Tuff Country 16985 - GM 00-06 K2500 HD 4wd 6 kit - Manual (Page 13)

62. Working on the driver side, secure the front CV axle to
the hub assembly using the stock hardware. Make sure to
use loctite and torque to 112 ft. lbs. Also, re-install the hub
assembly center cap. Repeat procedure on the passenger
side.
63. Working on the driver side, reconnect the stock ABS
lines back together. Also reconnect all other mounting points
on the ABS line. Repeat procedure on the passenger side.
64. Working on the driver side, install the rotor into the stock
location. Repeat procedure on the passenger side.
65. Working on the driver side, re-install the brake caliper to
the newly installed knuckle and secure using the hardware.
Make sure to use loctite and torque to 76 ft. lbs. Repeat
procedure on the passenger side.
66. Locate the new brake line brackets, (4) 1/4” x 3/4” bolts,
(6) 1/4” flat washers, (2) 1/4” lock washers and (2) 1/4” uni-
torque nuts from hardware bag 16985NB6. Working on the
driver side and using the new hardware, install the new
brake line bracket to the tapped hole on the inside of the new
knuckle. Do not tighten at this point. Carefully open up the
brake line bracket. Next, secure the brake line bracket to the
new brake line bracket using the new 1/4” x 3/4” bolt and
hardware from hardware bag 16985NB6. Also, use some
shock ties from hardware bag 16985PL and shock tie the
stock ABS line and the stock brake lines together. Repeat
procedure on the passenger side. Special note: In this step
make sure that once you shock tie the stock brake lines
and ABS lines to the knuckle, there will be no contact on
the new wheels and tires. If contact occurs, the stock
brake lines or ABS lines may be damaged.
67. 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 nitro-
gen gas shock. Locate (2) S10073 from hardware bag
16985SL. Install the new sleeves into the new shocks.
Special note: Make sure to use a lithium or moly base
grease prior to inserting the sleeves into the lower
shock eyelet. This will increase the life of the bushing as
well as prevent squeaking. Working on the driver side,
install the new shock into the lower location using the stock
hardware and the new hardware on the top mount. Repeat
procedure on the passenger side. Make sure to use loctite
and torque torque the lower shock mount to 65 ft lbs.
and the upper hardware to 22 ft lbs. Repeat on passenger
side. Special note: Tuff Country EZ-Ride Suspension
highly recommends that the shocks are installed with
shock boots. If shock boots are not installed, damage
may occur to the piston of the new shock.
68. Working on the driver side, install the outer tie rod to the
new steering knuckle using the stock hardware. Make sure
to use loctite and torque to 53 ft. lbs. Special note: The
new steering knuckle has a reverse taper on it where the
outer tie rod mounts to it, make sure to install the outer
tie rod the proper way. The outer tie rod nut will now be
installed on the bottom side of the new steering knuck-
le. Repeat procedure on the passenger side.
69. Locate (2) new torsion bar cross member relocation
brackets. Locate (4) MO2220 poly bushings from hardware
bag 16985PL. Also, locate (2) S10074 sleeves from hard-
ware bag 16985SL. Install the new poly bushings and
sleeves into the new torsion bar cross member relocation
brackets. Special note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
and sleeves into the new torsion bar cross member relo-
cation brackets. This will increase the life of the bushing
as well as prevent squeaking.
70. Working on the driver side, hold the new torsion bar
cross member relocation bracket to the new location on the
frame rail. Special note: Using the larger cut out holes in
the torsion bar cross member relocation bracket over
the stock rivets on the bottom of the stock frame rail
with help center the new torsion bar cross member relo-
cation bracket. With the new torsion bar cross member
relocation bracket in place, use a pair of vice grips and
secure the new torsion bar drop bracket to the frame rail.