Tuff Country 16955 - GM 99-05 Silverado K1500 6 kit - Manual (Page 17)

contact between the new front shock and the stock
bump stop bracket, carefully cut off the corner of the
stock bump stop bracket for proper shock clearance.
74. Locate (2) 1/2” x 15” bolts and (2) 1/2” unitorque nuts
from hardware bag 16955NB3. Locate (2) new sway bar end
links from hardware bag 16955SL. Also, locate (8) sway bar
end link bushings and (8) sway bar end link washers from
hardware bag 16955PL. Working on the driver side, install
the new sway bar end link and hardware into the stock loca-
tion. Do not tighten at this point. Special note: When
installing the new sway bar end link bolt, make sure to install
the bolt from the top down. We want the nut to be on the bot-
tom of the lower control arm. Also, this bolt will be torqued to
proper torque settings once the weight of the vehicle is on
the ground. Repeat procedure on passenger side.
75. Locate the stock outer tie rod ball joint hardware.
Working on the driver side, install the stock outer tie rod to
the new steering knuckle using the stock hardware. Make
sure to use thread locker or lock tite and torque to 53 ft. lbs.
Special note: The new steering knuckle has a reverse
taper on it where the stock outer tie rod mounts to it,
make sure to install the outer tie rod the proper way. The
stock outer tie rod nut will now be installed on the bot-
tom side of the new steering knuckle. Repeat procedure
on the passenger side. This picture shows the new sway bar
end link and outer tie rod installed.
76. Locate (2) new torsion bar cross member relocation
brackets. Locate (4) MO2220 poly bushings from hardware
bag 16955PL. Also, locate (2) S10074 sleeves from hard-
ware bag 16955SL. Install the new poly bushings and
sleeves into the new torsion bar cross member relocation
brackets. Special note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
and sleeves into the new torsion bar cross member relo-
cation brackets. This will increase the life of the bush-
ing as well as prevent squeaking.
77. Working on the driver side, hold the new torsion bar cross
member relocation bracket to the new location on the stock
frame rail. Special note: Using the larger cut out holes in
the torsion bar cross member relocation bracket over
the stock rivets on the bottom of the stock frame rail will
help center the new torsion bar cross member relocation
bracket. With the new torsion bar cross member relocation
bracket in place, use a pair of vice grips and secure the new
torsion bar drop bracket to the frame rail. Using the new tor-
sion bar cross member relocation bracket as a guide, care-
fully drill (4) 7/16” holes into the frame. (2) on the side of the
frame rail and (2) on the bottom. Special note: take special
care not to drill into any stock hoses and/or lines run-
ning down the inside of the frame rail. Remove the pair
of vice grips that is holding the new torsion bar cross
member relocation bracket to the frame rail. Repeat pro-
cedure on the passenger side of the vehicle.
78. Locate (8) 7/16” x 1 1/2” bolts, (16) 3/8” USS flat wash-
ers and (8) 7/16” unitorque nuts from hardware bag
16955NB2. Working on the driver side, secure the new driv-
er side torsion bar cross member relocation bracket to the
frame rail using the new 7/16” x 1 1/2” bolt and hardware. Do
not tighten at this point. Repeat procedure on the passen-
ger side.
79. Locate the stock torsion bars. Refer to the marks that
were made earlier in the installation. This will allow you to re-
install the stock torsion bars back into the stock location.
Example: Driver vs. Passenger and Front vs. Rear.
Working on the driver side, slide the stock torsion bar back
into the stock rear lower control arm. Slide the stock torsion
bar far enough forward so that the stock torsion bar cross
member can be re-installed. Repeat procedure on the pas-
senger side.
80. Locate the stock torsion bar cross member and stock
hardware. Install the stock torsion bar cross member to the
newly installed torsion bar cross member relocation brackets