Tuff Country 14985 - GM 00-06 K2500 HD 4wd 4 kit - Manual (Page 10)

87. Working on the driver side. Special note: New
longer rear shocks are needed, if you have not
already ordered shocks, please contact Tuff Country
or your local Tuff Country dealer and order the
proper shocks. Tuff Country recommends using a
30” fully extended nitrogen gas shock. Locate (2)
S10074 from hardware bag 14985SL. Working on the
new shocks, install the new shock bushing into the upper
and lower eyelets of the new shocks. Next, install the
new shock sleeves into the previously installed shock
bushings. Special note: Use the new S10074 shock
sleeves and the proper shock sleeves that are
located in the new sleeve bag that was provide with
your new shocks. Make sure to use a lithium or moly
base grease prior to inserting the new lower shock
bushings and sleeves into the new lower shock
eyelet. This will increase the life of the bushing as
well as prevent squeaking. Working on the driver side,
install the new shock into the stock location and secure
using the stock hardware that was removed in step # 88.
Special note: Make sure to use thread locker or lock
tite and torque to 75 ft lbs. Repeat procedure on the
passenger side. Special note: Tuff Country EZ-Ride
Suspension highly recommends that the shocks are
installed with shock boots. If shock boots are not
installed, damaged my occur to the piston of the new
shock.
Photo # 19 / complete installation of the new blocks,
u-bolts and shocks.
88. Carefully remove the (2) hydraulic floor jacks from
under the rear differential.
89. Locate (2) PB6199 poly bump stops and (2) PB6052
poly bump stops from hardware bag 14985PL. Also,
locate (4) 3/8” unitorque nuts and (4) 5/16” USS flat
washers from hardware bag 14985NB. Working on the
driver side of the stock rear spring assembly. Remove
the (2) stock teflon inserts located on the stock over load
in the stock spring assembly. Discard the stock teflon
inserts. Install (1) PB6052 (taller poly bump stop) in front
location on the stock spring assembly. Secure using the
new 3/8” hardware. Torque to 28 ft lbs. Install (1)
PB6199 (shorter poly bump stop) in the rear location on
the stock spring assembly. Secure using the new 3/8”
hardware. Torque to 28 ft lbs. Repeat procedure on the
passenger side.
Photo # 20 / front location
Photo # 21 / rear location
90. Install the tires and wheels and carefully lower the
vehicle to the ground.
Step # 91 and # 92 needs to be performed with the
weight of the vehicle on the ground.
91. Working on the driver side, move back to the new
5/8” hardware attaching the stock lower control arms to
the newly installed one piece lower sub frame and torque
to 125 ft lbs. Repeat procedure on the passenger side.
78. There is still a couple of steps that need to be
completed on the front end but these steps will not be
completed until the rear end installation is completed and
the weight of the vehicle is on the ground. These steps
include; the installation of the front sway bar end links
and the tightening of the new hardware that connects the
lower control arms to the newly installed sub frame.
Rear end installation:
79. To begin installation, block the front tires of the
vehicle so that the vehicle is stable and can’t roll forward.
Safely lift the rear of the vehicle and support the frame
with a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next, remove the wheels and
tires from both sides.
80. Working on the driver side, remove the stock shock
from the stock upper and lower mounting points and save
the stock hardware for later re-installation. The stock
shocks may be discarded. Special note: New longer
rear shocks are needed, if you have not already
ordered shocks, please contact Tuff Country or your
local Tuff Country dealer and order the proper
shocks. Tuff Country recommends using a 30” fully
extended nitrogen gas shock. Repeat procedure on the
passenger side.
81. Place a pair of hydraulic floor jacks under the rear
differential and carefully raise up on both hydraulic floor
jacks at the same time until they come into contact with
the rear differential.
82. Working on the driver side, remove the stock u-bolts
from the stock location and discard the stock u-bolts and
hardware. Set the stock upper and lower u-bolt plates a
side for later re-installation. Repeat procedure on
passenger side.
83. Carefully lower down both hydraulic floor jacks at the
same time approximately 3”. Special note: Take special
care not to over extend any brake lines and/or hoses.
84. Locate (2) new rear 2” lifted blocks. Working on the
driver side, install the new 2” lifted block into the stock
location. Repeat procedure on the passenger side.
85. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with
the newly installed 2” lifted block.
86. Locate (4) 5/8” x 2 3/4” x 12 7/8” square u-bolts, (8)
5/8” u-bolt high nuts and (8) u-bolt washers from box kit
17652. Also, locate the stock upper and lower u-bolt
plates that were removed from step # 82. Working on the
driver side, install the new u-bolts into the stock location
and secure using the new 5/8” high nuts and washers.
Special note: Make sure to re-install the stock upper
and lower u-bolt plates. Torque to 135 ft lbs. Repeat
procedure on passenger side.