Tuff Country 54900 - Toyota Tacoma 95-04 5 lift kit - Manual (Page 10)

104. Locate (2) new 4” lifted blocks. Working on the
driver side, install the new 4” lifted block between the
stock spring assembly and the stock axle. Special Note:
The new 4” lifted block has a slight taper to it, make
sure that when you install the new block that you
install it with the taper going towards the front of the
vehicle. Repeat procedure on the passenger side.
105. Carefully raise up on both hydraulic floor jacks at
the same time until the new 4” lifted rear blocks seat
properly to the stock rear springs.
106. Locate (4) 9/16” x 2 1/2” x 10 5/8” square U-bolts
and (8) 9/16” U-bolt high nuts and (8) U-bolt harden
washers from hardware bag 916NW. Also, locate the
stock upper bump stops and the stock lower U-bolt
plates that removed in step # 102. Working on the driver
side, install the stock upper bump stop, lower U-bolt
plate and the new U-bolts into the stock location and
secure using the new high nuts and harden U-bolt
washers. Torque to 115 ft lbs. Repeat procedure on the
passenger side.
Photo # 31
107. Carefully remove both hydraulic floor jacks from
under the vehicle.
108. Locate (1) new rear brake proportioning valve
bracket, (2) 8 mm x 35 mm bolts, (2) 8 mm flat washers
and (2) 8 mm lock washers from hardware bag
54900NB. Also, locate (2) S10021 from hardware bag
54900SL. Install the new rear brake proportioning valve
bracket to the stock location using the new 8 mm x 35
mm bolts, spacer sleeves and hardware. Special Note:
Make sure to use thread locker or lock tight and do
not tighten at this point. See photo # 32 for proper
spacer sleeve placement.
Photo # 32
109. Locate (2) 5/16” x 1 1/2” bolts, (2) 5/16” lock
washers, (4) 5/16” flat washers and (2) 5/16” unitorque
nuts from hardware bag 54900NB. Install the stock rear
brake proportioning valve bracket to the newly installed
rear brake proportioning valve bracket using the new
5/16” x 1 1/2” bolts and hardware. Special Note: Make
sure to use thread locker or lock tite. Torque to 18 ft
lbs. Also, torque the 8 mm x 35 mm bolts that where
installed in step # 108 to 12 ft lbs.
Photo # 32
110. Locate (1) new emergency brake cable extension
bracket and the stock hardware that was removed from
step # 99. Also, locate (1) 5/16” x 1 1/2” bolt, (2) 5/16”
flat washers, (1) 5/16” lock washer and (1) 5/16”
unitorque nut from hardware bag 54900NB. Working on
the driver side, install the new emergency brake cable
extension bracket to the stock location on the rear axle
using the stock hardware. Special Note: Make sure to
use thread locker or lock tight and do not tighten at
this point. Next, secure the stock emergency brake
94. With the weight of the vehicle on the ground, working
on the driver side, torque the stock cam bolts that attach
the stock front lower control arm to the newly installed
one piece lower sub frame to 96 ft lbs. Repeat
procedure on the passenger side.
95. Check and double check to make sure that all steps
were performed properly. And then check them again.
Front End Installation Complete:
Rear End Installation:
96. To begin installation, block the front tires of the
vehicle so that the vehicle is stable and can’t roll forward.
Safely lift the rear 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 rear wheels
and tires from both sides.
97. Using a pair of hydraulic floor jacks, place one
hydraulic floor jack on the driver side of the rear axle and
one on the passenger side.
98. Working on the driver side, remove the stock shock
from the stock location and discard. Save the stock
hardware for later re-installation. Special Note: New
longer rear shocks are needed, if you have not
already ordered your new rear shocks, please
contact Tuff Country or your local Tuff Country
dealer and order the proper shocks. Tuff Country
recommends using a 26” fully extended nitrogen gas
shock. Repeat procedure on passenger side.
99. Working on the driver side of the stock rear axle,
remove the stock hardware that attaches the stock
emergency brake cable to the stock location. Save the
stock hardware for later re-installation.
100. Working on the passenger side of the rear axle,
remove the stock brake proportioning valve bracket from
the stock location and save stock hardware for later re-
installation. Save the stock hardware for later re-
installation.
101. Working on the driver side, remove the stock rear
brake line from the stock upper and lower location. The
stock brake line may be discarded. Special Note: Brake
fluid will drain out, so place something under the
vehicle to catch the fluid as it drains out.
102. Working on the driver side, remove the stock U-
bolts for the stock location and discard the stock U-bolts
and U-bolt hardware. Set the stock upper bump stop and
lower U-bolt plate a side for later re-installation. Repeat
procedure on the passenger side.
103. Carefully lower down on both hydraulic floor jacks at
the same time approximately 4.5”. Take special care not
to kink on over extend any brake lines and or hoses.