Tuff Country 16985 - GM 00-06 K2500 HD 4wd 6 kit - Manual (Page 14)

Using the new torsion bar cross member relocation bracket
as a guide, carefully drill (4) 7/16” holes into the frame. (2)
on the side of the frame rail and (2) on the bottom. Special
note: take special care not to drill into any stock hoses
and/or lines running down the inside of the frame rail.
Remove the pair of vice grips that is holding the new tor-
sion bar cross member relocation bracket to the frame
rail. Repeat procedure on the passenger side of the vehicle.
71. Locate (8) 7/16” x 1 1/2” bolts, (16) 3/8” USS flat wash-
ers and (8) 7/16” unitorque nuts from hardware bag
16985NB2. Working on the driver side, secure the new
driver side torsion bar cross member relocation bracket to
the frame rail using the new 7/16” x 1 1/2” bolt and hardware.
Do not tighten at this point. Repeat procedure on the pas-
senger side.
72. Refer to the marks that were made earlier in the installa-
tion. This will allow you to re-install the stock torsion bars
back into the stock location. Example: Driver vs.
Passenger and Front vs. Rear. Working on the driver side,
slide the torsion bar back into the rear lower control arm.
Slide the torsion bar far enough forward so that the torsion
bar cross member can be re-installed. Repeat procedure on
the passenger side.
73. Install the torsion bar cross member to the newly
installed torsion bar cross member relocation brackets and
secure using the stock hardware. Make sure to use loctite
and torque to 90 ft lbs.
74. Move back to the new 7/16” x 1 1/2” bolts attaching the
new driver and passenger side torsion bar cross member
relocation bracket to the frame rail and add some loctite and
torque all (8) bolts to 70 ft lbs.
75. Working on the driver side, install the torsion bar key
back into the stock location in the torsion bar cross member.
Slide the torsion bar back into the previously installed torsion
bar key. Repeat procedure on the passenger side. Special
note: Make sure that the torsion bars are installed in the
stock location in the lower control arm and the torsion
bar key. Refer to the marks that were scribed earlier in
the installation.
76. Working on the driver side, attach the torsion bar remov-
ing tool to the torsion bar cross member, making sure that
the unloading bolt in the center of the torsion bar removing
tool is in the small divot of the stock torsion bar key. Adjust
the torsion bar key up high enough so that the stock small
metal adjusting block and bolt can be re-installed back into
the stock location. Remove the torsion bar removal tool from
the stock torsion bar cross member. Special note: Set the
driver and the passenger side torsion bar bolt so that
there is 3/4” of thread showing between the head of the
bolt and the adjusting block. Repeat on the passenger
side.
77. Locate (2) 3/8” x 7” bolts and (2) 3/8” unitorque nuts from
hardware bag 16985NB1. Locate (2) S10067 sway bar end
link sleeves from hardware bag 16985SL. Also, locate (8)
sway bar end link poly bushings and (8) sway bar end link
washers from hardware bag 16985PL. Special note: If you
have not already inverted the sway bar, invert the sway
bar now. Working on the driver side, install the new sway
bar end link and hardware to the sway bar and the lower
control arm. Do not tighten at this point. Repeat procedure
on passenger side.
78. Referring to the photo’s, measure 2 5/8” from the leading
edge of the skid plate and scribe a mark. Carefully cut along
the scribed mark.