Tuff Country 16985 - GM 00-06 K2500 HD 4wd 6 kit - Manual (Page 17)

secure using the stock hardware. Special note: Make sure
to use loctite and torque to 75 ft lbs. Repeat procedure
on the 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.
102. Carefully remove the (2) hydraulic floor jacks from
under the rear differential.
103. Locate (2) PB6199 poly bump stops and (2) PB6052
poly bump stops from hardware bag 16985PL. Also, locate
(4) 3/8” unitorque nuts and (4) 5/16” USS flat washers from
hardware bag 16985NB1. Working on the driver side of the
rear spring assembly, remove the (2) teflon inserts located
on the over load in the spring assembly. Discard the teflon
inserts. Install (1) PB6052 (taller poly bump stop) in front
location on the spring assembly. Secure using the new 3/8”
hardware. Torque to 28 ft lbs. Install (1) PB6199 (shorter
poly bump stop) in the rear location on the spring assembly.
Secure using the new 3/8” hardware. Torque to 28 ft lbs.
Repeat procedure on the passenger side.
If the vehicle that you are working on has a 2 piece rear
drive shaft, please follow step 104 — 105.
If the vehicle that you are working on does not have a 2
piece rear drive shaft, please skip to step # 106.
104. Carefully place a hydraulic floor jack under the rear
drive line near the carrier bearing mounting location. Raise
up on the hydraulic floor jack until it comes into contact with
the rear drive line. Remove the hardware that connects the
carrier bearing to the OE location and discard the hardware.
Carefully lower down on the hydraulic floor jack allowing
enough room for the new rear carrier bearing drop bracket to
be installed.
105. Locate the new rear carrier bearing drop. Locate (2)
S10007 crush sleeves from hardware bag 16985SL. Also,
locate (2) 3/8” x 3 1/2” bolts, (4) 5/16” USS flat washers and
(2) 3/8” unitorque nuts from hardware bag 16985NB1. Install
the new carrier bearing drop bracket between the carrier
bearing and the mounting point. Secure using the new 3/8” x
3 1/2” bolts, crush sleeves and hardware. Make sure to use
loctite and torque to 28 ft lbs. Carefully remove the
hydraulic floor jack from under the rear drive line. Special
note: The carrier bearing mount has slotted holes, make
sure that when you torque the new 3/8” hardware that
the new carrier bearing is pushed as far forward as pos-
sible.
106. Install the tires and wheels and carefully lower the
vehicle to the ground.
Step # 107 and # 108 needs to be performed with the
weight of the vehicle on the ground.
107. Working on the driver side, move back to the new 5/8”
hardware attaching the lower control arms to the newly
installed sub frame and add some loctite and torque to 125
ft lbs. Repeat procedure on the passenger side.
108. Working on the driver side, move back to the newly
installed sway bar end link bolt and add some loctite and
tighten the bolt until the bushings start to bulge. Repeat pro-
cedure on the passenger side.
109. Check and double check to make sure that all steps
were performed properly. And then check them again.
Congratulations, installation complete!
Special note: After the completion of the installation,
Tuff Country EZ-Ride Suspension recommends taking
the vehicle to an alignment shop and having a proper
front end alignment performed.
Special note: After the vehicle has been aligned, in 2WD,
test drive the vehicle to check for any drive line
vibrations. If drive live vibrations occur, the stock drive
line may need to be rebalanced. If the stock drive line is
rebalanced and vibration still occurs, please follow
steps 110 — 111.
110. Place a pair of hydraulic floor jacks under the transfer
case cross member. Carefully raise up on both hydraulic
floor jacks at the same time until the hydraulic floor jacks
come into contact with the transfer case cross member.
Working on the driver side, remove the (2) bolts and hard-
ware that connects the transfer case cross member to the
bottom sides of the frame rail. On the side of the stock frame
rail, remove and discard the transfer case support bracket
and hardware. Repeat procedure on the passenger side.
111. Carefully lower down on both hydraulic floor jacks at the
same time about 3/4”. Locate (8) 2” x 2” square washers.
Also, locate (4) 1/2” x 2” bolts, (8) 7/16” USS flat washers
and (4) 1/2” unitorque nuts from hardware bag 16985NB3.
Working on the driver side, install (4) shims, (2) in the
forward hole and (2) in the rearward hole, between the