Tuff Country 55906 - Toyota Tundra 2004 knuckle 5 lift kit - Manual (Page 11)

Photo # 100
89. Locate (2) new front upper strut spacers. Locate the
stock hardware that connected the stock strut into the stock
location that was removed from step # 19. Locate the stock
driver side strut that was removed in step # 20. Working on
the driver side strut, install the new front upper strut spacer
to the stock strut using the stock hardware. Special note:
Make sure to use thread locker or lock tite. Torque to
38 ft lbs. Repeat procedure on the passenger side strut.
Photo # 101
90. Locate (6) 3/8” nylock nuts, (6) 5/16” flat washers and
(6) 3/8” lock washers from hardware bag 55907NB.
Working on the driver side, install the stock driver side strut
into the stock upper location, secure using the new 3/8”
hardware. Special note: Make sure to use thread locker
or lock tite. Torque to 38 ft lbs. Also, make sure that
you install the driver side strut on the driver side of the
vehicle and the same goes for the passenger side strut.
Refer to the markings that were made in step # 18.
Repeat procedure on passenger side.
Photo # 102
91. Locate the stock lower hardware that attached the
stock strut to the stock lower control arm that was removed
from step # 20. Working on the driver side, install the lower
eyelet of the stock strut into the stock location using the
stock hardware. Special Note: Make sure to use thread
locker or lock tite. Torque to 85 ft lbs. Repeat procedure
on the passenger side.
Photo # 103
92. Working on the driver side, remove the stock front
bump stop from the stock location. Save the stock bump
stop for later re-installation. Repeat procedure on the
driver side rear bump stop. Repeat procedure on the
passenger side.
Photo # 104
93. Locate (4) new bump stop relocation brackets. Locate
(4) 10 mm flat washers, (4) 10 mm lock washers and (4) 10
mm x 25 mm fine bolts from hardware bag 55907NB.
Working on the driver side, install the new bump stop
relocation brackets to the stock front and rear location and
secure using the new 10 mm x 25 mm fine bolts and
hardware. Make sure to use thread locker or lock tite and
torque to 28 ft lbs. Repeat procedure on the passenger
side.
Photo # 105
94. Locate (4) 10 mm fine nuts, (4) 10 mm flat washers and
(4) 10 mm lock washers from hardware bag 55907NB.
Also, locate the stock front and rear bump stops that were
removed in step # 92. Working on the driver side, install the
stock front and rear bump stops to the newly installed front
and rear bump stop relocation brackets and secure using
the new 10 mm hardware. Make sure to use thread locker
or lock tite and torque to 28 ft lbs. Repeat procedure on the
passenger side.
Photo # 106
95. Locate the stock skid plate that was removed in step #
2. Place the stock skid plate flat on a work bench. Working
on the driver side of the stock skid plate and referring to
Photo # 107 measure from the leading edge of the stock
skid plate towards the back of the stock skid plate 1 1/4”
and scribe a mark with white out or a white marker. Now
referring to Photo # 108 measure 1 1/2” from the leading
edge towards the inside of the vehicle and scribe a mark.
Repeat procedure on the passenger side of the stock from
skid plate. With a suitable cutting tool, carefully notch out
the stock skid plate on the lines that were scribed earlier in
this step.
Photo # 107
Photo # 108
96. Locate the stock skid plate hardware that was removed
in step # 2. Install the stock skid plate into the stock
location and secure using the stock hardware. Make sure
to use thread locker or lock tite and torque to 18 ft lbs.
Photo # 109
97. Locate the stock rack and pinion outer ball joint cotter
pin and nut that was removed in step # 6. Working on the
driver side, install the stock rack and pinion outer ball joint
to the stock lower ball joint plate and secure using the stock
nut. Torque to 75 ft lbs. Making sure that the holes in the
stock castle nut and the stock rack and pinion outer ball
joint lined up, install the stock cotter pin. Special note: If
the stock cotter pin can not be installed because the
hole in the stock castle nut does not line up with the
stock rack and pinion ball joint, DO NOT loosen the
stock castle nut so that the cotter pin can fit, tighten
the stock castle nut some more so that the stock
cotter pin can be installed. Repeat procedure on the
passenger side.
Photo # 110
98. Install the tires and wheels and carefully lower the
vehicle to the ground.
99. 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.
100. 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:
101. 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