Tuff Country 16962 - GM 00-03 Suburban / Tahoe K1500 6 STRONG kit - Manual (Page 13)

from step # 106. Secure the stock track bar to the newly
installed track bar relocation bracket and secure using the
stock hardware. Make sure to use thread locker or lock tite.
Torque the stock bolt to 108 ft lbs. Special Note: If you are
not able to line up the hole on the track bar and the new
track bar relocation bracket, you may have to perform
this step once the weight of the vehicle is on the ground.
Photo # 96
113. Locate (2) new rear shock relocation brackets. Locate
(2) 9/16” x 3” bolts, (4) 1/2” USS flat washer and (2) 9/16”
unitorque nuts from hardware bag 16965NB4. Locate (2)
7/16” x 1 1/4” bolt, (4) 3/8” USS flat washers and (2) 7/16”
unitorque nuts from hardware bag 16965NB2. Also, locate
(2) S10019 crush sleeves from hardware bag 16965SL.
Working on the driver side, install the new shock relocation
bracket into the stock location and secure using the new
9/16” x 3” bolt, hardware and (1) S10019 crush sleeve. Do
not tighten at this point. Make sure that the new rear shock
relocation bracket is sitting flush with the stock shock
bracket, carefully drill a 7/16” hole in the bottom of the stock
shock bracket and the newly installed shock relocation
bracket. Secure the shock relocation bracket to the stock
shock bracket using the new 7/16” x 1 1/4” bolt and hard-
ware. Move back the new 9/16” bolt and add some thread
locker or lock tite and torque to 112 ft lbs. Now move back to
the new 7/16” hardware and add some thread locker or lock
tite and torque to 35 ft lbs. Repeat procedure on the
passenger side.
Photo # 97
114. Locate the stock rear coil springs that were removed
from step # 107. Working on the driver side, re-install the
stock rear coil spring into the stock lower coil spring pocket.
Repeat procedure on the passenger side. Special note:
make sure to re-install the stock coil spring back into the
stock location, refer to the marks that were scribed in
step # 107. Carefully raise up on both hydraulic floor jacks at
the same time until the stock coil springs seats properly with
the newly installed upper coil spring spacers.
115. Locate the stock lower shock mounting hardware that
was removed from step # 105. Working on the driver side,
install the lower portion of the stock shock into the newly
installed lower shock relocation bracket. Secure using the
stock hardware. Make sure to add some thread locker or lock
tite and torque to 112 ft. lbs. Repeat procedure on the
passenger side.
Photo # 98
116. Carefully remove the (2) hydraulic floor jacks from under
the rear differential.
117. Locate (2) new actuator rods from hardware bag
16965NB1. Working on the driver side, carefully install the
new actuator rod into the stock rear location by inserting the
actuator rod into the bottom ball joint cap and then into the
top. Repeat procedure on the passenger side.
Photo # 99
118. Locate (2) new rear sway bar end links. Locate (8)
MO2220 poly bushings from hardware bag 16965PL. Also,
locate (4) S10026 sleeves from hardware bag 16965SL.
Install the new poly bushings and sleeves into each end of
the new rear sway bar end links. Special Note: Make sure
to use a lithium or moly base grease prior to inserting
the new bushings and sleeves into the new rear sway
bar end links. This will increase the life of the bushing
as well as prevent squeaking.
119. Locate (2) 1/2” x 2 1/2” bolts, (4) 7/16” USS flat
washers and (2) 1/2” unitorque nuts from hardware bag
16965NB3. Also, locate the stock upper sway bar mounting
hardware that was removed in step # 103. Working on the
driver side, install the new sway bar end link into the stock
uppr location and secure using the stock hardware. Now
install the lower portion of the new sway bar end link to the
stock sway bar and secure using the new 1/2” x 2 1/2” bolt
and hardware. Do not tighten at this point. Repeat
procedure on the passenger side. Once both new sway bar
end links are secure to the stock location add some thread
locker or lock tite to the new and stock bolts and torque to 85
ft lbs. Special Note: If you are not able to connect the
new rear sway bar end link to the stock location, the
weight of the vehicle may need to be on the ground. If
this is the case, perform this step once the tires have
been installed and the vehicle is on the ground.
Photo # 100 / Photo # 101
120. Locate (1) BLR01, (1) 5/16” x 1” bolt (2) 1/4” USS flat
washers and (1) 5/16” unitorque nuts from hardware bag
16965PL. Working on the driver side, remove the emer-
gency brake line bracket from the stock frame rail. Using the
stock bolt, secure the BLR01 to the stock location. Make
sure to use thread locker or lock tite and torque the stock
bolt to 12 ft lbs. Now, install the stock emergency brake
cable bracket to the newly installed BLR01 and secure using
the new 5/16” x 1 1/2” bolt and hardware. Make sure to use
thread locker or lock tite and torque to 18 ft lbs.
Photo # 102
121. Install the tires and wheels and carefully lower the
vehicle to the ground.
122. If you were not able to attach the stock track bar to the
new track bar relocation bracket in step # 112, perform this
step now that the weight of the vehicle is on the ground.
Photo # 96
123. If you were not able to attach the new sway bar end
links to the stock location in step # 119, perform this step
now that the weight of the vehicle is on the ground.
Photo # 100 / Photo # 101
124. Install the tires and wheels and carefully lower the
vehicle to the ground.
Step # 125 and # 126 needs to be performed with the
weight of the vehicle on the ground.
125. Working on the driver side, move back to the new 5/8”
hardware attaching the stock lower control arms to the newly