Tuff Country 16985 - GM 00-06 K2500 HD 4wd 6 kit - Manual (Page 16)

87. Working on the driver side lateral compression arm,
remove the new lateral compression arm mount from the
new lateral compression arm and save the new hardware for
later re-installation. Repeat procedure on the passenger
side.
88. Locate (2) 3/8” x 1 1/2” self threading bolts from hard-
ware bag 16985NB1. Working on the driver side, secure the
new rear lateral compression arm mount to the previously
drilled hole in the transfer case cross member. Use the new
3/8” x 1 1/2” self threading bolt. Torque to 28 ft lbs. Make
sure to use loctite. Repeat procedure on the passenger
side. Special note: Make sure that the longer leg of the
new lateral compression arm is towards the rear of the
vehicle.
89. Working on the driver side, secure the new lateral com-
pression arm to the previously installed rear lateral com-
pression arm mount. Secure using the new 1/2” x 3 1/2” bolt
and hardware. Make sure to use loctite and torque the front
and rear mount to 85 ft lbs. Repeat procedure on the pas-
senger side.
90. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
91. Check and double check to make sure that all steps were
performed properly and check again.
92. There are still a couple of steps that need to be complet-
ed 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 tight-
ening 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.
Rear end installation:
93. 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 passen-
ger side. Next, remove the wheels and tires from both sides.
94. Working on the driver side, remove the shock from the
upper and lower mounting points and save the hardware for
later re-installation. The stock shocks may be discarded.
Special note: New longer rear 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 30”
fully extended nitrogen gas shock. Repeat procedure on
the passenger side.
95. Place a pair of hydraulic floor jacks under the rear differ-
ential and carefully raise up on both hydraulic floor jacks at
the same time until they come into contact with the rear dif-
ferential.
96. Working on the driver side, remove the u-bolts from the
OE location and discard the u-bolts and hardware. Set the
upper and lower u-bolt plates aside for later re-installation.
Repeat procedure on passenger side.
97. 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.
98. Locate (2) new rear 4” lifted blocks. Working on the driv-
er side, install the new lifted block into the OE location.
Repeat procedure on the passenger side.
99. Carefully raise up on both hydraulic floor jacks at the
same time until the spring assembly sits flush with the newly
installed lifted block.
100. Locate (4) 5/8” x 2 3/4” x 14” square u-bolts. Also,
locate (8) 5/8” u-bolt high nuts and (8) u-bolt washers from
hardware bag 58NW. Working on the driver side, install the
new u-bolts into the OE location and secure using the new
5/8” high nuts and washers. Special note: Make sure to re-
install the upper and lower u-bolt plates. Torque to 135 ft
lbs. Repeat procedure on passenger side.
101. Special note: New longer rear 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
30” fully extended nitrogen gas shock. Locate (2) S10074
from hardware bag 16985SL. Working on the new shocks,
install the new shock bushing into the upper and lower eye-
lets of the new shocks. Next, install the new shock sleeves
into the previously installed shock bushings. Special note:
Use the new S10074 shock sleeves and the proper
shock sleeves that are located in the new sleeve bag
that was provided with your new shocks. Make sure to
use a lithium or moly base grease prior to inserting the
new lower shock bushings and sleeves into the new
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 OE location and