Tuff Country 16720 - GM 73-87 6 3/4 ton box kit - Manual (Page 6)

loctite and torque to 95 ft lbs. Special note: Once the stock
drag link castle nut has been torqued, install the new
cotter pin that was packaged in the hardware bag that
came with the new steering arm. If the new cotter pin
can not be installed because the hole in the stock drag
link does not line up with the stock castle nut, DO NOT
loosen the stock castle nut so that the cotter pin can fit,
tighten the stock castle nut some more so that the cot-
ter pin can be installed.
23. Place a pair of hydraulic floor jacks under the transfer
case cross member and carefully raise up on both hydraulic
floor jacks at the same time until they come into contact with
the transfer case cross member.
24. Working on the driver side, remove the stock hardware
that connects the stock transfer case cross member to the
stock frame rail. The stock hardware may be discarded.
Repeat procedure on the passenger side.
25. Carefully lower down on both hydraulic floor jacks at the
same time allowing enough room for the new transfer case
drop sleeves to be installed.
26. Locate the new hardware bag 10703NB. Working on the
driver side, install (2) sleeves between the stock transfer
case cross member and the stock frame rail. Secure using
the new 7/16” x 3” bolt and hardware that was packaged in
hardware bag 10703NB. Do not tighten at this point.
Repeat procedure on the passenger side.
27. Move back to the new 7/16” x 3” bolts on the driver and
passenger side and add some thread locker or loctite and
torque all (4) new 7/16” x 3” bolts to 42 ft lbs.
28. Remove the hydraulic floor jacks from under the transfer
case cross member.
29. Check and double check to make sure that all steps
associated with front end have been completed and check
again.
Rear end installation:
30. 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 the pas-
senger side. Next, remove the front wheels and tires from
both sides.
31. Place a pair of hydraulic floor jacks under the rear differ-
ential. Place one on the driver and one on the passenger
side. Carefully raise up on both hydraulic floor jacks at the
same time until they make contact with the rear differential.
32. Working on the driver side, remove the stock shock from
the stock location. The stock shock may be discarded. Save
the stock hardware. Special note: New longer rear shocks
are needed after this suspension system has been
installed and the rear shocks need to be ordered as a
separate part #. If you have not already ordered your
rear shocks, please feel free to contact Tuff Country or
your local Tuff Country dealer and order your new rear
shocks. Tuff Country recommends installing a 30” fully
extended nitrogen gas shock in the rear. Repeat proce-
dure on the passenger side.
33. Working on the driver side, remove the stock u-bolts from
the stock location. The stock u-bolts and hardware may be
discarded. Save the stock u-bolt plates. Repeat procedure
on the passenger side.
34. Remove the stock rear brake line bracket from the stock
rear differential. Save the stock hardware.
35. Locate the rear brake line relocation bracket, (1) 5/16” x
1” bolt, (2) 1/4” USS flat washers and (1) 5/16” unitorque nut
from hardware bag GMBL. Install the new rear brake line
relocation bracket to the stock rear differential using the
stock hardware. Make sure to use thread locker or loctite
and torque to 12 ft lbs. Now secure the stock brake line
bracket to the newly installed brake line relocation bracket
using the new 5/16” x 1” bolt and hardware. Make sure to
use thread locker or loctite and torque to 12 ft lbs.
36. Carefully lower down on both hydraulic floor jacks at the
same time allowing enough room for the new rear add-a-
leafs and new rear blocks to be installed. Special note:
Take special care not to over extend any brake lines and
or hoses.
37. Working on the driver side, place a pair of “C” clamp vise