Tuff Country 16840 - GM 94-98 K1500 Tahoe 4-door 6 kit - Manual (Page 7)

cooling fin contact occurs the aluminum fins must be
trimmed to allow the differential to center without
contacting the stock rear lower control arm pocket or
the stock frame rail. These fins are important for the
cooling of the differential. When trimming the cooling
fins you should only remove enough material to
allow for proper clearance.
See Illustration # 12
45. Locate the stock upper front differential hardware that
was removed from step # 34. Working on the driver side,
secure the new driver side relocation bracket to the front
part of the newly installed one piece lower sub frame and
secure using the stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
See Illustration # 13
46. Using a pair of hydraulic floor jacks, carefully raise up
on the front portion on the new one piece lower sub
frame until the new one piece lower sub frame sits flush
with the stock front cross member. Using the holes in the
front part of the new one piece lower sub frame as a
guide, carefully drill (2) 1/2” holes into the stock front
cross member.
47. Locate (2) 1/2” x 1 1/4” bolts, (2) 1/2” unitorque nuts,
(4) 1/2” flat washers and (2) 1/2” lock washers from
hardware bag 16810NB3. Secure the new one piece
lower sub frame to the stock front cross member using
the new 1/2” x 1 1/4” bolts and hardware. Torque to 85 ft
lbs. Make sure to use thread locker or lock tite.
See Illustration # 14
48. Carefully remove both hydraulic floor jacks from
under the front portion of the new one piece lower sub
frame.
49. Move back to all the stock and new hardware
associated with the new driver and passenger side
differential drop brackets, the rear portion of the stock
front differential that mounts to the new one piece lower
sub frame and the stock mounting points were the new
one piece lower sub frame mounts. Torque all hardware
to proper torque specifications. Refer to the torque
setting sheet on the first page of the installation
manual.
50. Locate (2) poly bump stops from hardware bag
16810SL. Also, locate (2) 3/8” lock nuts, (2) 3/8” flat
washers and (2) 3/8” lock washers from hardware bag
16810NB1. Working on the driver side, install the new
poly bump stop into the newly installed one piece lower
sub frame and secure using the new 3/8” hardware.
Torque to 28 ft. lbs. Make sure to use thread locker or
lock tite. Repeat procedure on passenger side.
See Illustration # 15
51. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2”, (4) 5/8”
unitorque nuts, (8) 5/8” flat washers, (4) 5/8” unitorque
nuts, (4) 5/8” lock washers from hardware bag
16810NB5. Also, locate the stock driver and passenger
side lower control arms that were removed from step #
28. Working on the driver side, install the stock lower
control into the newly installed one piece lower sub frame
front location and secure using the new 5/8” x 4 1/2” bolt
and hardware. Next, secure the rear portion of the stock
lower control arm into the rear portion of the newly
installed one piece lower sub frame and secure using the
new 5/8” x 5 1/2” bolt and hardware. Do not tighten at
this point. Make sure to use thread locker or lock tite.
Repeat procedure on passenger side.
See Illustration # 16 / Front Location
See Illustration # 17 / Rear Location
52. Locate (12) 10 mm x 70 mm bolts and (12) 10 mm
lock washers from hardware bag 16810NB1. Locate (2)
new axle half shaft spacers. Also, locate the stock driver
and passenger side CV axles that were removed from
step # 27. Working on the driver side, install (1) new axle
spacer between the stock front differential and the stock
axle. Secure using the new 10 mm x 70 mm bolts and
hardware. Torque to 65 ft. lbs. Make sure to use thread
locker or lock tite. Special Note: Make sure that the
stock axle is re-installed back into the stock location
on the stock front differential. Refer to the marks that
were scribe in step # 26. Repeat on the passenger side.
See Illustration # 18
53. Locate the new driver side spindle and the stock hub
assembly, the stock hardware for the upper control arm
ball joint and the lower control arm ball joint that was
removed from step # 20. Using the stock hardware,
secure the new driver side spindle and stock hub
assembly to the stock upper control arm ball joint and the
stock lower control arm ball joint. Torque the stock
hardware on the upper and lower ball joints to 85 ft lbs.
Also, when performing this step, slide the stock axle into
the stock hub assembly location. Repeat procedure on
the passenger side using the passenger side steering
knuckle.
See Illustration # 19
54. Locate the stock cotter pins that were removed from
step # 18 and 19. Install the stock cotter pins back into
the stock location on the stock upper and lower control
arm ball joints.
55. Locate the stock hardware that was removed from
step # 17. Working on the driver side, install the stock
outer tie rod ball joint to the newly installed driver side
spindle, secure using the stock hardware. Torque the
outer tie rod ball joint hardware to 68 ft. lbs. Make sure
to use thread locker or lock tite. Repeat procedure on
passenger side.
56. Locate the stock hardware that connects the stock
front axle to the stock hub assembly that was removed in
step # 15. Working on the driver side, secure the stock
front axle to the hub assembly using the stock hardware.
Torque to 112 ft. lbs. Make sure to use thread locker
or lock tite. Repeat procedure on the passenger side.