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

Please follow instructions carefully:
Before installation begins, measure from the center of
the hub, to the bottom of the fender well, and record
measurements below.
Pre-installation measurements:
Driver side front:_______________________________
Passenger side front:___________________________
Driver side rear:________________________________
Passenger side rear:____________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post installation measurements:
Driver side front:______________________________
Passenger side front:__________________________
Driver side rear:_______________________________
Passenger side rear:___________________________
Front end installation:
1. To begin installation, block the rear tires of the vehicle so
that the vehicle is stable and can’t roll backwards. Safely lift
the front of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and the
passenger side. Next, remove the front wheels and tires
from both sides.
2. Working on the driver side, attach the torsion bar
removing 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 torsion bar key.
Adjust the torsion bar key up high enough so that the stock
small metal adjusting block and bolt can be removed. Set
the torsion bar block and hardware aside for later re-instal-
lation. Repeat procedure on passenger side.
3. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:
Driver vs. Passenger and front vs. rear. Tap the torsion
bars forward until the torsion bar cross member can be
removed. Once you tap the torsion bar out of the torsion
bar cross member, the torsion bar key will fall out. Set the
torsion bar key aside for later re-installation. Repeat proce-
dure on the passenger side.
4. Working on the driver side, remove the hardware that
connects the torsion bar cross member to the mounting
point. Set the stock hardware aside for later re-installation.
Special note: The stock mounting point is on the inside
of the frame rail. Repeat procedure on the passenger
side. Remove the torsion bar cross member and set aside
for later re-installation.
5. Working on the driver side, slide the torsion bar out of the
rear lower control arm and set aside for later re-installation.
Repeat procedure on passenger side.
6. Remove the stock lower skid plate and discard the stock
lower skid plate and the stock hardware.
7. Remove the upper skid plate. Save the skid plate and
the upper hardware. The lower hardware may be discard-
ed.