Tuff Country 16985 - GM 00-06 K2500 HD 4wd 6 kit - Manual (Page 9)

care not to kink wiring. Also, disconnect the 4WD wire
harness from any other attaching points of the front
differential.
31. Working on the driver side of the front differential,
locate and pull the vent tube off of the differential.
32. Place a pair of hydraulic floor jacks under the front
differential, and carefully raise up on both hydraulic floor
jacks at the same time, until they come into contact with the
front differential.
33. Working on the driver side, remove and save the hard-
ware that connects the upper driver side tab of the front dif-
ferential to the OE location.
34. Working on the passenger side, remove the (2) nuts
that connect the passenger side of the front differential to
the OE location and save the hardware for later re-installa-
tion.
35. Carefully lower down on both hydraulic floor jacks at the
same allowing enough room to remove the front differential
completely from the vehicle. With the help from a buddy,
carefully remove the front differential completely from
underneath the vehicle and set the front differential on the
ground or on a work bench.
36. Working on the driver side of the front differential upper
tab, measure 2” from the mounting point and scribe a mark
on the front differential. Using a sawzall, carefully cut the
upper tab off of the front differential and discard.
37. Locate the new driver side differential relocation
bracket. Locate (2) PB2408 poly bushings from hardware
bag 16985PL and (1) S10082 crush sleeve from hardware
bag 16985SL. Install the new poly bushings and crush
sleeve into the new driver side differential relocation
bracket. Special note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new driver side differential relocation bracket.
This will increase the life of the bushing as well as
prevent squeaking.
38. Locate (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut and
(2) 3/8” USS flat washers from hardware bag 16985NB2.
Locate (4) 10 mm x 60 mm bolts and (4) 10 mm lock
washers from hardware bag 16985NB1. Also, locate (1)
S10120 from hardware bag 16985SL. Working on the front
differential, remove the (4) stock differential mounting bolts