Tuff Country 16959 - GM 99-05 K1500 4wd 6 kit - Manual (Page 9)

Working on the driver side, install the stock rotor into the
stock location. Repeat procedure on the passenger side.
67. Locate the stock brake caliper hardware that was
removed in step # 13. Working on the driver side, re-install
the stock brake caliper to the newly installed knuckle and
secure using the stock hardware. Make sure to use thread
locker or lock tite and torque to 76 ft. lbs. Repeat
procedure on the passenger side.
68. Locate the stock brake line hardware that was removed
in step # 11. Working on the driver side, attach the stock
brake line bracket to the stock upper control arm and
secure using the stock hardware. Make sure to use thread
locker or lock tite and torque to 18 ft lbs. Now working on
the inside of the newly installed driver side knuckle,
reconnect the stock brake line bracket to the new driver
side knuckle. Secure using the stock hardware. Make sure
to use thread locker or lock tite and torque to 18 ft lbs.
Repeat procedure on the passenger side. Special note: If
need be, the stock bracket line bracket that wraps
around the stock brake line may need to be opened up
so that the brake line does not get kinked.
Photo # 82 / Photo # 83
69. Locate the new driver and passenger side front shock
relocation bracket. Locate (2) 1/2” USS flat washers from
hardware bag 16955NB4. Locate (2) SUW-916 u-bolts
washers from hardware bag 16955PL. Locate (2) 1/2” x 3
1/4” 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 driver side shock relocation bracket
into the stock shock location on the stock lower control arm.
Secure using the new 1/2” x 3 1/4” bolts and hardware. Do
not tighten at this point. Special note: We want to
install (1) 9/16” u-bolts washer as a spacer between the
new bracket and the front of the stock location. Please
see photo # 84 for proper washer placement. Also, we
want to use (1) 1/2” USS flat washer as a spacer
between the new bracket and the rear of the stock
location. Please see photo # 85 for proper washer
placement. Repeat procedure on the passenger side.
Photo # 84 / Photo # 85
70. Locate (2) 7/16” x 1 1/2” bolt, (4) 3/8” USS flat washers
and (2) 7/16” unitorque nuts from hardware bag 16955NB2.
Working on the driver side, push the new driver side shock
relocation bracket towards the inside of the vehicle and
using the driver side shock relocation bracket as a guide,
drill a 7/16” hole into the stock lower control arm bump stop
location. Secure the new driver side shock relocation
bracket to the stock lower control arm using the new 7/16”
x 1 1/2” bolt and hardware. Do not tighten at this point.
Photo # 86 / Photo # 87
71. Move back to the new 1/2” x 3 1/4” bolt holding the new
driver side shock relocation bracket into the stock location
and add some thread locker or lock tite and torque to 80 ft
lbs. Repeat procedure on the passenger side.
Photo # 88
72. Move back to the new 7/16” x 1 1/2” bolt holding the
new driver side shock relocation bracket to the stock bump
stop on the stock lower control arm and add some thread
locker or lock tite and torque to 42 ft lbs. Repeat procedure
on the passenger side.
Photo # 89
73. Working on the driver side and using a sawzall or a die
grinder, carefully cut off the front corner of the stock front
bump stop. This will allow clearance so the front shock
does not contact the front corner of the stock front bump
stop. Special note: Make sure to check that there is
clearance once the new shock is installed. If contact
occurs, carefully cut more out of the front corner of the
stock front bump stop. Repeat procedure on the
passenger side.
Photo # 90
74. Locate the new front shocks. Special note: New
longer front 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 23” fully extended
nitrogen gas shock. Locate the new lower poly bushings
and proper shock sleeves that are packaged with the new
shocks and install the new lower shock bushings and
proper shock sleeves into the lower eyelet of the new
shocks. Special note: If need be, locate (2) S10074
sleeves from hardware bag 16955SL. Make sure to use
a lithium or moly base grease prior to inserting the new
lower shock bushings and sleeves into the new lower
shock eyelet. This will increase the life of the bushing as
well as prevent squeaking. Locate (4) PB8297 upper shock
bushings and (4) S10107 upper shock washers from
hardware bag 16955PL. Working on the driver side, install
the new shock into the stock upper location and secure
using the new shock nut that was packaged with the new
shock. Also, make sure to use the new upper shock
bushings and upper shock washers. Torque to 28 ft lbs.
Repeat procedure on the passenger side. Tuff Country
EZ-Ride Suspension highly recommends that the
shocks are installed with shock boots. If shock boots
are not installed, damaged my occur to the piston of
the new shock.
75. Locate (2) 1/2” x 3 1/4” bolts, (4) 7/16” USS flat
washers and (2) 1/2” unitorque nuts from hardware bag
16955NB3. Also, locate (2) 1/2” USS flat washers from
hardware bag 16955NB4. Working on the driver side,
secure the bottom of the new shock to the newly installed
shock relocation bracket using the new 1/2” x 3 1/4” bolt
and hardware. Make sure to use thread locker or lock tite
and torque the lower 1/2” bolt to 80 ft lbs. Special note:
When installing the new shock into the lower shock
relocation bracket, make sure to use (1) 1/2” USS flat
washers as a spacers on the front lower portion of the
new shock relocation bracket. Repeat procedure on the