Tuff Country 14840 - GM 94-98 Tahoe 4-door K1500 4 - Manual (Page 3)

Please follow instructions carefully:
Front End 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 jack stands. Place a jack stand on both the driver
and passenger side. Next remove the wheels and tires
from both sides.
2. Working on the driver side, remove the inner rubber
fender splash guard and save for later re-installation.
Repeat procedure on passenger side.
3. Working on the driver side, remove the stock shock
from the stock location and save the stock hardware for
later re-installation. Longer shocks are needed, so the
stock shocks may be discarded. Special Note: Shocks
are not included with this suspension system and
need to be ordered as a separate part number, Tuff
Country EZ-Ride Suspension recommends using a
23” fully extended nitrogen gas shocks. Repeat
procedure on passenger side.
4. Remove the stock differential skid plate. The stock
front differential skid plate can be discarded. Also at this
time remove the stock front driveline and save the
stock driveline and hardware for later re-installation.
5. Measure exposed threads on the torsion bar
adjustment bolt and record measurement here for a later
reference.
Record Driver Side measurement here:______________
Record Passenger Side measurement here:__________
See Illustration # 1
6. Working on the driver side, attach the torsion bar
removing tool, making sure that the unloading bolt in the
center of the torsion bar removing tool is in the small
divot of the stock torsion bar key. Adjust the torsion bar
key up high enough so that the stock small metal
adjusting block and bolt can be removed. Save the stock
hardware for later re-installation. Repeat procedure on
passenger side.
See Illustration # 2
7. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:
Driver vs. Passenger and front vs. rear. Tap the stock
torsion bars forward until the stock torsion bar cross
member can be removed.
8. Working on the driver side, remove the stock bolt that
connect the stock torsion cross member to the stock
mounting point and save hardware for later re-
installation. Special Note: The stock mounting point is
on the inside of the stock frame rail. Repeat procedure
on the passenger side
9. Remove the stock torsion bar cross member from the
stock location and set a side for later re-installation.
10. Working on the driver side, slide the stock torsion bar
out of the stock rear lower control arm and set a side for
later re-installation. Repeat procedure on passenger side.
11. Working on the driver side, remove the stock brake
line bracket from the stock upper control arm bracket and
save hardware for later re-installation. Repeat procedure
on passenger side.
12. Working on the driver side, remove the front sway bar
end link from the stock sway bar and the stock lower
control arm location. The stock end link and hardware
may be discarded. Repeat procedure on passenger side.
Special Note: At this time invert the stock front sway
bar.
13. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock rotor.
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.
14. 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
15. Working on the driver side, disconnect the ABS lines
from each other. Also disconnect the ABS line from any
other mounting points.
16. 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.
17. 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.
18. Working on the driver side, loosen the stock nut that
connects the stock outer tie rod ball joint to the stock