Tuff Country 35920 - Dodge 94-02 Ram 2500 / 3500 4.5 kit - Manual (Page 7)

Working on the driver side, locate the steering box that is
secured to the inside of the stock frame rail. Remove the
rear bolt that connects the steering box to the stock
frame rail. Secure the new track bar kicker support
bracket to the rear hole of the steering box using the
stock bolt. Special note: Make sure to use locktite
when re-installing the stock steering box bolt. Do not
tighten at this point. Secure the other end of the new
kicker support bracket to the new track bar relocation
bracket that was installed in step # 44 using the new 3/8”
x 1” bolt and hardware. Make sure to use thread locker
or lock tite. Do not tighten at this point.
Illustration # 9
46. Locate the new 1/8” x 1 3/4” cotter pin from hardware
bag 35910NB. Working on the driver side, torque the new
M18 x 75 mm bolt to 135 ft. lbs. Install the new cotter pin
into the newly tighten M18 x 75 mm bolt. Special note:
Once the new 18 mm castle nut has been torqued,
install the new cotter pin. If the new cotter pin can
not be installed because the hole in the new M18 x 75
mm bolt does not line up with the new 18 mm castle
nut, DO NOT loosen the new castle nut so that the
cotter pin can fit, tighten the new castle nut some
more so that the cotter pin can be installed. Torque
the 1/2” bolt that connects the new track bar relocation
bracket to the stock cross member to 80 ft lbs. Next,
torque the stock rear bolt that connect the steering box to
the stock frame rail to 125 ft. lbs. Finally, tighten the 3/8”
bolt and hardware that connect the new kicker support
bracket to the newly installed track bar relocation bracket
to 32 ft lbs.
47. Locate the new 3/32” x 1 1/4” cotter pin from
hardware bag 35910NB. Install the stock track bar into
the newly installed track bar relocation bracket and
secure using the stock castle nut that was removed from
step # 5. Torque to 65 ft. lbs. Install the new cotter pin
into the stock track bar and castle nut. Special note:
Once the stock track bar castle nut has been torqued,
install the new cotter pin. If the new cotter pin can
not be installed because the hole in the stock track
bar does not line up with the stock castle nut, DO
NOT loosen the stock castle nut so that the cotter pin
can fit, tighten the stock castle nut some more so
that the cotter pin can be installed. Also, if you are
not able to line up the hole in the new track bar
relocation bracket and the stock track bar, the weight
of the vehicle may need to be on the ground. If this is
the case, perform this step at the end of the
installation once the tires and wheels have been re-
installed and the weight of the vehicle is on the
ground.
Illustration # 8
48. Locate the new driver and passenger side sway bar
drop brackets. Also, locate the stock way bar mounting
hardware that was removed in step # 3. Working on the
driver side, install the new driver side sway bar drop
bracket to the stock frame location and secure using the
installed front shock. Now install the new front upper
shock bushing and new upper shock 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.
41. Locate (4) 3/8” x 1 1/2” bolts, (10) 3/8” flat washers
and (6) 3/8” nylon insert nuts from hardware bag
35910NB. 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 # 7
42. 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.
43. Working on the driver side, carefully clean the excess
slag from the bottom side of the stock track bar location,
use a grinder and safely clean the bottom surface.
Special note: If this step is not performed properly,
the new track bar relocation bracket will not seat
flush to the stock track bar location. Thus, allowing
the new track bar bracket to work itself loose, which
may cause the new M18 bolt to come loose causing
damage to the new track bar bracket and/or vehicle.
44. Locate the new driver side track bar relocation
bracket. Locate (1) 1/2” x 2 1/2” bolt, (1) 1/2” unitorque
nut, (2) 7/16” USS flat washers, (1) M18 x 75 mm bolt, (2)
3/4” USS flat washers and (1) M18 castle nut from
hardware bag 35910NB. Locate the new S10078,
tapered crush sleeve and the new 9/16” modified washer
from hardware bag 35910NB1. Working on the driver
side, install the new tapered sleeve into the stock location
where the stock track bar was located. Next, install the
new track bar relocation bracket to the stock location and
secure using the new M18 x 75 mm bolt and hardware.
Do not tighten at this point. Hold the leg on the new
track bar relocation bracket on the back side of the stock
cross member. Using the hole in the new track bar
relocation bracket as a guide, carefully drill a 1/2” hole in
the stock cross member. Special note: there is a seam
that goes right down the middle of the stock cross
member, the new hole that is drilled should pass
through this seam. Secure the new track bar relocation
bracket to the back side of the stock cross member using
the new 1/2” x 2 1/2” bolt, 1/2” hardware and the new
9/16” modified washer. Refer to the illustration on how
to install the new 9/16” modified washer between the
new 1/2” washer and the stock cross member. Do not
tighten at this point.
Illustration # 8
45. Locate the new track bar kicker support bracket.
Locate (2) 3/8” x 1” bolts, (4) 5/16” USS flat washers, (2)
3/8” unitorque nuts from hardware bag 35910NB.