Tuff Country 16955 - GM 99-05 Silverado K1500 6 kit - Manual (Page 18)

and secure using the stock hardware. Make sure to use
thread locker or lock tite and torque to 90 ft lbs.
81. Move back to the new 7/16” x 1 1/2” bolts attaching the
new driver and passenger side torsion bar cross member
relocation bracket to the frame rail and add some thread
locker of lock tite and torque all (8) bolts to 52 ft lbs.
82. Locate the stock torsion bar keys. Working on the driver
side, install the stock torsion bar key back into the stock
location in the stock torsion bar cross member. Slide the tor-
sion bar back into the previously installed torsion bar key.
Repeat procedure on the passenger side. Special note:
Make sure that the torsion bars are installed in the stock
location in the lower control arm and the stock torsion
bar key. Refer to the marks that were scribed earlier in
the installation.
83. Locate the torsion bar adjusting blocks and hardware.
Working on the driver side, attach the torsion bar removing
tool to the stock torsion bar cross member, making sure that
the unloading bolt in the center of the torsion bar removing
tool is in the small divot of the stock torsion bar key. Adjust
the torsion bar key up high enough so that the stock small
metal adjusting block and bolt can be re-installed back into
the stock location. Remove the torsion bar removal tool from
the stock torsion bar cross member. Special note: Set the
driver and the passenger side torsion bar bolt so that
there is 3/4” of thread showing between the head of the
bolt and the adjusting block. Repeat on the passenger
side.
84. Locate (2) front lateral compression arms. Locate (8)
PB2408 poly bushings from hardware bag 16955PL. Also,
locate (4) S10058 crush sleeves from hardware bag
16955SL. Install the new poly bushings into each end of the
new front lateral compression arms. Next, install the new
crush sleeve into the newly installed poly bushings. Special
note: Make sure to use a lithium or moly base grease
prior to inserting the new bushings and sleeves into the
new front lateral compression arms. This will increase
the life of the bushing as well as prevent squeaking.
If the vehicle that you are working on has the stock
transfer case cross member bolted to the bottom of the
stock frame rail, please follow steps 85 — 90 to install
the new rear lateral compression arm mounts.
If the vehicle that you are working on has the stock
transfer case bolted to brackets that are welded to the
inside of the stock frame rail, please follow steps 91 —
95 to install the new rear lateral compression arm
mounts.
85. Locate (2) 1/2” x 3 1/2” bolts, (4) 7/16” USS flat washers
and (2) 1/2” unitorque nuts from hardware bag 16955NB3.
Working on the driver side, install the new lateral compres-
sion arm onto the lateral compression arm mounts located
on the previously installed rear portion of the sub frame.
Secure using the new 1/2” x 3 1/2” bolts and hardware. Do
not tighten at this point. Let the new lateral compression
arm hang. Repeat procedure on the passenger side.
86. Working on the driver side, remove and discard the stock
bolt and hardware that connects the transfer case cross
member to the stock transfer case cross member frame sup-
port bracket. Repeat procedure on the passenger side.
87. Locate (2) new rear lateral compression arm mounts.
Locate (2) 1/2” x 2 1/4” bolts, (4) 7/16” USS flat washers and
(2) 1/2” unitorque nuts from hardware bag 16955NB3.
Working on the driver side, secure the new lateral compres-
sion arm mount to the stock transfer case cross member
using the new 1/2” x 2 1/2” bolt and hardware. The mount will
be located where you removed the stock bolt in an earlier
step. Special note: Make sure that the new rear lateral
compression mount is parallel to the stock frame rail. Lift
the new lateral compression arm up to see if it will be able to
mount to the new rear lateral compression arm mount, if the
hole lines up, torque to 70 ft lbs. If the holes do not line up,
slide the new rear lateral compression arm mount forward or
rearward so that the new lateral compression arm will mount
up to the new rear lateral compression arm mount. Make
sure to use thread locker or lock tite. Repeat procedure on
the passenger side. Special note: The passenger side rear
lateral compression arm mount will be mounted oppo-
site of the driver side rear lateral compression arm
mount.
88. Working on the driver side, using the newly installed rear
lateral compression arm bracket as a guide, carefully drill a
5/16” hole into the stock cross member. Special note: There
are (2) 3/8” holes in the new rear lateral compression
arm mounting bracket, use the rear hole as a guide. The
stock transfer case cross member is boxed in, so you
only need to drill through the bottom wall of the cross
member. Make sure not to drill all the way through the
stock transfer case cross member. Repeat procedure on
the passenger side, using the rear hole in the new rear lat-
eral compression
arm bracket as a
guide. Driver side
shown here.