Tuff Country 16960 - GM 2006 K1500 4wd 6 kit - Manual (Page 11)

thread showing between the head of the bolt and the
adjusting block. Repeat on the passenger side.
86. 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 bolted to the bottom of the stock frame
rail, please follow steps 87 — 92.
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 93 —
97.
87. 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 compression arm into the lateral compression arm
mounts located on the previously installed rear cross
member. 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.
88. Working on the driver side, remove and discard the
stock bolt and hardware that connects the stock transfer
case cross member to the stock transfer case cross
member frame support bracket.
89. 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
compression 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
step # 88. 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 opposite of
the driver side rear lateral compression arm mount.
Photo # 96 / driver side shown
90. 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 lateral compression arm bracket as a
guide.
Photo # 96 / driver side shown
91. Locate (2) 3/8” x 3/4” self threading bolt from hardware
bag 16955NB1. Working on the driver side, install the new
3/8” x 3/4” self threading bolt into the previously drilled
5/16” hole. Torque to 28 ft lbs. Make sure to sure thread
locker or lock tite. Repeat procedure on the passenger
side.
92. 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 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 # 98 / driver side rear location
Photo # 99 / passenger side rear location
If the vehicle that you are working on has the stock
transfer case bolted to the bottom of the stock frame
rail, please skip to step # 98.
93. 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 compression arm into the lateral compression arm
mounts located on the previously installed rear cross
member. 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.
94. Locate (2) new rear lateral compression arm mounts.
Also, locate (2) 1/2” x 3 1/2” bolts from hardware bag
16955NB3. Working on the driver side, secure the
previously installed lateral compression arm to the new rear
lateral compression arm bracket using the 1/2” x 3 1/2” bolt.
For now, just use the bolt to hold the bracket to the lateral
compression arm. Swing the lateral compression arm back
towards the rear of the vehicle until the new rear lateral