Tuff Country 16962 - GM 00-03 Suburban / Tahoe K1500 6 STRONG kit - Manual (Page 10)

actuator into the stock location. Repeat procedure on the
passenger side.
Photo # 86
79. Locate (2) 1/2” x 15” bolts and (2) 1/2” unitorque nuts
from hardware bag 16965NB3. Locate (2) new sway bar
end links from hardware bag 16965SL. Also, locate (8)
sway bar end link bushings and (8) sway bar end link
washers from hardware bag 16965PL. Working on the
driver side, install the new sway bar end link and hardware
into the stock location. Do not tighten at this point. This
bolt will be torqued to proper torque settings once the
weight of the vehicle is on the ground. Repeat procedure
on passenger side.
Photo # 87
80. Locate the stock outer tie rod ball joint hardware that
was removed from step # 11. Working on the driver side,
install the stock outer tie rod to the new steering knuckle
using the stock hardware. Make sure to use thread locker
or lock tite and torque to 53 ft. lbs. Special note: The new
steering knuckle has a reverse taper on it where the
stock outer tie rod mounts to it, make sure to install the
outer tie rod the proper way. The stock outer tie rod nut
will now be installed on the bottom side of the new
steering knuckle. Repeat procedure on the passenger
side.
Photo # 87
81. Locate (4) new torsion bar drop plates. Locate (2) 9/16”
x 3 1/2” bolts, (4) 1/2” USS flat washers and (2) 9/16”
unitorque nuts from hardware bag 16965NB4. Working on
the driver side, install the new torsion bar drop plates to the
stock torsion bar cross member location and secure using
the new 9/16” x 3 1/2” bolt and hardware. Do not tighten
at this point. Repeat procedure on the passenger side.
Special note: When installing these brackets, the bend
of the bracket will go towards the inside of the vehicle
then out towards the outside of the vehicle.
82. Locate the stock torsion bars that were removed from
step # 5. Refer to the marks that were made in step # 3.
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
stock torsion bar back into the stock rear lower control arm.
Slide the stock torsion bar far enough forward so that the
stock torsion bar cross member can be re-installed. Repeat
procedure on the passenger side.
83. Locate the stock torsion bar cross member that was
removed in step # 4. Working on the stock torsion bar cross
member, remove the stock nut that is tack welded to the
back side of the torsion bar cross member. Make sure to
remove from both the driver and the passenger side of the
stock torsion bar cross member. Set the torsion bar cross
member aside for later re-installation.
84. Locate (2) 9/16” x 3 1/2” bolt, (4) 1/2” USS flat washers
and (2) 9/16” unitorque nuts from hardware bag 16965NB4.
Locate (2) S10020 crush sleeves from hardware bag
16965SL. Also, locate the newly modified stock torsion bar
cross member. Working on the driver side, install the stock
torsion bar cross member to the newly installed torsion bar
drop plates and secure using the new 9/16” x 3 1/2” bolt,
hardware and crush sleeve. Do not tighten at this point.
On the rear tab of the stock torsion bar cross member, you
will notice that this hole is larger in diameter than the front
hole, the new crush sleeve outside diameter will be small
enough for the tab of the stock torsion bar cross member to
slide over the sleeve. Repeat procedure on the passenger
side. Move back to the upper and lower mounting bolts and
add some thread locker or lock tite and torque the upper
and lower mounting bolt to 95 ft lbs.
Photo # 88
85. Locate the stock torsion bar keys that were removed in
step # 3. Working on the driver side, install the stock torsion
bar key back into the stock location in the stock torsion bar
cross member. Slide the stock 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
stock lower control arm and the stock torsion bar key.
Refer to the marks that were scribed in step # 3.
86. Locate the torsion bar adjusting blocks and hardware
that was removed from step # 2. Working on the driver side,
attach the torsion bar removing tool to the stock 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.
If the vehicle that you are working on has the stock
transfer case bolted to the bottom of the stock frame
rail, please follow steps 87 — 92.
If the vehicle that you are working on has the stock
transfer case bolted to brackets that are welded to the
inside of the stock frame rail, please follow steps 93 —
97.
87. Locate (2) 1/2” x 3 1/2” bolts, (4) 7/16” USS flat
washers and (2) 1/2” unitorque nuts from hardware bag
16965NB3. Working on the driver side, install the new
lateral compression arm into the lateral compression arm
mounts located on the previously installed rear cross
member. Secure using the new 1/2” x 3 1/2” bolts and
hardware. Do not tighten at this point. Let the new
lateral compression arm hang. Repeat procedure on the
passenger side.