Tuff Country 16840 - GM 94-98 K1500 Tahoe 4-door 6 kit - Manual (Page 10)

Rear End Installation:
80. 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.
81. Locate (1) rear brake line extending bracket. (1) 5/16”
x 1 1/4” bolt, (2) 5/16” flat washers, (1) 5/16” unitorque
nut and (1) 5/16” lock washer from hardware bag
16810NB1. Remove the stock brake line bracket from the
rear differential and save stock bolt for later re-
installation. Secure the new brake line bracket to the rear
differential housing using the stock bolt. Special Note:
Make sure to use thread locker or lock tite. Next,
attach the stock brake line bracket to the newly installed
brake line bracket and secure using the new 5/16” x 1
1/4” bolt and hardware. Torque to 16 ft. lbs. Special
Note: If you feel that the stock rear brake line is to
tight, wait and perform this step once the rear end
installation is complete and the weight of the vehicle
is on the ground.
See Illustration # 27
82. Position a pair of hydraulic floor jacks under the rear
axle. Place one jack stand on the driver side and one on
the passenger side. Raise up on both hydraulic floor
jacks at the same time until they make contact with the
rear axle.
83. Working on the driver side, remove the stock sway
bar end link from the stock location. The stock sway bar
end link may be discarded. Save the stock hardware for
later re-installation. Repeat procedure on the passenger
side.
84. Working on the driver side, remove the stock shock
and save the stock hardware for later re-installation.
Longer shocks are needed, so the stock shocks may be
discarded. Special Note: Shocks are not included with
this suspension system and need to be ordered as a
separate part number, Tuff Country EZ-Ride
Suspension recommends using a 30” fully extended
nitrogen gas shocks. Repeat procedure on passenger
side.
85. Working on the driver side, remove the (2) stock rear
U-bolts and discard. Set the upper and lower U-bolt
plates a side for later re-installation. Repeat procedure on
passenger side
86. Lower down on both hydraulic floor jacks at the same
time until the stock springs separate from the stock rear
axle. Lower down approximately 5”. Special Note: Make
sure not to over extended any brake lines or hoses
when lowering axle. This will allow you enough room for
the new rear blocks and add-a-leafs to be installed.
87. Locate (2) new rear add-a-leafs. (2) 3/8” centering
bolts and nuts from hardware bag CB38. Working on the
driver side, place a pair of “C” clamps around the rear
springs about 2” from the stock spring clamps. Safely
remove the stock centering bolt and discard. Install the
new add-a-leaf to the stock spring assembly. Secure the
new rear add-a-leaf to the stock spring assembly using
the new 3/8” center bolt and nut. Special Note: The new
add-a-leaf should be installed into the stock spring
assembly in progression in order. The new add-a-leaf
should be installed between the stock overload and
the stock spring pack. The stock overload is usually
the un-arched spring at the bottom of the stock leaf
pack. Also Tuff Country EZ-Ride Suspension
recommends not using any air tools when installing
the new add-a-leafs into the stock spring assembly. If
air tools are used the centering bolt may strip,
causing the stock spring assembly to come apart.
Torque the new centering bolt and nut to 28 ft. lbs.
Remove the “C” clamps from the stock spring assembly.
With a suitable cutting tool, cut off the thread from the
new centering bolt. Repeat procedure on passenger side.
See Illustration # 28
88. Locate (2) new 4” lifted rear blocks. Working on the
driver side, install (1) new 4” lifted block between the
stock rear axle and the stock spring assembly. Special
Note: The new 4” lifted block has a slight taper to it,
the small end of the new block needs to be installed
with the small end towards the front of the vehicle.
Repeat procedure on passenger side.
See Illustration # 28
89. Raise up on both hydraulic floor jacks at the same
time until the driver and passenger side stock spring
assembly seats flush with newly installed 4” block.
90. Locate (4) new 9/16” x 2 3/4” x 14 5/8” Square U-
bolts. (8) 9/16” U-bolt high nuts, (8) 9/16” U-bolt washers
from hardware bag 916NW. Also locate the stock upper
and lower U-bolt plates that were removed from step #
85. Working on the driver side, install (2) new 9/16” x 2
3/4” x 14 5/8” square U-bolts into the stock location and
secure using the new 9/16” high nuts and washers.
Torque to 120 ft lbs. Repeat procedure on passenger
side.
See Illustration # 28
91. Working on the driver side, install the new rear
shocks absorbers using the stock hardware removed
from step # 84. Special Note: Shocks are not included
with this suspension system, shocks need to be
ordered as a separate part number, Tuff Country EZ-
Ride Suspension recommends using a 30” fully
extended nitrogen gas shocks. Locate the new rear
upper clevis mount and install the new clevis mount into
the upper eyelet of the rear shock before installation.
Repeat procedure on passenger side.