buddy, carefully lift the stock
front differential back onto the (2) hydraulic floor jacks.
Carefully raise up on both hydraulic floor jacks at the
same time until the passenger side of the stock front
differential can be attached to the newly installed
passenger side differential drop bracket.
39. Locate (2) 9/16” x 1 3/4” bolts, (4) 9/16” flat washers,
(2) 9/16” unitorque nuts and (2) 9/16” lock washers from
hardware bag 14810NB4. Carefully install the passenger
side of the stock front differential to the previously
installed passenger side differential drop bracket. Secure
using the new 9/16” x 1 3/4” bolts and hardware. Do not
tighten at this point. Also, make sure to use thread
locker or lock tite. Using a bungee cord, carefully tie
the driver side of the stock front differential up and
out of the way so that the new one piece lower sub
frame can be installed. Once the driver side of the
stock front differential is secured up and out of the
way, the (2) hydraulic floor jacks may be removed
from under the stock front differential.
See Illustration # 9
40
. Locate the new one piece lower sub frame and the
stock lower control arm hardware that was removed in
step # 26. Working on the driver side, install the front and
rear part of the new one piece lower sub frame into the
stock front and rear lower control arm stock pockets and
secure using stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Repeat procedure on passenger side.
See Illustration # 10 / Front Location
See Illustration # 11 / Rear Location
41. Carefully remove the bungee cord that is holding the
driver side of the front differential up and out of the way.
Let the stock front differential rest on the newly installed
one piece lower sub frame.