Tuff Country 16985 - GM 00-06 K2500 HD 4wd 6 kit - Manual (Page 10)

that connect to two halves of the front differential together.
The hardware may be discarded. Secure the new driver
side differential relocation bracket to the stock front
differential using the new 10 mm x 60 mm bolts and
hardware. Special note: Get all (4) new 10 mm x 60 mm
bolts started but do not tighten at this point. Secure the
lower portion of the new driver side differential relocation
bracket to the stock front differential using the new 7/16” x
3” bolt and hardware and new spacer sleeve. Add some
loctite and torque to 34 ft. lbs. Move back to the (4) new 10
mm x 60 mm bolts and add some loctite and torque to 34
ft lbs. Special note: Make sure not to over tighten the
new hardware associated with the front differential. If
bolts are over tightened, the front differential could
crack. Also, Tuff Country EZ-Ride Suspension highly
recommends adding a minimum of 1 pint, but no more
that 1 1/2 pints, of proper front differential fluid into the
front differential. To achieve this, you may have to fill
the differential with it on its side or you may have to
insert the fluid through the vent tube opening. On
occasion, the customer may find burping of fluid com-
ing out of the front vent tube.
39. Locate the new passenger side differential relocation
bracket. Working on the passenger side, install the new
passenger side differential relocation bracket into the upper
location and secure using the OE hardware. Do not tighten
at this point. Special note: There is a “6F” cut out in this
bracket, the “6F” will go towards the front of the vehi-
cle and also if you are standing on the passenger side
wheel well looking at the new passenger side differen-
tial relocation bracket, you should not be able to see
the mounting hardware. This will help you make sure
that the bracket is installed properly.
40. With the help from a buddy, carefully lift the modified
front differential back onto a pair of hydraulic floor jacks and
move the hydraulic floor jacks back underneath the vehicle
so that the newly modified front differential can be
re-installed.
41. Locate (2) 9/16” x 1 3/4” bolts, (4) 1/2” USS flat
washers and (2) 9/16” unitorque nuts from hardware bag
16985NB4. Carefully install the passenger side of the front
differential to the previously installed passenger side differ-
ential drop bracket. Secure using the new 9/16” x 1 3/4”
bolts and hardware. Do not tighten at this point. Also at
this time, use a tie down strap and tie the driver side of the
front differential up and out of the way so that the hydraulic
floor jacks can be removed. Remove both hydraulic floor
jacks from under the front differential.
42. Locate (2) 7/16” x 1 1/2” bolts and (2) 3/8” USS flat
washers from hardware bag 16985NB2. Working on the
driver side, install (1) 7/16” x 1 1/2” bolt and hardware
through the stock cross member and let hang. Repeat
procedure on the passenger side.
43. Locate the new sub frame and install the sub frame into
the front and rear lower control arm pockets on the driver
and passenger side and secure using the stock lower con-
trol arm hardware. Do not tighten at this point.
44. Place a hydraulic floor jack on the driver side of the
front differential and carefully raise up until it makes contact
with the front differential. Remove the tie down strap that is
holding the driver side of the front differential.
45. Carefully lower down on the hydraulic floor jack holding
the driver side of the front differential until the front differ-