Tuff Country 33920 - Dodge 94-02 Ram 2500 / 3500 3 kit - Manual (Page 6)

location and secure using the stock hardware. Make
sure to use thread locker or lock tite. Do not tighten at
this point. Repeat procedure on the passenger side.
36. Locate the stock upper shock tower brackets that
where removed in step # 8. Locate (2) new 3/8” x 1 1/2”
fender washers from hardware bag D3INB. Locate (2)
PB8297 front upper shock bushings that were packaged
with the installer copy of the installation manual. Also,
locate the new upper shock nut that was included with
your new front shocks. Working on the driver side, install
the stock upper shock tower to the new stud on top of the
newly installed front shock. Now install the new front
upper shock bushing and new 3/8” x 1 1/2” fender
washer and secure the newly installed front shock to the
stock upper shock bracket using the upper shock
hardware. Do not tighten at this point. Repeat
procedure on the passenger side.
37. Locate (4) 3/8” x 1 1/2” bolts, (10) 3/8” flat washers
and (6) 3/8” nylon insert nuts and from hard bag D3INB.
Working on the driver side, secure the new upper coil
spring spacer to the stock upper coil spring tower and the
stock upper shock tower using the new 3/8” hardware.
Make sure to use thread locker or lock tite. Torque the
new 3/8” hardware to 28 ft lbs. Repeat procedure on the
passenger side.
Illustration # 6
38. Working on the driver side, torque the stock lower
shock bolt to 80 ft lbs and the new upper shock nut to 22
ft lbs. Repeat procedure on passenger side.
39. Locate the new track bar relocation bracket. Also,
locate (2) 1/2” x 1 1/2” bolts (4) 7/16” USS flat washers
and (2) 1/2” unitorque nuts from hardware bag D3INB.
Working on the passenger side, place the new track bar
relocation bracket on the outside of the stock track bar
bracket keeping the new bracket flush with the bottom of
the stock bracket. Clamp the new bracket into place.
Using the (2) holes in the new bracket as a guide,
carefully drill (2) 1/2” holes into the passenger side stock
bracket. Special note: When drilling the new holes make
sure to drill straight through the existing bracket. Secure
the new bracket to the stock bracket using the new 1/2” x
1 1/2” bolt and hardware. Torque to 80 ft lbs. Using the
hole on the front of the newly installed track bar bracket
as a guide, carefully drill a 1/2” hole into the front and
back portion of the stock track bar bracket.
Illustration # 7
40. Locate the stock track bar mounting hardware that
was removed in step # 4. Working on the passenger side,
install the stock track bar into the newly installed track
bar bracket and secure using the stock hardware. Make
sure to use thread locker or lock tite and torque to 75
ft lbs. Special note: If you are not able to install the
stock track bar to the newly installed track bar
bracket, you will have to perform this step with the
weight of the vehicle on the ground.
Illustration # 8
arms make sure that the alignment marks that were
made in step # 5 are still lined up.
32. Locate the new upper coil spring spacers and the
stock rubber isolator pads that were removed in step #
13. Insert the stock rubber isolator pads inside the recess
in the new upper coil spring spacer.
33. Working on the driver side, place the new upper coil
spring spacer on the top of the stock coil spring and
insert the stock coil spring into the stock lower location.
Special note: Make sure that the marks that were
scribed in step # 6 line up with each other. Repeat
procedure on the passenger side. Carefully raise up on
both hydraulic floor jacks at the same time until the driver
side and passenger side new upper coil spring spacers
and stock coil springs seat properly into the stock upper
location. Special note: There is (1) 3/8” x 1 1/2” bolt
that is welded to the new upper coil spring spacer,
this bolt needs to be line up with the back side stock
hole. This will make installation easier to tighten the
new nut down.
34. Locate the new front shocks. Special note: New
longer front shocks are needed once this suspension
system has been installed and the front shocks need
to be ordered as a separate part #. If you have not
already ordered your new front shocks, please feel
free to contact Tuff Country or your local Tuff
Country dealer and order your new front shocks. Tuff
Country recommends installing a 26” fully extended
nitrogen gas shock in the front end of your vehicle.
Locate (2) new 3/8” x 1 1/2” fender washers from
hardware bag D3INB. Also, locate (2) PB8297 front
upper shock bushings that were packaged with the
installer copy of the installation manual. Install the new
bushings and proper sleeves into each end of the new
shocks. Special note: The new bushings and sleeves
are supplied with your new shocks. Also, make sure
to use a lithium or moly base grease prior to
inserting the new bushings and sleeves into the new
shocks. This will increase the life of the bushings
and will help prevent squeaking. Install the new shock
boots onto the new shocks. Special note: The new
shock boots are not included with this suspension
system and the new shock boots need to be ordered
as a separate part #. If you have not already ordered
your new shock boots, please feel free to contact
Tuff Country or your local Tuff Country dealer and
order your new shock boots. Once the new shock
boots have been installed, working on the driver side,
install the new shock into the stock coil spring by
inserting it through the engine compartment. Install the
new fender washer and the new front upper shock
bushing onto the stud of the new shock. Repeat
procedure on the passenger side.
35. Locate the stock lower shock mounting hardware that
was removed in step # 9. Working on the driver side,
secure the newly installed front shock into the stock lower