Tuff Country 14985 - GM 00-06 K2500 HD 4wd 4 kit - Manual (Page 8)

60. Locate the stock rotors that were removed in step #
15. Working on the driver side, install the stock rotor into
the stock location. Repeat procedure on the passenger
side.
61. Locate the stock brake caliper hardware that was
removed in step # 12. Working on the driver side, re-
install the stock brake caliper to the new driver side
spindle and secure using the stock hardware. Torque to
96 ft. lbs. Make sure to use thread locker or lock tite.
Repeat procedure on the passenger side.
62. Locate the stock brake line hardware that was
removed in step # 12. Also, locate (10) shock ties
packaged with the instruction sheet. Working on the
driver side, secure the stock brake line bracket to the
stock upper control arm using the stock hardware. Next,
shock tie the stock ABS line and the stock brake line to
the newly installed spindle. Also, shock tie the stock ABS
line and the stock brake lines together. Repeat procedure
on the passenger side. Special note: In this step make
sure that once you shock tie the stock brake lines
and ABS lines to the spindle, there will be no contact
on the new wheels and tires. If contact occurs, the
stock brake lines or ABS lines may be damaged.
63. Locate the stock outer tie rod ball joint hardware that
was removed from step # 11. Working on the driver side,
install the stock outer tie rod to the new steering knuckle
using the stock hardware. Make sure to use thread locker
or lock tite and torque to 53 ft. lbs. Special note: The
new steering knuckle has a reverse taper on it where
the stock outer tie rod mounts to it, make sure to
install the outer tie rod the proper way. The stock
outer tie rod nut will now be installed on the bottom
side of the new steering knuckle.
64. Locate (2) new torsion bar cross member relocation
brackets. Locate (4) PB4902 poly bushings from
hardware bag 14985PL. Also, locate (2) S10074 sleeves
from hardware bag 14985SL. Install the new poly
bushings and sleeves into the new torsion bar cross
member relocation brackets. Special note: Make sure to
use a lithium or moly base grease prior to inserting
the new bushings and sleeves into the new torsion
bar cross member relocation brackets. This will
increase the life of the bushing as well as prevent
squeaking.
65. Working on the driver side, hold the new torsion bar
cross member relocation bracket to the new location on
the stock frame rail. Special note: Using the larger cut
out holes in the torsion bar cross member relocation
bracket over the stock rivets on the bottom of the
stock frame rail with help center the new torsion bar
cross member relocation bracket. With the new torsion
bar cross member relocation bracket in place, use a pair
of vice grips and secure the new torsion bar drop bracket
to the stock frame rail. Using the new torsion bar cross
member relocation bracket as a guide, carefully drill (4) front location and secure using the new 5/8” x 4 1/2” bolt
and hardware. Do not tighten at this point. Make sure
to use thread locker or lock tite. Install the stock lower
control into the newly installed one piece lower sub
frame’s rear location and secure using the new 5/8” x 5
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.
55. Locate the new driver side steering knuckle and stock
hub assembly, the stock hardware for the upper control
arm ball joint and the lower control arm ball joint that was
removed in step # 22. Using the stock hardware, secure
the new driver side steering knuckle and stock hub
assembly to the stock upper control arm ball joint and the
stock lower control arm ball joint. Special note: Do not
install the stock outer tie rod to the new steering
knuckle at this point. Torque the stock upper ball joint
hardware to 74 ft lbs. and the stock lower ball joint
hardware to 101 ft lbs. Special note: When installing
the new driver side spindle, make sure that the stock
brake line is located towards the inside of the
vehicle. Make sure to use thread locker or lock tite.
Repeat procedure on the passenger side using the
passenger side steering knuckle.
56. Locate the stock CV axles that were removed from
step # 19. Working on the driver side, carefully install the
stock CV axle back into the stock hub assembly. Repeat
procedure on the passenger side.
57. Locate (12) 10 mm x 35 mm bolt and (12) 10 mm lock
washers from hardware bag 14985NB. Also, locate (2)
9802 CV axle shims. Working on the driver side, install
(1) new CV axle shim between the stock front differential
and the stock CV axle. Secure using the new 10 mm x 35
mm bolts and hardware. Torque to 45 ft. lbs. Make sure
to use thread locker or lock tite. Special note: Make
sure that the stock axle is re-installed back into the
stock location on the stock front differential. Refer to
the scribe mark that was made in step # 18. Repeat on
the passenger side.
58. Locate the stock hardware that connects the stock
front axle to the stock hub assembly that was removed in
step # 17. Also, locate the stock hub assembly caps that
were removed in step # 16. Working on the driver side,
secure the stock front axle to the hub assembly using the
stock hardware. Torque to 154 ft. lbs. Make sure to use
thread locker or lock tite. Re-install the stock hub
assembly cap back into the stock location. Repeat
procedure on the passenger side.
59. Working on the driver side, reconnect the stock ABS
lines back together. Also reconnect all other stock
mounting points on the stock ABS line. Repeat procedure
on the passenger side.