Tuff Country 55906 - Toyota Tundra 2004 knuckle 5 lift kit - Manual (Page 7)

driver side differential relocation bracket to the new
one piece lower sub frame, make sure that the new
driver side differential relocation bracket is installed
towards the inside of the new differential tabs on the
new one piece lower sub frame.
Photo # 42
42. Locate (1) 1/2” x 1 1/2” bolt, (2) 7/16” USS flat washers,
and (1) 1/2” unitorque nut from hardware bag 55907NB.
Working on the passenger side, install the newly installed
one piece lower sub frame to the newly installed passenger
side differential relocation bracket and secure using the
new 1/2” x 1 1/2” bolt and hardware. Special note: Do not
tighten at this point. Also, when installing the new
passenger side differential relocation bracket to the
new one piece lower sub frame, make sure that the new
passenger side differential relocation bracket is
installed towards the inside of the new differential tabs
on the new one piece lower sub frame.
Photo # 43
43. Locate the stock mounting hardware that was removed
in step # 28. Secure the rear mounting stud on the rear
portion of the front differential to the new one piece lower
sub frame using the stock hardware. Do not tighten at this
point.
44. Move back to the newly installed 3/4” x 5” bolts and 3/4”
x 5 1/2” bolts securing the new one piece lower sub frame
into the new location and add some thread locker or lock
tite. Torque the new 3/4” bolts and hardware to 125 ft lbs.
Photo # 44
45. Move back to the (3) stock bolts holding the newly
installed driver side differential relocation bracket to the
stock front differential and add some thread locker or lock
tite. Torque to 85 ft lbs. Repeat procedure on the
passenger side.
Photo # 45
46. Move back to the new 1/2” x 1 1/2” bolts holding the
newly installed driver side differential relocation bracket to
the tab on the newly installed one piece sub frame and add
some thread locker or lock tite. Torque to 75 ft lbs. Repeat
procedure on the passenger side.
Photo # 46
47. Move back to the stock hardware holding the newly
installed driver side differential relocation bracket to the
stock front cross member and add some thread locker or
lock tite. Torque to 85 ft lbs. Repeat procedure on the
passenger side.
Photo # 47
48. Move back to the rear mounting stud on the rear
portion of the front differential and add some thread locker
or lock tite. Torque to 75 ft lbs.
Photo # 48
49. It is now ok to remove the tie down strap holding the
stock front differential to the stock frame rail.
50. Locate the stock lower control arm mounting cams and
the stock lower control arms that were removed in step #
29. Working on the driver side, install the stock lower
control arm to the newly installed one piece lower sub
frame using the stock cams. Do not tighten at this point.
Repeat procedure on the passenger side.
Photo # 49
51. Working on the driver side of the stock rack and pinion,
remove the stock rubber bushing and discard.
Photo # 50
52. Working on the center of the stock rack and pinion,
remove the stock rubber bushing and discard.
Photo # 51
53. Locate (2) new MO3354 poly bushings and (1) S10075
sleeve from hardware bag 55906NB1. Working on the
center of the stock rack and pinion, install the new bushings
and sleeves into the stock rack and pinion. Special note:
Make sure to use a lithium or moly base grease prior to
inserting the new bushings into the stock rack and
pinion. This will increase the life of the bushings as
well as prevent squeaking.
Photo # 52
54. Locate (2) MO2382 poly bushings and (1) S10076
sleeve from hardware bag 55906NB1. Working on the
driver side of the stock rack and pinion, install the new
bushings and sleeves into the stock rack and pinion.
Special note: Make sure to use a lithium or moly base
grease prior to inserting the new bushings into the
stock rack and pinion. This will increase the life of the
bushings as well as prevent squeaking.
Photo # 53
Photo # 54
55. Working on the driver side stock sway bar mounting
bracket attached to the inside part of the stock frame rail
and using a tape measure, measure from the top leading
edge of the front portion of the bracket downward 1 1/2”.
Using some white out or a white marker, scribe a line. Now
measure from the inside leading edge towards the stock
frame rail 1”. Using some white out or a white marker,
scribe a line.
Photo # 55
56. Using a die grinder, carefully cut out the front portion of
the stock sway bar mount. Special note: Tuff Country
does not recommend using a torch when making this
cut. Tuff Country recommends using a die grinder to
make this cut. The stock gas line runs on the inside of
the stock frame rail, take special care not to cut the
stock gas lines. Also when making this cut, take spe-
cial care not to cut into the stock frame rail. Clean up
any exposed slag from the trimming performed in this