Tuff Country 16955 - GM 99-05 Silverado K1500 6 kit - Manual (Page 11)

squeaking.
37. Locate (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut and
(2) 3/8” USS flat washers from hardware bag 16955NB2.
Locate (4) 10 mm x 60 mm bolts and (4) 10 mm lock
washers from hardware bag 16955NB1. Also, locate (1)
S10120 sleeve from hardware bag 16955PL. Working on
the front differential, remove the (4) stock differential
mounting bolts that connect to two halves of the front dif-
ferential together. The stock hardware may be discarded.
Secure the new driver side differential relocation bracket to
the front differential using the new 10 mm x 60 mm bolts
and hardware. Special note: Get all (4) new 10 mm x 60
mm bolts started but do not tighten at this point.
Secure the lower portion of the driver side differential relo-
cation bracket to the front differential using the new 7/16”
x 3” bolt and hardware and new spacer sleeve. Add some
thread locker or lock tite and torque to 34 ft. lbs. Move back
to the (4) 10 mm x 60 mm bolts that hold the driver side dif-
ferential relocation bracket to the front differential and add
some thread locker or lock tite and torque to 34 ft lbs.
Special note: Make sure not to over tighten the new
hardware associated with the front differential. If bolts
are over tightened, the front differential could crack.
Also, Tuff Country EZ-Ride Suspension highly recom-
mends adding a minimum of 1 pint, but no more that 1
1/2 pints, of proper front differential fluid into the front
differential. To achieve this, you may have to fill the dif-
ferential with it on its side or you may have to insert the
fluid through the vent tube opening. On occasion, the
customer may find burping of fluid coming out of the
front vent tube.
38. Working on the passenger side mounting location on
the front differential, carefully cut off the passenger side
rear corner of the mounting surface.
39. Locate the new passenger side differential relocation
bracket and the stock hardware. Working on the passenger
side, install the new passenger side differential relocation
bracket into the upper location and secure using the stock
hardware. Do not tighten at this point. Special note: There
is a “F” cut out in this bracket, the “F” will go towards
the front of the vehicle and also if you are standing on
the passenger side and looking at the new differential
relocation bracket, you should not be able to see the
mounting hardware. This will help you make sure that
the bracket is installed properly.
40. With the help from a buddy, carefully lift the modified
front differential back onto a pair of hydraulic floor jacks and
move the hydraulic floor jacks back underneath the vehicle
so that the newly modified front differential can be
re-installed.
41. Locate (2) 9/16” x 1 3/4” bolts, (4) 1/2” USS flat
washers and (2) 9/16” unitorque nuts from hardware bag
16955NB4. Carefully install the passenger side of the front
differential to the previously installed passenger side differ-
ential drop bracket. Secure using the new 9/16” x 1 3/4”
bolts and hardware. Do not tighten at this point. Special
note: This picture that is shown is of a 4” bracket. The
6” bracket looks the same but is a taller bracket. Also at
this time, use a bungee cord or tie down strap and careful-
ly tie the driver side of the front differential up and out of the
way so that the new sub frame can be installed. Once the
front differential has been tied up and out of the way,
remove both hydraulic floor jacks that was holding the front
differential.