Tuff Country 16959 - GM 99-05 K1500 4wd 6 kit - Manual (Page 12)

compression arm bracket can be mounted to the stock
transfer case cross member. Special note: Once the new
rear lateral compression arm bracket is attached to the
stock transfer case cross member and the new lateral
compression arm is secured to the new rear lateral
compression arm bracket, the new lateral compression
arm should be parallel to the stock frame rail. Holding
the new rear lateral compression arm bracket to the bottom
side of stock transfer case cross member, remove the new
1/2” x 3 1/2” bolt that is holding the lateral compression arm
to the new rear lateral compression arm bracket. Set the
1/2” x 3 1/2” bolt aside for later re-installation. Let the new
lateral compression arm hang. Using the round holes in the
new rear lateral compression arm mount as guides, scribe
2 marks on the bottom side of the stock transfer case cross
member. Repeat procedure on the passenger side. Set the
new rear lateral compression arm mount brackets aside for
later re-installation.
95. Working on the driver side, carefully drill (2) 5/16” holes
into the bottom side of the stock transfer case cross
member. Repeat procedure on the passenger side.
96. Locate the new rear lateral compression arm bracket.
Also, locate (4) 3/8” x 3/4” self threading bolts from
hardware bag 16955NB1. Working on the driver side,
secure the new rear lateral compression arm brackets to
the bottom side of the stock transfer case cross member
using the new 3/8” x 3/4” self threading bolts. Torque to 28
ft lbs. Make sure to use thread locker or lock tite. Repeat
procedure on the passenger side.
Photo # 100 / Driver side shown
97. Locate the (2) 1/2” x 3 1/2” bolts that were used in step
# 94. Also, locate (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 compression arm to
the previously installed rear lateral compression arm mount
and secure using the new 1/2” x 3 1/2” bolts and hardware.
Make sure to use thread locker or lock tite. Torque to 85 ft
lbs. Move back to the new 1/2” x 3 1/2” bolts holding the
new lateral compression arms to the newly installed rear
cross member and add some thread locker or lock tite and
torque to 85 ft lbs.
Photo # 97 / front location
Photo # 101 / driver side rear location
Photo # 102 / passenger side rear location
98. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
99. Check and double check to make sure that all steps
were performed properly and check again.
100. There are still a couple of steps that need to be
completed on the front end but these steps will not be
completed until the rear end installation is completed and
the weight of the vehicle is on the ground. These steps
include the tightening of the front sway bar end links and
the tightening of the new hardware that connects the stock
lower control arms to the newly installed front and rear
cross member.
Front end installation complete:
Rear-end installation:
101. 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.
102. Working on the driver side, remove the stock shock
from the stock location and save the stock hardware for
later re-installation. The stock shock may be discarded.
Special note: New longer rear shocks are needed, if
you have not already ordered shocks, please contact
Tuff Country or your local Tuff Country dealer and
order the proper shocks. Tuff Country recommends
using a 30” fully extended nitrogen gas shock. Repeat
procedure on the passenger side.
103. Locate (1) BLR01, (1) 5/16” x 1” bolt (2) 1/4” USS flat
washers and (1) 5/16” unitorque nuts from hardware bag
16955PL. Working on the driver side, remove the
emergency brake line bracket from the stock frame rail.
Using the stock bolt, secure the BLR01 to the stock
location. Make sure to use thread locker or lock tite and
torque the stock bolt to 12 ft lbs. Now, install the stock
emergency brake cable bracket to the newly installed
BLR01 and secure using the new 5/16” x 1 1/2” bolt and
hardware. Make sure to use thread locker or lock tite and
torque to 18 ft lbs.
Photo # 103
104. Place a pair of hydraulic floor jacks under the rear
differential and carefully raise up on both hydraulic floor
jacks at the same time until they come into contact with the
rear differential.
105. Remove the stock brake line bracket that connects the
stock brake line bracket to the rear differential. Save the
stock hardware for later re-installation. Also, at this time
remove the stock brake line bracket that connects to the
stock rear shock braket. Save the stock hardware for later
re-installation.
106. Working on the driver side, remove the stock u-bolts
from the stock location and discard the stock u-bolts and
hardware. Set the stock upper and lower u-bolt plates a
side for later re-installation. Repeat procedure on
passenger side.
107. Carefully lower down both hydraulic floor jacks at the
same time approximately 5”. Special note: Take special
care not to over extend any brake lines and/or hoses.