Tuff Country 14993 - GM 01-09 K2500 HD 4wd 4 kit - Manual (Page 10)

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.
75. Locate the stock torsion bar cross member and stock
hardware that was removed from step # 4. Install the stock
torsion bar cross member to the newly installed torsion bar
cross member relocation brackets and secure using the
stock hardware. Make sure to use thread locker or lock tite
and torque to 90 ft lbs.
Photo # 69
76. Move back to the new 7/16” x 1 1/2” bolts attaching the
new driver and passenger side torsion bar cross member
relocation bracket to the stock frame rail and add some
thread locker or lock tite and torque all (8) bolts to 70 ft lbs.
77. Locate the stock torsion bar keys that were removed in
step # 3. Working on the driver side, install the stock torsion
bar key back into the stock location in the stock torsion bar
cross member. Slide the stock torsion bar back into the
previously installed torsion bar key. Repeat procedure on
the passenger side. Special note: Make sure that the
torsion bars are installed in the stock location in the
stock lower control arm and the stock torsion bar key.
Refer to the marks that were scribed in step # 3.
78. Locate the torsion bar adjusting blocks and hardware
that was removed from step # 2. Working on the driver side,
attach the torsion bar removing tool to the stock torsion bar
cross member, 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 re-installed back into the stock location.
Remove the torsion bar removal tool front he stock torsion
bar cross member. Special note: Set the driver and the
passenger side torsion bar bolt so that there is 3/4” of
thread showing between the head of the bolt and the
adjusting block. Repeat on the passenger side.
79. Locate (2) 3/8” x 7” bolts and (2) 3/8” unitorque nuts
from hardware bag 14985NB. Locate (2) S10067 sway bar
end link sleeves from hardware bag 14985SL. Also, locate
(8) sway bar end link poly bushings and (8) sway bar end
link washers from hardware bag 14985PL. Special note: If
you did not invert the stock sway bar in step # 9, invert
the stock sway bar now. Working on the driver side,
install the new sway bar end link and hardware into the
stock location . Do not tighten at this point. Repeat
procedure on passenger side.
80. Locate the stock skid plate that was removed in step #
7. Referring to photo # 70, measure 2 5/8” from the leading
edge of the stock skid plate and scribe a mark. Carefully cut
along the scribed mark.
Photo # 70 / 2 5/8” measurement
Photo # 71 / post cut view
81. Locate the (3) stock upper skid plate mounting
hardware that we removed in step # 7. Install the newly
modified skid upper skid plate to the stock upper location
using the stock hardware. Special note: Make sure to use
thread locker or lock tite and torque to 28 ft lbs.
82. Holding the stock skid plate to the front cross member,
carefully drill a 3/16” hole through the stock skid plate and
the stock front cross member.
Photo # 72
83. Locate (1) 1/4” x 1” self threading bolt from hardware
bag 14985NB. Secure the stock skid plate to the stock
cross member using the new 1/4” x 1” self threading bolt.
Photo # 73
84. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
85. Check and double check to make sure that all steps
were performed properly and check again.
86. There are 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 tightening of the front sway bar end links and
the tightening of the new hardware that connects the stock
lower control arms to the newly installed front and rear
cross member.
Rear end installation:
87. 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.
88. 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.
89. 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.
90. Working on the driver side, remove the stock u-bolts