Tuff Country 34003 - Dodge 03-07 Ram 2500 / 3500 4.5 kit - Manual (Page 5)

12. Working on the driver side, remove the stock lower con-
trol arm from the stock frame rail and axle location. Save the
stock hardware for later re-installation. Remove the stock
lower control arm and discard. Repeat procedure on the
passenger side.
Photo # 12 / Photo # 13
13. Working on the driver side, remove the stock upper
control arm from the stock frame mount and axle location.
The stock hardware may be discarded. Remove the stock
upper control arm and discard. Repeat procedure on the
passenger side. Special note: Due to clearance issues
with the stock exhaust, the passenger side upper
control arm frame mounting hardware will need to be
cut off. Carefully cut the stock bolt and discard the stock
hardware. New hardware is provided for the new upper
control arms. Carefully pushing the stock exhaust over
to the driver side will help make clearance to perform
this step on the passenger side.
Photo # 14
14. Locate (2) new upper coil spring spacers, the stock rub-
ber isolator pads and the stock coil springs. Insert the stock
rubber isolator pads inside the recess in the new upper coil
spring spacers. Working on the driver side, place the new
upper coil spring spacer on the top of the stock coil spring
and insert the bottom of the stock coil spring back into the
stock lower pocket. Special note: Refer to the mark that
was scribed in step # 8 so that you can re-install the bot-
tom of the stock coil spring back into the stock location.
Carefully raise up on the hydraulic floor jack until the top of
the stock coil spring and the new coil spring spacer seat
properly into the upper stock coil spring pocket. Special
note: When installing the upper coil spring spacer into
the stock upper pocket, make sure that the (3) holes in
the new upper coil spring spacer and the stock pocket
line up with each other. Repeat procedure on the passen-
ger side.
15. Locate the new front shocks. Special note: Shocks are
not included with this suspension system, shocks need
to be ordered as a separate part number. Tuff Country
EZ—Ride Suspension recommends using a 30” fully
extended nitrogen gas shock. If you have not already
ordered your shocks, please contact Tuff Country or
your local Tuff Country dealer and order the proper front
shocks. Install the new poly bushings and proper crush
sleeve into the bottom part of the new shock. Special note:
Make sure to use a lithium or moly base grease prior to
inserting the new bushings and sleeves into the new
lower eyelet of the new shock. This will increase the life
of the bushing as well as prevent squeaking.
16. Locate the new upper shock grommets from hardware
bag 34000PL. Also, locate (4) S10107 upper shock washers
from hardware bag 36000NB1. Install the new shock grom-
mets and washers onto each of the new front shocks.
Working on the driver side, install the new front shock back
into the stock location. Repeat procedure on the passenger
side. Special note: Install the new shock through the
engine compartment to make shock installation easier.
Also, Tuff Country EZ-Ride Suspension highly recom-
mends that the shocks are installed with shock boots. If
shock boots are not installed, damage may occur to the
piston of the new shock.
17. Locate the stock lower shock hardware. Working on the
driver side, secure the lower portion of the new shock into
the stock lower location using the stock hardware. Make
sure to use thread locker or lock tite and torque to 85 ft lbs.
Repeat procedure on the passenger side.
18. Locate the stock upper shock tower. Also locate (6) 3/8”
x 1 1/2” bolts, (12) 5/16” USS flat washers and (6) 3/8”
nylock nuts from hardware bag 36000NB1. Working on the
driver side, install the stock upper shock tower into the stock
location and secure the new upper coil spring spacer and the
stock upper shock tower to the stock location using the new
3/8” x 1 1/2” bolts and hardware. Make sure to use thread
locker or lock tite. Torque the new 3/8” hardware to 35 ft lbs.
Repeat procedure on the passenger side. Special note:
Make sure that the new shock seats properly into the
stock upper shock tower.
19. Working on the driver side, install the new upper shock
grommet and washer and secure using the new shock nut.
Torque to 32 ft lbs. Repeat procedure on the passenger
side.
Photo # 15 / stock coil spring, coil spring
spacer and new shock installation.
20. Locate the new upper control arms. Locate (8) control
arm bushings from hardware bag 34000PL. Also, locate (4)
S10059, upper control arm sleeves from hardware bag
36005SL. Special note: The new upper control arms are
the shorter of the 2 arms. Insert the new poly bushings into
each end of the new upper control arms. Special note:
Make sure to use a lithium or moly base grease prior to
inserting the new bushings into the new upper control
arms. This will increase the life of the bushing as well as
prevent squeaking. Next, install the new upper control
arm sleeves into the previously installed poly bushings.
21. Locate (1) 9/16” x 6” bolts, (1) 9/16” x 5 1/2” bolt, (2)
9/16” x 4” bolts, (6) 1/2” USS flat washers, (2) 9/16” u-bolt
harden washers and (3) 9/16” unitorque nuts from hardware
bag 36000NB1. Also, locate (1) 34000-07 (nut bracket) from
hardware bag 36005SL. Working on the driver side, install
the new upper control arm to the stock frame mount location
and secure using the new 9/16” x 6” bolt, hardware and 9/16”
u-bolt harden washer. Special note: the new 9/16” special
washers needs to be installed on the inner part of the
stock frame rail. Do not tighten at this point. Next, install
the new upper control arm to the stock mounting location on
the stock front axle. Secure using the new 9/16” x 4” bolt and
hardware. Do not tighten at this point. Special note:
Raising the axle to ride height and moving the axle up
and down will make for easier upper control arm instal-
lation. Slight prying of the stock control arm bracket
also may be needed to make installation easier. Working
on the passenger side, install the new upper control arm to
the stock upper frame mount and secure using the new 9/16”