Tuff Country 14993 - GM 01-09 K2500 HD 4wd 4 kit - Manual (Page 8)

sure to use thread locker or lock tite. Repeat procedure
on the passenger side. Carefully remove the hydraulic floor
jack from under the front cross member.
Photo # 51
51. Move back to the stock and new hardware that is
attaching the new passenger side differential relocation
bracket to the stock location and the stock differential and
and some thread locker or lock tite and torque the stock
hardware to 75 ft lbs. and the new 9/16” hardware to 85 ft
lbs.
Photo # 52
52. Locate the new 4” integrating skid plate. Also, locate (6)
1/2” x 1 1/2” bolts, (12) 7/16” USS flat washers and (6) 1/2”
unitorque nuts from hardware bag 14959NB1. Install the
new 4” integrating skid plate to the front and rear cross
members and secure using the new 1/2” x 1 1/2” bolts and
hardware. Do not tighten at this point.
Photo # 53
53. Working on the driver side, move back to the stock
hardware attaching the new front cross member into the
stock lower control arm pocket and add some thread
locker or lock tite and torque to 105 ft lbs. Repeat
procedure on the passenger side.
Photo # 54
54. Working on the driver side, move back to the stock
hardware attaching the new rear cross member into the
stock lower control arm pocket and add some thread
locker or lock tite and torque to 105 ft lbs. Repeat
procedure on the passenger side.
Photo # 55
55. Working on the driver side, move back to the stock
hardware attaching the newly installed driver side
differential relocation bracket to the newly installed front
cross member and add some thread locker or lock tite and
torque to 75 ft lbs.
Photo # 56
56. Working on the driver side, move back to the stock
hardware attaching the rear portion of the stock front
differential to the newly installed rear cross member and
add some thread locker or lock tite and torque to 75 ft lbs.
Photo # 57
57. Move back to the new hardware attaching the new skid
plate to the front and rear cross member and add some
thread locker or lock tite on all (6) bolts and torque all (6)
bolts to 70 ft lbs.
Photo # 58 / Photo # 59
58. Reconnect the 4WD wiring to the front differential. Also,
reconnect any other vent hoses and/or wiring that was
connected to the stock front differential.
Photo # 60
59. Locate the stock front drive line hardware that was
removed in step # 29. Re-install the stock front drive line to
the stock front differential using the stock hardware. Make
sure to use thread locker or lock tite and torque to 18 ft lbs.
Photo # 61
60. Locate (2) PB6199 poly bump stops from hardware bag
14985PL. Special note: There are (6) poly bump stops
located in the poly bag, (4) are the same size and (2)
are taller, locate (2) of the shorter poly bump stops.
Also, locate (2) 3/8” unitorque nuts and (2) 5/16” USS flat
washers from hardware bag 14985NB. Working on the
driver side rear portion of the newly installed rear cross
member, secure the new poly bump stop using the new
3/8” hardware. Torque to 28 ft lbs. Repeat procedure on
the passenger side. Make sure to use thread locker or lock
tite.
Photo # 62 / Photo # 63
61. Locate the new driver side steering knuckle and the
stock hub assembly. Also, locate the stock hardware for the
upper control arm ball joint and the lower control arm ball
joint that was removed in step # 21. 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 using the stock
hardware. Torque the stock upper control hardware to 74 ft
lbs. and the stock lower control arm hardware to 101 ft lbs.
Make sure to use thread locker or lock tite. Repeat
procedure on the passenger side using the passenger side
steering knuckle.
62. Locate the stock CV axles that were removed from step
# 18. Working on the driver side, carefully install the stock
CV axle back into the stock hub assembly. Repeat
procedure on the passenger side.
63. Locate (2) axle half shaft spacers. Also, locate (12) 10
mm x 35 mm hex bolts and (12) 10 mm lock washers from
hardware bag 14985NB. Working on the driver side, install
(1) new axle spacer between the stock front differential and
the stock CV axle. Secure using the new 10 mm x 35 mm
bolts and hardware. Make sure to use thread locker or lock
tite and torque to 65 ft. lbs. Special note: Make sure that
the stock axle is re-installed back into the stock loca-
tion on the stock front differential. Refer to the scribe
mark that was made in step # 17. Repeat on the
passenger side.
Photo # 64
64. Locate the stock hardware that connects the stock front
axle to the stock hub assembly that was removed in step #
16. Working on the driver side, secure the stock front axle
to the stock hub assembly using the stock hardware. Make
sure to use thread locker or lock tite and torque to 112 ft.
lbs. Also, re-install the hub assembly center cap that was
removed from step # 15. Repeat procedure on the
passenger side.