Tuff Country 16993 - GM 01-09 K2500 HD 4wd 6 kit - Manual (Page 12)

the proper shock sleeves that are located in the new
sleeve bag that was provided with your new shocks.
Make sure to use a lithium or moly base grease prior to
inserting the new lower shock bushings and sleeves
into the new lower shock eyelet. This will increase the
life of the bushing as well as prevent squeaking.
Working on the driver side, install the new shock into the
stock location and secure using the stock hardware that
was removed in step # 96. Special note: Make sure to use
thread locker or lock tite 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.
104. Carefully remove the (2) hydraulic floor jacks from
under the rear differential.
105. 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
stock rear spring assembly. Remove the (2) stock teflon
inserts located on the stock over load in the stock spring
assembly. Discard the stock teflon inserts. Install (1)
PB6052 (taller poly bump stop) in front location on the stock
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 stock spring assembly.
Secure using the new 3/8” hardware. Torque to 28 ft lbs.
Repeat procedure on the passenger side.
Photo # 77 / front location
Photo # 78 / rear location
If the vehicle that you are working on has a 2 piece rear
drive shaft, please follow step 106 — 107.
If the vehicle that you are working on does not have a
2 piece rear drive shaft, please skip to step # 108.
106. Carefully place a hydraulic floor jack under the rear
drive line near the stock carrier bearing mounting location.
Raise up on the hydraulic floor jack until it comes into
contact with the rear drive line. Remove the stock hardware
that connects the stock carrier bearing to the stock location
and discard the stock hardware. Carefully lower down on
the hydraulic floor jack allowing enough room for the new
rear carrier bearing drop bracket to be installed.
107. 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
stock carrier bearing and the stock mounting point. Secure
using the new 3/8” x 3 1/2” bolts, crush sleeves and
hardware. Torque to 28 ft lbs. Carefully remove the
hydraulic floor jack from under the rear drive line. Special
note: The stock 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 possible.
108. Install the tires and wheels and carefully lower the
vehicle to the ground.
Step # 109 and # 110 needs to be performed with the
weight of the vehicle on the ground.
109. Working on the driver side, move back to the new 5/8”
hardware attaching the stock lower control arms to the newly
installed front and rear cross members and add some thread
locker or lock tite and torque to 125 ft lbs. Repeat procedure
on the passenger side.
110. Working on the driver side, move back to the newly
installed sway bar end link bolt and add some thread
locker or lock tite and torque to 38 ft lbs. Repeat procedure
on the passenger side.
111. 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 112 — 113.
112. Place a pair of hydraulic floor jacks under the stock
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 stock transfer case cross
member. Working on the driver side, remove the (2) stock
bolts and hardware that connects the stock transfer case
cross member to the bottom sides of the stock frame rail. On
the side of the stock frame rail, remove and discard the stock
transfer case support bracket and hardware. Repeat
procedure on the passenger side.
113. 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 stock
transfer case cross member and the stock frame rail. Secure
using the new 1/2” x 2” bolt and hardware. Torque to 85 ft
lbs. Repeat procedure on the passenger side. Remove both
hydraulic floor jacks.