Tuff Country 34100 - Dodge 09-11 Ram 1500 4 kit - Manual (Page 6)

25. Locate the (2) 1/2” x 2 3/4” bolts, (4) 1/2” SAE washers
and (2) 1/2” unitorque nuts from hardware bag 34100NB8.
Working on the passenger side, install the passenger side
of the differential to the newly installed passenger side dif-
ferential relocation bracket and secure using the new 1/2”
x 2 3/4” bolts and hardware. Do not tighten at this point.
26. Attach the differential to the newly installed driver side
rear bracket using the (3) stock differential bolts and the
supplied nuts that were earlier removed from the stock
cross member.
27. Move back to the (4) bolts securing the driver side /
front bracket to the stock location and differential and add
some thread locker or loctite and torque to 70 ft lbs. Move
back to the (4) bolts securing the passenger side bracket to
the stock location and differential and add some thread
locker or loctite and torque to 70 ft lbs. Move back the the
(6) bolts securing the driver side / rear bracket to the stock
location and differential and add some thread locker or loc-
tite and torque to 70 ft lbs.
28. Locate the new vacuum line adapter and vacuum line
from hardware bag 34100NB1. Install the vacuum line
adapter and new vacuum line. Reconnect the electrical
lines, retaining clips may need to be removed to create
enough room to reconnect.
29. Locate the new front cross member. Working on the
driver side, install the new front cross member into the
stock location. Special note: Make sure the tab with the
skid plate holes are towards the rear of the vehicle.
Install the new S10225 in the middle of the stock lower con-
trol arm mount then insert the new 18 mm x 150 mm bolt
and flat washer from the front, then through the cross mem-
ber and sleeve. Place the 1 1/2” x 2” washer onto the bolt
(this washer is going to seat in the stock rear cam
washer location). Install the supplied flat washer then the
18 mm nylock nut. Do not tighten at this point. Repeat
procedure on the passenger side.
30. Locate the new front drive shaft spacer. Also, locate (4)
new 12 mm x 50 mm bolts from hardware bag 34100NB3.
Install the new spacer between the drive shaft and the dif-
ferential flange and secure using the new 12 mm x 50 mm
bolt. Make sure to use thread locker or loctite and torque to
85 ft lbs.
31. Working on the driver side, install the stock lower con-
trol arm into the newly installed front and rear cross mem-
ber and secure using the stock cam bolts. Install the cam
bolts fro the front with the cam lobes in the upright centered
location. Do not tighten at this point.
32. Locate the new upper strut spacers. Install the new
strut spacer onto the stock struts and secure using the
stock hardware. Make sure to use thread locker or loctite
and torque to 45 ft lbs. Special note: If the vehicle that
you are working on is equipped with the factory TRX
package, different front strut spacers will need to be
ordered. Please contact Tuff Country or your local Tuff
Country dealer and order (2) of part # 34100-21. If the
strut spacers that are included in this box kit are
installed on a vehicle equipped with the TRX package,
the vehicle will be sitting 1” higher in the front than in
the rear.
33. Locate (6) 7/16” SAE washers and (6) 7/16” flange nuts
from hardware bag 34100NB3. Also, locate the lower strut
hardware. Working on the driver side, install the modified
strut into the upper strut location using the new 7/16” hard-
ware. Do not tighten at this point. Now install the bottom
of the stock strut into the stock location on the lower con-
trol arm. Do not tighten at this point. Move back to the
upper 7/16” hardware and add some thread locker or loc-
tite and torque to 45 ft lbs. Repeat procedure on the pas-
senger side.
34. Working on the driver side, insert the inner CV axle
shaft into the differential then push firmly to engage CV
axle shaft retaining ring. Repeat procedure on the passen-
ger side.
35. Locate where the upper end of the rubber brake hose
passes through the frame and connects to a metal brake
line. Using a cut off wheel, carefully cut a notch in the frame
to allow removal of the brake line or hose. Special note:
Take special care not to damage the brake line or hose.
Remove the brake line bracket bolt then free the line / hose
connector from frame. There are a couple bends in the
metal lines that are just above the line / hose connector.
Carefully straighten out the bends as much as needed to
allow the stock brake line bracket to sit flush with the new
bracket. Special note: Take special care not to kink or
damage the line.