Tuff Country 55906 - Toyota Tundra 2004 knuckle 5 lift kit - 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:___________________________
Driver side rear:________________________________
Passenger side rear:____________________________
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:__________________________
Driver side rear:_______________________________
Passenger side rear:___________________________
Front end installation:
1. To begin installation, 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 the
passenger side. Next, remove the front wheels and tires
from both sides.
2. Remove the stock front upper skid plate and set the
stock front upper skid plate and hardware aside for later
re-installation.
Photo # 1
3. Working on the driver side, remove the stock lower sway
bar end link mounting hardware from the stock location and
set aside for later re-installation. Repeat procedure on the
passenger side.
Photo # 2
4. Working on the driver side, remove the stock mounting
hardware that connects the stock end link to the stock sway
bar. Save the stock mounting hardware for later
re-installation. Repeat procedure on the passenger side.
Photo # 3
5. Working on the driver side, remove the stock mounting
hardware that attaches the stock sway bar to the stock
sway bar mounting location. Save the stock hardware for
later re-installation. Repeat procedure on the passenger
side. Set the stock sway bar aside for later re-installation.
Photo # 4
6. Working on the driver side, remove the stock cotter pin
and nut that connects the stock rack and pinion outer ball
joint to the stock knuckle. Save the stock cotter pin and nut
for later re-installation. Carefully break the stock taper on
the stock rack and pinion outer ball joint and remove the
stock rack and pinion outer ball joint from the stock
knuckle. Special note: Take special care not to rip or
tear the stock rack and pinion outer ball joint dust
boot. A strike with a hammer will help break the stock
tapper. Repeat procedure on the passenger side.
Photo # 5
Photo # 6
7. Working on the driver side, remove the stock ABS plug
from the stock knuckle. Save the stock hardware for later
re-installation. Repeat procedure on the passenger side.
Special note: If the vehicle that you are working on is
equipped without ABS front brakes, (2) of part #
54900-13 (ABS plugs for new knuckles) need to be
purchased as a separate part #. If you have not already
ordered the new ABS plugs, please feel free to contact
Tuff Country or your local Tuff Country dealer and
order the new ABS plugs. If these parts are not
installed to the new knuckles, damage will occur to the
stock hub assembly and Tuff Country will not be
liable for damages.
Photo # 7
8. Working on the driver side, remove the stock brake line
bracket from the back side of the stock knuckle. Save the
stock hardware for later re-installation. Repeat procedure
on the passenger side.
Photo # 8
9. Working on the driver side, remove the stock ABS line
bracket that attaches the stock ABS line to the neck of the
stock knuckle. The stock hardware may be discarded.
Repeat procedure on the passenger side.
Photo # 9
10. Working on the driver side, remove the stock hardware
that connects the stock brake line to the stock upper
control arm. The stock hardware may be discarded. Also, at
this time, remove the stock brake line bracket from the
stock brake line and discard. Repeat procedure on the
passenger side.
Photo # 10
Photo # 11
11. Working on the driver side, remove the stock brake line
bracket from the stock bump stop bracket. Save the stock
hardware for later re-installation.
Photo # 12
12. Working on the driver side, remove the stock cotter pin
from the stock upper control arm ball joint. The stock cotter
pin may be discarded. Loosen, but do not remove the stock
upper control arm castle nut. With a hammer, strike the
stock upper control arm next to the stock ball joint to brake
the stock upper ball joint tapper. Remove the stock upper
castle nut completely. The stock upper castle nut may be
discarded. Remove the stock knuckle from the stock upper
control arm. Repeat procedure on the passenger side.