Tuff Country 14965 - GM 00-03 Suburban / Tahoe K1500 4 kit - Manual (Page 9)

system, shocks need to be ordered as a separate
part number, Tuff Country EZ-Ride Suspension
recommends using a 23” fully extended nitrogen gas
shock. Make sure to use a lithium or moly base
grease prior to inserting the new bushings into the
new shock. This will increase the life of the bushing
as well as prevent squeaking. Also, after the
installation of the new front shock, check to make
sure that there is proper clearance between the new
front shock and the stock bump stop bracket. If there
is contact between the new front shock and the stock
bump stop bracket, carefully cut off the corner of the
stock bump stop bracket for proper shock clearance.
75. Locate (4) new torsion bar drop plates, (2) 9/16” x 3
1/2” bolts, (4) 9/16” flat washers, (2) 9/16” unitorque nuts
and (2) lock washers from hardware bag 14965NB4.
Working on the driver side, install the new torsion bar
drop plates to the stock torsion bar cross member
location and secure using the new 9/16” x 3 1/2” bolt and
hardware. Do not tighten at this point. Make sure to
use thread locker or lock tite. Repeat procedure on the
passenger side.
See Illustration # 24
76. Locate the stock torsion bars that were removed from
step # 12. Refer to the marks that were made in step #
10. This will allow you to re-install the stock torsion bars
back into the stock location. Example: Driver vs.
Passenger and Front vs. Rear. Working on the driver
side, slide the stock torsion bar back into the stock rear
lower control arm. Slide the stock torsion bar far enough
forward so that the stock torsion bar cross member can
be re-installed. Repeat procedure on the passenger side.
77. Locate (2) 9/16” x 3 1/2” bolt, (4) 9/16” flat washers,
(2) 9/16” unitorque nuts and (2) 9/16” lock washers from
hardware bag 14965NB4. Also, locate (2) S10020 crush
sleeves that were packaged with your instruction sheet
and the stock torsion bar cross member that was
removed from step # 10. Working on the driver side,
install the stock torsion bar cross member to the newly
installed torsion bar drop plates and secure using the
new 9/16” x 3 1/2” bolt, hardware and crush sleeve.
Special Note: The stock nut that is attached to the
stock torsion bar cross member needs to be removed
before installing the stock torsion bar cross member
to the new torsion bar drop plates. Do not tighten at
this point. Make sure to use thread locker or lock tite.
Special Note: Refer to the illustration # 25 on how to
install the new crush sleeve. On the rear tab of the
stock torsion bar cross member, you will notice that
this hole is larger in diameter than the front hole, the
new crush sleeve will be small enough for the tab of
the stock torsion bar cross member to slide over the
sleeve. Repeat procedure on the passenger side. Torque
the upper and lower mounting bolt to 95 ft lbs.
See Illustration # 25
the front lower portion of the new shock relocation
bracket and the stock location. Refer to illustration # 22
for proper 9/16” flat washer placement. Using the
passenger side shock relocation bracket as a guide, drill
a 7/16” hole into the stock lower control arm. Secure the
new passenger side bracket to the stock lower control
arm using the new 7/16” x 1 1/2” bolt and hardware.
Torque to 42 ft lbs. Torque the new 9/16” bolt 110 ft lbs.
Repeat procedure on the driver side.
See Illustration # 22
If the vehicle that you are working on is equipped
with the Air Ride Load Sensor Shocks, please follow
step # 71 — 72
If the vehicle that you are working on is not equipped
with Air Ride Load Sensor Shocks but you are going
to re-install the stock shocks, please follow step # 73
71. Locate the stock load sensor shocks and hardware
that was removed from step # 5. Working on the driver
side, re-install the lower mount on the stock load sensor
shock to the newly installed relocation bracket and
secure using the stock hardware. Do not tighten at this
point. Secure the upper mount on the stock load sensor
shock to the stock location and secure using the stock
hardware. Torque the upper hardware to 18 ft lbs.
Torque the lower stock mount to 95 ft lbs. Next,
reconnect the load sensor valve bracket back on the top
of the stock shock. Repeat procedure on the passenger
side. Special Note: After the installation of the stock
load sensor shock, check to make sure that there is
proper clearance between the stock load sensor
shock and the stock bump stop bracket. If there is
contact between the stock load sensor shock and the
stock bump stop bracket, carefully cut off the corner
of the stock bump stop bracket for proper shock
clearance.
72. Locate the stock actuator rods that were removed
from step # 7. Working on the driver side, install the stock
actuator rod into the stock upper and lower location.
Repeat procedure on the passenger side.
73. Locate the stock shock and hardware that was
removed from step # 5. Working on the driver side, re-
install the stock shock to the newly installed shock
relocation bracket and secure using the stock hardware.
Do not tighten at this point. Secure the upper mount of
the stock shock into the stock location and secure using
the stock hardware. Torque the upper hardware to 18 ft
lbs. Torque the lower stock mount to 95 ft lbs. Repeat
procedure on the passenger side.
See Illustration # 23
74. Locate the new front shocks and the stock hardware
that was removed from step # 5. Working on the driver
side, install the new front shock into the stock upper and
lower location. Secure using the stock hardware. Special
Note: Shocks are not included with this suspension