Tuff Country 14993 - GM 01-09 K2500 HD 4wd 4 kit - Manual (Page 11)

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.
91. 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.
92. 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.
93. 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.
94. 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 # 90. 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.
95. 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 provided 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.
96. Carefully remove the (2) hydraulic floor jacks from
under the rear differential.
97. 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 # 74 / front location
Photo # 75 / rear location
98. Install the tires and wheels and carefully lower the
vehicle to the ground.
Step # 99 and # 100 needs to be performed with the
weight of the vehicle on the ground.
99. Working on the driver side, move back to the new 5/8”
hardware attaching the stock lower control arms to the
newly installed front and rear cross members and add
some thread locker or lock tite and torque to 125 ft lbs.
Repeat procedure on the passenger side.
100. Working on the driver side, move back to the newly
installed sway bar end link bolt and add some thread
locker or lock tie and torque to 38 ft lbs. Repeat procedure
on the passenger side.
101. Check and double check to make sure that all steps
were performed properly. And then check them again.
Congratulations, installation complete!