Tuff Country 34100 - Dodge 09-11 Ram 1500 4 kit - Manual (Page 7)

36. Locate the new driver and passenger side brake line
relocation brackets. Locate (2) 1/4” x 3/4” bolt and (2) 1/4”
nyloc nuts from hardware bag 34100NB3. Working on the
driver side, install the new brake line relocation bracket to
the stock brake line bracket using the new 1/4” x 3/4” bolt
and hardware. Do not tighten at this point. Repeat pro-
cedure on the passenger side.
37. Locate (2) 3/8” x 1” bolts and (2) 3/8” flange nuts from
hardware bag 34100NB3. Also, locate the stock brake line
bracket hardware. Working on the driver side, install the
newly installed brake line bracket to the frame using the
new 3/8” x 1” bolt into the upper location and the stock
hardware into the lower location. Make sure to use thread
locker or loctite and torque the 3/8” bolt to 30 ft lbs. and the
stock bolt to 95 in. lbs. Move back to the 1/4” hardware and
add some thread locker or loctite and torque to 95 in. lbs.
Repeat procedure on the passenger side.
38. Locate the new driver and passenger side knuckles.
Also, locate the stock driver and passenger side knuckles.
Working on the stock driver side knuckle, remove the bolt
that secures the Wheel Speed Sensor wire mounting
bracket and now attach the Wheel Speed Sensor wire
mounting bracket to the new driver side knuckle in the
same orientation that it was removed from the stock knuck-
le. Repeat procedure on the passenger side stock and new
knuckle.
39. Working on the driver side stock knuckle, carefully
remove the hub assembly and dust shield. Special note:
Do not disconnect the Wheel Speed Sensor wire for the
hub assembly. Install the stock hub assembly and dust
shield to the new driver side knuckle. Special note: The
hub must be positioned with the Wheel Speed Sensor
wire routed forward and inside the machined into the
knuckle face. Apply thread locker or loctite to the stock
hardware then secure the hub assembly and dust shield to
the new knuckle and torque to 95 ft lbs. Repeat procedure
on the passenger side stock and new knuckle.
40. Locate the stock upper and lower ball joint nuts. Also,
locate the CV axle shaft nuts and outer tie rod nuts.
Working on the driver side, install the new knuckle to the
lower control arm and hand tighten the lower control arm
nut. Slide the CV axle shaft through the hub bearing and
then install the new knuckle to the upper control arm and
hand tighten the upper control arm nut. Now install the
outer tie rod to the new knuckle using the stock hardware.
Add some thread locker or loctite to the CV axle shaft and
install the nut and torque to 100 ft lbs. Add some thread
locker or loctite to the upper control arm, lower control arm
and outer tie rod nuts and torque the lower control arm nut
and outer tie rod nut to 85 ft lbs. Torque to upper control
arm nut to 50 ft lbs. Repeat procedure on the passenger
side.
41. Working on the driver side, route the Wheel Speed
Sensor wire to the mounting bracket on the knuckle as
shown in the picture. The rubber grommet on the Wheel
Speed Sensor wire must be shifted. Apply some windex on
the Wheel Speed Sensor wire and rubber grommet so that
the Wheel Speed Sensor wire will slide easily through the
rubber grommet. When satisfied with the routing, insert the
Wheel Speed Sensor and rubber grommet into the mount-
ing bracket. Repeat procedure on the passenger side.
42. Working on the driver side, install the brake rotor and
caliper using the stock hardware. Make sure to use thread
locker or loctite and torque to 130 ft lbs. Repeat procedure
on the passenger side.
43. Working on the driver side, we are now going to
route/attach the Wheel Speed Sensor wire at the following
points in this order. At the rubber brake hose, at the rear leg
of the upper control am and then reconnect the Wheel
Speed Sensor wire at the quick disconnect point. Special
note: We will not be reattaching the connector to the inner
fender well. Repeat procedure on the passenger side.
44. Working on the driver side apply some anti-seize to the
factory anti-sway bar link threads. Install (3) 7/16” SAE
washers per side then install the anti-sway bar link bush-
ings and hardware. Attach anti-sway bar links to anti-sway
bar body. Tighten until the bushings start to mushroom.
Repeat procedure on the passenger side.
45. Locate the new skid plate. Also, locate the (6) new 3/8”
x 1” counter sunk bolts and (6) 3/8” flange lock nuts from
hardware bag 34100NB4. Install the new skid plate to the
front and rear cross members and secure using the new
3/8” x 1” bolts and hardware. Make sure to use thread lock-
er or loctite and torque to 30 ft lbs.