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

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.
20. 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
grommets 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.
21. 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.
Photo # 19
22. Locate the stock upper shock tower and the stock
hardware. Working on the driver side, install the stock upper
shock tower into the stock location and secure using the
stock hardware. Make sure to use thread locker or lock tite
and torque to 38 ft lbs. Special note: Make sure that the
new shock that was installed in step # 20 fits properly
into the upper shock tower. Repeat procedure on the pas-
senger side.
23. Locate the upper shock grommets and the new upper
shock stud hardware that was supplied with the new shocks.
Working on the driver side, secure the new shock to the
stock upper shock tower using the new shock stud hard-
ware, new grommets and washer. Torque to 38 ft lbs.
Repeat procedure on the passenger side.
24. Locate the new track bar relocation bracket. Locate (1)
9/16” x 3 1/2” bolt, (2) 1/2” USS flat washers and (1) 9/16”
unitorque nut from hardware bag 36000NB1. Also, locate (1)
S10061 crush sleeve from hardware bag 36005SL. Working
on the driver side, install the new track bar relocation
bracket into the stock location and secure using the new
9/16” x 3 1/2” bolt, crush sleeve and hardware. Do not
tighten at this point.
Photo # 20 / Photo # 21
Photo # 22
25. Hold the newly installed track bar relocation bracket up
flush with the stock track bar location. Use the holes in the
new track bar relocation bracket as guides, carefully drill (2)
1/2” holes into the stock track bar location. Special Note: To
make drilling easier, remove the (3) stock bolts that hold
the stock steering box to the inside of the stock frame
rail. Move the stock steering box out of the way during
drilling. After the (2) 1/2” holes have been drilled into the
stock track bar bracket, re-install the stock steering box
back into the stock location using the stock hardware.
Make sure to use thread locker or lock tite. Torque the
stock steering box hardware to 95 ft lbs.
Photo # 23
26. Locate (1) 1/2” x 4” bolt, (2) 7/16” USS flat washers and
(1) 1/2” unitorque nut from hardware bag 36000NB1. Also
locate (1) S10062 crush sleeve from hardware bag
36005SL. Secure the new track bar bracket to the
previously drilled holes using the new 1/2” x 4 1/4” bolt,
crush sleeve and hardware. Make sure to use thread locker
or lock tite. Torque the new 1/2” bolt to 85 ft lbs. Move back
to the new 9/16” x 3 1/2” bolt that was installed in step # 25
and add some thread locker or lock tite and torque to 95 ft
lbs.
Photo # 24 / Photo # 25
27. Locate (1) 14 mm x 80 mm bolt and (2) 14 mm flat
washers from hardware bag 36000NB1. Also, locate the
stock retaining nut. Install the stock track bar into the newly
installed track bar relocation bracket and secure using the
new 14 mm x 80 mm bolt, flat washers and stock retaining
nut. Make sure to use thread locker or lock tite. Torque to
110 ft lbs. Special note: If you are not able to install the
stock track bar into the previously installed track bar
relocation bracket, you will need to perform this step
once the weight of the vehicle is on the ground.
28. Locate the new pitman arm and the stock pitman arm
hardware. Install the new pitman arm into the stock location
on the stock sector shaft and secure using the stock hard-
ware. Make sure to use thread locker or lock tite. Torque the
stock nut on the sector shaft to 225 ft lbs.
Photo # 26
29. Locate the stock outer tie rod hardware. Special note:
The new pitman arm has a reverse taper on it, if you
have not already rotated the stock outer tie rod 180
degrees, rotate the stock outer tie rod at this point.
Secure the stock outer tie rod to the previously installed new
pitman arm using the stock hardware. Make sure to use
thread locker or lock tite. Torque to 85 ft lbs.
Photo # 27
30. Locate the stock brake line bracket hardware. Working
on the driver side, install the stock brake line bracket to the
stock location and secure using the stock hardware. Make
sure to use thread locker or lock tite and torque to 12 ft lbs.
Repeat procedure on the passenger side.
Photo # 28
31. Carefully remove both hydraulic floor jacks from under
the front differential.
32. Working on the driver side, remove the stock sway bar
from the stock frame location and save the stock hardware.
Repeat procedure on the passenger side. Set the stock
sway bar aside for later re-installation.
Photo # 29
33. Locate the new driver and passenger side sway bar
relocation brackets. Also, locate the stock sway bar