Tuff Country 16961 - GM 2006 K1500 4wd 6 kit (w/factory air shocks) - Manual (Page 12)

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 # 94 / 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 16957NB3. 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 # 91 / front location
Photo # 95 / driver side rear location
Photo # 96 / 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 lower
shock mounting bolt and set aside for later re-installation.
special note: We are adding a shock relocation brack-
et so the upper hardware does not need to be removed.
Let the stock shock hang. 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
16957PL. 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 # 97
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.
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.
Working on the driver side, remove and discard the stock
rear block. Repeat procedure on the passenger side.
108. Working on the driver side, place a pair of “C” clamp
vise grips on each side of the stock centering bolt. Carefully
remove the stock centering bolt and nut and discard.
Carefully remove the “C” clamp vise grips that are holding
the stock springs together. Special note: Be very
careful when removing the “C” clamps, the stock
springs are under tension and can be dangerous.
Repeat procedure on passenger side.
109. Locate (2) new rear add-a-leaf, (2) 3/8” x 6” centering
bolt and (2) 3/8” fine nut from box kit 81350. Install the new
rear add-a-leaf into the stock spring assembly. Secure the
new rear add-a-leaf to the stock spring assembly using the
new 3/8” center bolt and nut. Torque to 28 ft. lbs. Special
note: If the new add-a-leaf that you are installing into
the stock spring assembly has an offset center hole
location, place the longest side of the add-a-leaf
towards the rear of the vehicle. Also the new add-a-leaf
should be installed into the stock spring assembly in
progression in order, from longest to shortest. The
new add-a-leaf should be installed between the stock
overload and the stock spring pack. The stock
overload is usually the un-arched spring at the bottom
of the stock leaf pack. Also, Tuff Country EZ-Ride
Suspension recommends not using any air tools when
installing the new add-a-leafs into the stock spring
assembly. If air tools are used the centering bolt may
strip, causing the stock spring assembly to come
apart. With a suitable cutting tool, cut off the extra
thread from the new centering bolt. Repeat procedure