Tuff Country 36005 - Dodge 03-07 Ram 2500 / 3500 6 kit (with front coil springs) - Manual (Page 4)

Please follow instructions carefully:
Before installation begins, measure from the center of
the hub, to the bottom of the fender well, and record
measurements below.
Pre-installation measurements:
Driver side front:_______________________________
Passenger side front:___________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post-installation measurements:
Driver side front:______________________________
Passenger side front:__________________________
Front end installation:
1. Working on the driver side, remove the stock sway bar
from the stock sway bar end link. Save the stock sway bar
end link hardware for later re-installation. Repeat the
procedure on the passenger side. Now remove the stock
sway from the stock end links and let the stock sway bar
hang.
Photo # 1
Special note: Step # 1 needs to be performed with
weight of the vehicle on the ground. If this step is not
performed with the weight of the vehicle on the ground,
damage will occur to the stock sway bar end links.
2. Block the rear tires of the vehicle so that the vehicle is
stable and can’t roll backwards. Safely lift the front of the
vehicle, and support the frame with a pair of jack stands.
Place a jack stand on both the driver and passenger side.
Next, remove the tires and wheels from both sides.
3. Place a pair of hydraulic floor jacks under the front axle.
Place one on the driver side and one on the passenger side.
Carefully raise up on both hydraulic floor jacks at the same
time until the hydraulic floor jacks come into contact with the
front axle.
4. Working on the driver side, remove the stock nut that con-
nects the stock tie rod end to the stock pitman arm. Save the
stock nut for later re-installation. Using a hammer, carefully
break the taper on the stock tie rod that connects to the stock
pitman arm. Special note: Take special care not to rip or
tear the stock outer tie rod boot. The new pitman arm
has a reverse taper on it, after the new pitman arm has
been installed, the stock outer tie rod needs to be rotat-
ed 180 degrees.
Photo # 2
5. Next, remove the stock nut and lock washer from the
sector shaft on the stock steering box. Save the stock hard-
ware for later re-installation. Using a pitman arm puller,
carefully remove the stock pitman arm from the stock sector
shaft. The stock pitman arm may be discarded.
Photo # 3 / Photo # 4
6. Open the hood of your vehicle. Working on the driver side,
locate and remove the upper stock shock nut. Also, remove
the upper stock shock retainer washer and grommet. The
stock nut, retainer washer and grommet may be discarded.
Repeat procedure on the passenger side.
Photo # 5
7. Working on the driver side, remove the (3) stock nuts that
hold the upper stock shock tower to the stock location. Save
the stock nuts for later re-installation. Set the upper stock
shock tower aside for later re-installation. Repeat procedure
on the passenger side.
Photo # 6
8. Working on the driver side, remove the stock lower shock
bolt from the stock mounting location and save the stock
hardware for later re-installation. Carefully lower down on
the hydraulic floor jack holding the driver side axle about 2”.
Remove the stock shock and the stock coil spring from the
stock location. Save the stock upper coil mounting ring and
the stock isolator for later re-installation. The stock shock
and the stock coil spring may be discarded. Special note:
Shocks are not included with this kit box and the shocks
need to be ordered as a separate part number. Tuff
Country EZ-Ride Suspension recommends using a 30”
fully extended nitrogen gas shock. Also, the new front
coil springs are not included with this kit box and they
need to be ordered as a separate part #. If you have not
already ordered your shocks or your new front coil
springs, please contact Tuff Country or your local Tuff
Country dealer and order these part #’s for the new coil
springs and the new front shocks. Repeat procedure on
the passenger side.
Photo # 7 / Photo # 8
9. Working on the driver side, remove the stock hardware
that connects the stock track bar to the stock location. Save
the stock retaining nut for later re-installation. The stock bolt
may be discarded.
Photo # 9
10. Working on the driver side, remove the stock brake line
bracket that connects the stock brake line between the stock
upper and lower control arm mounts on the axle. Save the
stock hardware for later re-installation. Repeat procedure on
the passenger side.
Photo # 10
11. Working on the driver side lower control arm mounting
bracket that is located on the stock front axle, scribe a mark
on the stock alignment cams and another directly across on
the reinforcement bracket. This will give you a good
alignment reference until you get the vehicle to an alignment
shop for a proper front end alignment. Repeat procedure on
the passenger side.
Photo # 11