Tuff Country 16961 - GM 2006 K1500 4wd 6 kit (w/factory air shocks) - Manual (Page 13)

on passenger side.
110. Locate (2) new 4” lifted blocks. Working on the driver
side, install the new 4” lifted block into the stock location.
Repeat procedure on the passenger side.
111. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with the
newly installed 4” lifted block.
112. Locate (4) 9/16” x 2 3/4” x 12 5/8” square u-bolts.
Locate (8) 9/16” u-bolt high nuts and (8) u-bolt washers from
hardware bag 916NW. Also, locate the stock upper and
lower u-bolt plates that were removed from step # 106.
Working on the driver side, install the new u-bolts into the
stock location and secure using the new 9/16” high nuts and
washers. Special note: Make sure to re-install the stock
upper and lower u-bolt plates into the stock location.
Torque to 120 ft lbs. Repeat procedure on passenger side.
113. Locate (2) new rear shock relocation brackets. Locate
(2) 9/16” x 3” bolts, (4) 1/2” USS flat washer and (2) 9/16”
unitorque nuts from hardware bag 16957NB4. Locate (2)
7/16” x 1 1/4” bolt, (4) 3/8” USS flat washers and (2) 7/16”
unitorque nuts from hardware bag 16957NB2. Also, locate
(2) S10019 crush sleeves from hardware bag 16957SL.
Working on the driver side, install the new shock relocation
bracket into the stock location and secure using the new
9/16” x 3” bolt, hardware and (1) S10019 crush sleeve. Do
not tighten at this point. Make sure that the new rear shock
relocation bracket is sitting flush with the stock shock brack-
et, carefully drill a 7/16” hole in the bottom of the stock shock
bracket and the newly installed shock relocation bracket.
Secure the shock relocation bracket to the stock shock
bracket using the new 7/16” x 1 1/4” bolt and hardware.
Move back the new 9/16” bolt and add some thread locker or
lock tite and torque to 112 ft lbs. Now move back to the new
7/16” hardware and add some thread locker or lock tite and
torque to 35 ft lbs. Repeat procedure on the passenger side.
Photo # 98
114. Locate the stock lower shock mounting hardware that
was removed from step # 102. Working on the driver side,
install the lower portion of the stock shock into the newly
installed lower shock relocation bracket. Secure using the
stock hardware and add some thread locker or lock tite and
torque to 112 ft. lbs. Repeat procedure on the passenger
side.
Photo # 99
115. Locate the new rear brake line relocation bracket from
hardware bag 16957PL. Also, locate the stock brake line
bracket hardware that was removed in step # 105. Install the
new brake line relocation bracket to the stock rear
differential cover and secure using the stock hardware. Do
not tighten at this point and make sure to use thread locker
or lock tite.
116. Locate (1) 5/16” x 1” bolt, (2) 1/4” USS flat washers and
(1) 5/16” unitorque nuts from hardware bag 16957NB1.
Install the stock brake line bracket to the newly installed
brake line relocation bracket and secure using the new 5/16”
x 1” bolt and hardware. Make sure to use thread locker or
lock tite. Torque the new 5/16” x 1” bolt, hardware and the
stock differential cover hardware to 18 ft lbs.
117. Carefully remove the (2) hydraulic floor jacks from
under the rear differential.
118. Install the tires and wheels and carefully lower the vehi-
cle to the ground.
Step # 119 and # 120 needs to be performed with the
weight of the vehicle on the ground.
119. Working on the driver side, move back to the new 5/8”
hardware attaching the stock lower control arms to the newly
installed front and rear cross members and add some thread
locker or lock tite and torque to 125 ft lbs. Repeat procedure
on the passenger side.
120. Working on the driver side, move back to the newly
installed sway bar end link bolt and add some thread
locker or lock tite and torque to 55 ft lbs. Repeat procedure
on the passenger side.
121. Check and double check to make sure that all steps
were performed properly. And then check them again.
Congratulations, installation complete!